Guide Wire Segment Welding to Counter Rebound in Dissimilar Metals
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Solution Overview
Problem
Existing guide wires face challenges in balancing column strength and flexibility, with current methods struggling to effectively join dissimilar metallic materials like nitinol and stainless steel without compromising weld integrity.
Innovation Solution
The method involves aligning separate guide wire segments made of different materials, applying a first force while delivering electrical current for welding, and then applying a follow-up force greater than the initial force to enhance solid-state deformation and form a weld nugget with improved characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If electrical current is delivered through dissimilar metal segments to weld them together, then the segments are joined to form a weld nugget, but the materials may melt and create metallurgical incompatibilities
Solution Approach 1:
The patent applies solid state resistance welding which changes the thermal parameters of the welding process. By controlling the electrical current delivery and applying follow-up force, the materials are deformed and joined in a solid state without melting, avoiding metallurgical incompatibilities while still achieving strong welds between dissimilar metals like nitinol and stainless steel
Solution Approach 2:
The patent replaces traditional fusion welding mechanisms with solid state resistance welding. Instead of relying on melting and fusion of materials, the process uses electrical current to generate heat that softens the materials just enough for deformation and bonding, combined with mechanical follow-up force to create the weld nugget without full melting
2Manufacturing precision
If a follow-up force greater than the initial force is applied during welding, then the weld nugget becomes thinner with larger transverse cross-sectional area and more consistent strength, but the process complexity increases
Solution Approach 1:
The patent employs dynamic force application during the welding process. The follow-up force greater than the initial force is applied after electrical current delivery to continue deforming the materials while they are in a softened state, creating a thinner weld nugget with larger transverse cross-sectional area and more consistent strength characteristics
Solution Approach 2:
The patent maintains continuous useful action by applying follow-up force immediately after electrical current delivery without interruption. This continuous deformation process ensures the weld nugget achieves optimal geometry and strength consistency while the materials are still in a receptive softened state
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 allows for the direct joining of dissimilar metal segments with a solid-state weld, achieving consistent strength characteristics and reducing variability in weld strength, while avoiding the risks associated with melting and metallurgical incompatibilities.
Implementation Method 1
the applied electrical (e.g., DC, AC, or both) current serves to heat the portions of the members to be joined so that they undergo solid state deformation, such that the materials are not melted, but deform and form a weld joint while in a solid state
Implementation Method 2
delivering electrical (e.g., DC, AC, or both) current through the separate members so as to weld the separate portions to one another
Data Source
AI summary
The present disclosure is directed to a multi-segment device comprising an elongate first portion comprising a first metallic material, an elongate second portion comprising a different metallic material, the first and second elongate portions being directly joined together end to end, a heat affected zone surrounding an interface of the elongate first portion and the elongate second portion, a shapeable distal end formed from at least a portion of the elongate second portion, a coil disposed about a portion of the elongate second portion.