Impact Welding of Dissimilar Metals With an Intermediate Body
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Solution Overview
Problem
Existing methods for joining dissimilar metals or thin/sensitive materials are limited by high heat generation, material incompatibility, and regulatory constraints, particularly in small-scale applications like mobile devices.
Innovation Solution
A method using a vaporizing foil actuator system with an intermediate body, where a consumable metal foil accelerates to high velocity and collides with another metal, joining dissimilar metals through impact, with optional unstable energetic mixtures and polyurethane layers to enhance bonding, and employing specific shapes and hole configurations for efficient joining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional welding methods are used to join dissimilar metals, then joining strength may be achieved, but heat affected zones form causing brittle intermetallics and material damage
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 the heat affected zone and brittle intermetallic formation while achieving strong joints between dissimilar metals through solid-state bonding mechanisms.
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, the process achieves welding through impact force rather than heat, fundamentally altering the joining mechanism to avoid thermal damage to sensitive materials.
2Speed
If electromagnetic launching is used to accelerate workpiece to high velocity, then impact welding can be achieved, but coil lifespan is limited due to joule heat and pressure constraints
Solution Approach 1:
The patent employs a disposable flyer plate that is accelerated once and then consumed in the welding process. This eliminates the need for durable, expensive electromagnetic coils by using a simple capacitor-discharge system that launches a single-use metallic flyer, significantly reducing system cost and complexity for one-off or low-volume production.
Solution Approach 2:
The invention extracts the electromagnetic launching system from the main welding apparatus, using only simple capacitors and electrodes to accelerate the flyer plate. This separation allows the use of inexpensive, short-lived electromagnetic components only when needed for acceleration, while the welding itself relies on the kinetic energy of the flyer rather than sustained electromagnetic fields.
3Speed
If explosives are used for forming or welding, then high velocity impact can be achieved, but safety and regulatory constraints limit industrial application
Solution Approach 1:
The patent substitutes explosive propulsion with electromagnetic capacitor discharge to accelerate the flyer plate. This replacement maintains the high-velocity impact needed for welding while eliminating safety hazards associated with explosives, making the process suitable for industrial environments with standard safety protocols.
Solution Approach 2:
The invention uses an electromagnetic field (analogous to pneumatic/hydraulic systems in terms of using a field rather than direct mechanical contact) to accelerate the flyer plate. This field-based acceleration method provides precise control over velocity and timing without the uncontrolled energy release characteristic of explosives.
4Strength
If fusion welding is used to join metals, then strong joints can be achieved, but thin or sensitive materials are damaged by heat
Solution Approach 1:
The patent replaces thermal fusion welding with mechanical impact welding. The flyer plate is accelerated to high velocity and collides with the workpiece, creating a solid-state bond without melting the base materials. This preserves the integrity of thin or heat-sensitive materials while achieving strong joints.
Solution Approach 2:
The invention fundamentally changes the energy parameter from thermal to kinetic. By controlling the flyer plate velocity (150-500 m/s) and impact angle (5-20 degrees), the process achieves welding through controlled mechanical impact rather than uncontrolled thermal input, protecting sensitive materials from heat damage.
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
Achieves reliable and efficient joining of dissimilar metals with minimal heat impact, suitable for thin or sensitive materials, demonstrating 100% joint efficiency and overcoming limitations of traditional welding methods.
Implementation Method 1
a vaporizing foil actuator system with an intermediate body, where a consumable metal foil accelerates to high velocity and collides with another metal
Implementation Method 2
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
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.