FSW Stationary Shoulder With Adjustable Annular Gap
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Solution Overview
Problem
Current friction stir welding (FSW) tools face issues with pasty material penetrating into the annular gap between the welding rod and shoulder, leading to irregular welds and potential tool damage due to the required relative movement between these components.
Innovation Solution
A set of fittings for the FSW tool includes a conically shaped adapter and shoulder cap, allowing for adjustable annular gap width and independent positioning of the welding rod, which can be adjusted to prevent material penetration and optimize the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a gap is provided between the welding rod and shoulder to enable relative movement, then the welding tool can accommodate different welding conditions, but pasty material can penetrate into the gap causing irregular welds and tool damage
Solution Approach 1:
The adapter is designed with rotational capability relative to the shoulder cap, allowing dynamic adjustment of the annular gap width. This enables the gap to be widened when adaptability is needed and narrowed or closed when material penetration prevention is prioritized, resolving the contradiction between versatility and reliability
Solution Approach 2:
The conical shape of the adapter and shoulder cap allows the annular gap width to be varied by rotating the adapter. This parameter change enables optimization of the gap width for different welding conditions while preventing material penetration when required, addressing both adaptability and weld quality concerns
2Manufacturing precision
If the annular gap is widened to prevent material penetration, then material flow control improves, but the adapter positioning complexity increases
Solution Approach 1:
The conical geometry of the adapter and shoulder cap creates a self-aligning annular gap that maintains consistent radial spacing during rotation. This curved surface design simplifies positioning compared to linear mechanisms, as the conical surfaces naturally guide the adapter into proper alignment while enabling precise gap width control
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adjustable annular gap and positioning of the welding rod enable controlled adaptation to various welding conditions, reducing material penetration and enhancing the reliability and longevity of the FSW tool by preventing blockages and irregularities in the weld seam.
Implementation Method 1
Due to the friction between the rod and the surface, the material of the at least one component is heated to the point that it plasticizes
Implementation Method 2
Frictional heat, which promotes the plasticization at least in sections, may be generated by the translational movement and/or rotational movement (in general, relative movement) between the welding shoulder and the workpiece
Data Source
AI summary
A set of fittings for an FSW tool (friction-stir-welding tool) includes an adapter that can be inserted into a tool-receiving element and is designed to receive a welding rod, and a shoulder cap that includes a through-opening for the welding rod and the adapter. The shoulder cap includes a welding shoulder region adjacent to the through-opening on the outer surface. The adapter can be rotated in relation to the shoulder cap, about a longitudinal axis extending concentrically to the through-opening. The inner contour of the through-opening and a radial outer contour of the adapter have a conical shape at least on the end facing the welding point. In this way, a conical annular gap is created between the adapter and the shoulder cap, the width of which is adjustable by positioning the adapter along the longitudinal axis.