Hole-Free Component Joining Using Electric Arc Preheating
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Solution Overview
Problem
Existing methods for joining components made of high-strength materials, such as those used in the automotive industry, require pre-formed holes, which is time-consuming and risks misalignment of components, and are limited by the strength of conventional joining devices that cannot penetrate or connect materials effectively without pre-drilled holes.
Innovation Solution
A method that uses an auxiliary joining element actuated by a joining device to pass through a high-strength component's heat-affected zone created by an electric arc, allowing connection without pre-drilled holes, enabling the joining of components with reduced strength in the heat-affected zone, thereby simplifying the process and preventing misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-formed holes are used for joining high-strength components, then the joining process is simpler and components can be connected, but the process becomes time-consuming and components may lose relative position alignment
Solution Approach 1:
The patent applies preliminary action by heating the high-strength component before the joining operation. The component is heated to a temperature where its strength is reduced, making it easier to penetrate and join. This pre-heating action prepares the material in advance to overcome the high strength that would otherwise require pre-formed holes and time-consuming joining procedures.
Solution Approach 2:
The patent changes the temperature parameter of the high-strength component during the joining process. By heating the component to an elevated temperature, the material properties change - specifically, the strength decreases and ductility increases, allowing the joining element to penetrate and form connections without pre-formed holes, thereby eliminating alignment issues and reducing process time.
2Strength
If conventional joining methods are used on high-strength materials, then joining can be achieved, but the maximum forces are reduced and joining devices cannot penetrate or connect the materials effectively
Solution Approach 1:
The patent changes the temperature parameter of the high-strength material during the joining process. By heating the component to an elevated temperature, the material properties change - specifically, the strength decreases and ductility increases, allowing the joining element to penetrate and form connections without pre-formed holes, thereby eliminating alignment issues and reducing process time.
Solution Approach 2:
The patent applies dynamics by making the material properties changeable during the process. The high-strength component transitions from a cold, high-strength state to a heated, lower-strength state during the joining operation. This dynamic change in material properties allows conventional joining devices to effectively penetrate and connect materials that would otherwise be too strong, while the material retains its high strength after cooling.
3Reliability
If high-strength materials are used in automotive components, then fuel economy and passenger safety are improved, but the materials cannot be joined effectively without pre-drilled holes
Solution Approach 1:
The patent applies preliminary action by heating the high-strength component before the joining operation. The component is heated to a temperature where its strength is reduced, making it easier to penetrate and join. This pre-heating action prepares the material in advance to overcome the high strength that would otherwise require pre-formed holes and time-consuming joining procedures.
Solution Approach 2:
The patent changes the temperature parameter of the high-strength component during the joining process. By heating the component to an elevated temperature, the material properties change - specifically, the strength decreases and ductility increases, allowing the joining element to penetrate and form connections without pre-formed holes, thereby eliminating alignment issues and reducing process time.
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 method allows for the efficient joining of high-strength components without pre-drilling, reducing the need for high joining forces and eliminating the risk of misalignment, while enabling the connection of different materials like steel and aluminum, and accelerating the joining process.
Implementation Method 1
the first component in the region of the joining area is heat-treated via an electric arc, which is formed between the first component on the one hand and an electrode provided on the joining device on the other hand
Implementation Method 2
the first component is heated in such a way that a strength of the first component in the heat-affected zone is reduced
Data Source
AI summary
A joining method for connecting a first component to a second component without pre-punching. The first component and the second component are positioned relative to one another prior to the connection by an auxiliary joining element, which is joined via a joining device to the components positioned relative to one another. The auxiliary joining element firstly passes through the first component without pre-punching and is then connected to the second component without pre-punching. Before the components are connected by the auxiliary joining element, the first component is thermally pre-treated at the joining area via an electric arc formed between the first component and an electrode of the joining device. A heat-affected zone is formed on the first component in the joining area, and the first component in is weakened or melted in the heat-affected zone.