Capacitor Discharge Welding of Gas Generator Housing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The connection of radially arranged housing parts to the tubular body in gas generators poses challenges due to high pressures and temperatures, requiring a manufacturing method that minimizes expenses while ensuring a reliable attachment without compressing the tubular body, which could lead to stress in the weld seam.
Innovation Solution
A method involving capacitor discharge welding with a coordinated geometry of the tubular body's opening and housing part's attachment end, forming a contact edge and surface for a continuous contact along the circumference, allowing for a solid weld seam with moderate compressive stress without flattening the circumferential wall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the tubular body is flattened before welding the housing part, then the welding process becomes simpler, but the tubular body experiences radial compression that creates stress in the weld seam
Solution Approach 1:
The method performs preliminary preparation by forming a contact edge on the tubular body and a contact surface on the housing part before welding. This preliminary action enables direct welding on the curved surface without flattening, avoiding radial compression stress while maintaining manufacturing feasibility
Solution Approach 2:
The invention applies local quality by creating specific geometric features (contact edge and contact surface) only at the welding location. The contact edge is formed by chamfering the rim of the opening, and the contact surface is created on the attachment end, enabling localized welding without affecting the overall tubular structure
2Ease of operation
If a radially arranged housing part is connected to the tubular body, then the gas can be led off in a controlled manner, but the connection must withstand high pressures and temperatures reliably
Solution Approach 1:
The capacitor discharge welding process utilizes electrical energy to create a controlled thermal field that joins the housing part to the tubular body. The electrical discharge generates localized heat that melts and fuses the materials, creating a reliable connection capable of withstanding high pressures and temperatures during operation
Solution Approach 2:
The invention changes the physical state of the materials at the welding interface through capacitor discharge. The electrical energy transforms the materials from solid to molten state and then to a fused joint, creating a connection with enhanced strength and reliability for high-pressure and high-temperature applications
3Ease of manufacture
If the weld seam thickness varies along the circumference, then the manufacturing process is simpler, but the weld seam must still satisfy strength requirements
Solution Approach 1:
The invention accepts and utilizes the natural variation in weld seam thickness as a local characteristic. The weld seam is intentionally allowed to be wider at exterior points and narrower at interior points, with each local region satisfying the strength requirements appropriate to its position and stress conditions
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
This approach enables a reliable and cost-effective attachment under high pressures and temperatures, preventing radial compression and ensuring a strong, varying-thickness weld seam that maintains structural integrity.
Implementation Method 1
The tubular body and the housing part are joined to each other by capacitor discharge welding
Data Source
AI summary
For manufacturing a gas generator (1), a tubular body (10) having an opening (14) in a circumferential wall (12) and a housing part (16) having an attachment end (26) are provided. The geometry of a proximate rim (20) of the opening (14) and that of the attachment end (26) are coordinated such that a first contact region encircling the opening (14) and a second contact region on the attachment end (26), which is circumferentially closed, are formed. The housing part (16) is placed onto the tubular body (10) such that the first contact region is in contact with the second contact region. Then the body (10) and the housing part (16) are joined to each other by capacitor discharge welding.