Impact Welding With an Intermediate Body for Dissimilar Metals
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Solution Overview
Problem
Existing methods for joining dissimilar metals or thin/sensitive materials are limited by high heat requirements, material incompatibility, and safety concerns, particularly in small-scale applications like electronic devices.
Innovation Solution
A method using a vaporizing foil actuator system with an intermediate body, where a metal foil or sheet is accelerated to collide with another metal, forming a joint by shaping or welding, allowing dissimilar metals to be joined efficiently without heat damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional fusion welding is used to join dissimilar metals, then the materials can be joined, but heat-affected zones form and brittle intermetallics form reducing joint quality
Solution Approach 1:
The patent replaces thermal welding processes with impact welding, a mechanical process where kinetic energy from a high-velocity flyer plate creates a collision weld. This substitution eliminates heat-affected zones and prevents formation of brittle intermetallic compounds while achieving strong joints between dissimilar metals
Solution Approach 2:
The invention changes the fundamental parameter from thermal energy to kinetic energy. By accelerating the flyer plate to velocities between 150-500 m/s and controlling impact angles of 5-20 degrees, the process achieves welding through mechanical impact rather than thermal fusion, resolving the issues with heat-affected zones
2Speed
If electromagnetic forces are used to accelerate the workpiece to high velocity, then impact welding can be achieved, but the epoxy insulation melts at high energies and large numbers of operations
Solution Approach 1:
The patent employs a disposable flyer plate that is accelerated to high velocity and consumed in the welding process. This replaces the expensive, long-lived electromagnetic coil system with a low-cost, single-use component, enabling high-energy operations without concern for coil degradation or epoxy melting
Solution Approach 2:
The invention extracts the accelerating function from the expensive electromagnetic coil system and transfers it to a simple capacitor bank that accelerates a disposable flyer plate. This separation allows the electromagnetic system to remain intact and reusable while the consumable flyer plate absorbs the high-energy stress
3Power
If explosives are used for forming or welding, then large scale applications can be achieved, but safety concerns and infrastructure costs increase
Solution Approach 1:
The patent replaces explosive-based acceleration with an electromagnetic launch system using a capacitor bank and railgun configuration. This substitution provides comparable kinetic energy delivery without the safety hazards, infrastructure requirements, and regulatory burdens associated with explosives, enabling safe implementation in closed industrial settings
4Device complexity
If traditional quasi-static methods are used for metalworking, then the process is simple, but spring back is high and formability is reduced
Solution Approach 1:
The invention uses impulsive, periodic loading rather than continuous quasi-static force. The high-velocity impact delivers energy in a brief, concentrated pulse that plastically deforms the material before elastic recovery can occur, significantly reducing spring back and improving formability while maintaining 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
This method achieves reliable and efficient joining of dissimilar metals with high joint efficiency, reducing spring back and heat affected zones, suitable for thin or sensitive materials, and compliant with safety regulations.
Implementation Method 1
The two most common agents for driving the metallic workpiece to high velocities are electromagnetic forces and explosives
Implementation Method 2
The electromagnetic launch of the workpiece is based on laws of electromagnetic induction and Lorentz forces
Implementation Method 3
Collision welds are generally observed when the impact velocity is in the range of 150 m/s to 500 m/s and the impact angle is between 5 to 20 degrees
Implementation Method 4
When a sheet of metal is accelerated to very high speed and an obstacle is placed in its path, then because of its inertia, it would conform into or around that obstacle
Data Source
AI summary
A system and method for joining dissimilar metals. In one embodiment, a method comprises providing a first metal plate, a second metal plate, and an intermediate body that is positioned between the first metal plate and the second metal plate. The first metal plate is then driven into the intermediate body, which causes at least a portion of the intermediate body to collide with the second metal plate. As a result, the material of the intermediate body joins the first metal plate to the second plate. In another embodiment, a method for joining dissimilar metals comprises providing a first metal that is not amenable to welding, a second metal that is joinable to the first metal, and an intermediate body that is not joinable to at least the first metal. The intermediate body may have at least one hole such that the first metal and the second metal are positioned over and on opposite sides of the hole(s). At least a portion of the second metal may then be driven into the hole(s) to be joined to first metal.