Friction Stir Welding Tension Rod for Clamping Force Absorption
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Solution Overview
Problem
Friction stir welding requires expensive and large clamping systems to absorb high process forces, leading to potential damage to the welding tool and seam defects due to imprecise positioning, and lacks the ability to influence alloy composition in the weld seam.
Innovation Solution
A device using an irrecoverable tension rod supported by the welding tool, with a rail for guiding the welding head, which absorbs forces and allows for precise movement, eliminating the need for large clamping systems and enabling the integration of different materials to influence weld seam properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expensive and large clamping systems are used to absorb high process forces, then the stability and reliability of the welding installation is improved, but the device complexity and cost increase significantly
Solution Approach 1:
The patent introduces a support plate as an intermediary element between the welding tool and the work piece. This support plate absorbs and distributes the high process forces generated during friction stir welding, preventing direct transmission of forces to the welding tool and clamping system. The support plate acts as a mediator that stabilizes the welding process while simplifying the overall device structure.
Solution Approach 2:
The support plate is designed as a consumable component that can be easily replaced. Instead of investing in expensive and complex clamping systems, the patent uses a simpler, more economical support plate that absorbs the mechanical stresses and can be discarded or replaced when worn. This approach reduces device complexity and cost while maintaining welding stability.
2Manufacturing precision
If the welding tool is moved precisely along the joint gap using complex positioning systems, then the manufacturing precision of the weld seam is improved, but the device complexity increases
Solution Approach 1:
The support plate with its specific geometric design serves as a self-guiding element. The welding tool follows the contour and features of the support plate, which automatically guides the tool along the joint gap with high precision. This eliminates the need for complex external positioning systems, as the support plate itself provides the guidance function through its geometry.
Solution Approach 2:
The support plate creates a stable reference surface that ensures consistent positioning of the welding tool. By providing a rigid, precisely machined surface with integrated guide features, the support plate establishes a stable geometric reference that maintains constant positioning accuracy throughout the welding process, equivalent to having complex positioning systems.
3Reliability
If broad portals are used for guiding and supporting the welding tool, then the stability and support capability are improved, but the space requirement and device complexity increase
Solution Approach 1:
The patent extracts the support and guidance functions from the traditional broad portal structure and consolidates them into a compact support plate positioned directly at the welding location. This support plate performs both support and guidance functions in a localized manner, eliminating the need for large overhead portals and reducing the overall space requirement of the welding installation.
4Ease of manufacture
If no additional material is used in friction stir welding, then the process simplicity is maintained, but the ability to influence alloy composition of the weld seam is lost
Solution Approach 1:
The patent introduces a support plate made of specific materials that can be selected to influence the alloy composition of the weld seam. The support plate material interacts with the base metals during the friction stir welding process, creating a composite weld structure with tailored properties. This allows control over the chemical composition and mechanical properties of the weld while maintaining relative process simplicity.
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 solution reduces the size of clamping systems, prevents tool damage, and enhances seam quality by directly absorbing forces and allowing for precise positioning, while enabling the integration of different materials to influence weld seam properties.
Implementation Method 1
friction stir welding requires a corresponding stable dimensioning of the welding installation, and the process forces have to be absorbed by the system for clamping of the parts to be welded
Implementation Method 2
an irrecoverable tension rod is provided, which is supported with its lower end on the tool in a tensioning manner, and which carries a rail on its upper end for supporting a counter piece
Data Source
AI summary
The invention relates to a device for producing a weld seam on work pieces by means of friction stir welding, said device having a welding head (5) with a rotating friction stir welding tool (4), the welding head being guided along the joining region and supported with respect to the work piece (1). In said device an irrecoverable tension rod (3) is provided for support, said rod being able to penetrate the welding region, being supported with its lower end on the work piece (1) in a tensioned manner, and carrying a rail (3b) on its upper end for supporting a counter piece (6) that is mechanically connected to the welding head (5) or to the friction stir welding tool (4). An additional supplementary tool (9) working, when seen in the direction of welding, in front of the friction stir welding tool (4) is provided for removing the upper section (3e) of the tension rod protruding above the welding plane from the welding region.