Welded Component With Interlayer Protrusions For Dissimilar Metal Joining
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Solution Overview
Problem
Conventional joining methods fail to effectively weld dissimilar materials like steel to aluminum or steel to carbon fiber, and are compromised by differing corrosion potentials, especially in wet environments.
Innovation Solution
A method involving protrusions on one metal piece and openings in an interlayer material positioned between the metal pieces, allowing mechanical contact only through the protrusions with the second metal piece, preventing direct contact and using isolating materials to prevent corrosion, while using thermal joining processes like resistance or laser beam welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional joining methods are used to weld dissimilar materials like steel to aluminum, then welding capability is improved, but corrosion resistance deteriorates due to different corrosion potentials
Solution Approach 1:
The patent introduces a non-metallic interlayer material positioned between dissimilar metal pieces to be welded. This interlayer acts as a mediator that prevents direct contact between metals with different corrosion potentials, thereby eliminating galvanic corrosion while still allowing the metals to be welded together through the interlayer using protrusions and openings.
2Strength
If direct contact between metal pieces is maintained for structural integrity, then mechanical strength is improved, but corrosion resistance deteriorates
Solution Approach 1:
The patent segments the contact interface between metal pieces by introducing a non-metallic interlayer with protrusions and openings. This segmentation allows mechanical connection through the protrusions passing through openings while preventing direct metal-to-metal contact, thus maintaining strength without compromising corrosion resistance.
Solution Approach 2:
The interlayer is designed with localized features: protrusions in specific locations and openings positioned to receive them. This local quality approach ensures mechanical contact only at discrete points through the protrusions, while the majority of the interlayer surface prevents corrosion by isolating the metal pieces.
3Reliability
If material piece is positioned between metal pieces to prevent corrosion, then corrosion resistance is improved, but welding capability deteriorates
Solution Approach 1:
The interlayer material is prepared in advance with protrusions and openings configured for the welding process. The protrusions are positioned and sized beforehand to facilitate proper alignment and contact during welding, ensuring that the presence of the interlayer does not hinder but actually enables the welding of dissimilar materials.
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
Enables the welding of previously unweldable material combinations without direct contact, reducing corrosion risks and allowing for the use of diverse materials in multi-material designs, particularly in automotive and aerospace applications.
Implementation Method 1
Welding of the metal pieces together is carried out by focusing the weld effect to the surface of the second metal piece which is in connection with the protrusion
Implementation Method 2
mechanical contact through the upper end of the protrusion with the second metal piece to be welded is achieved
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method for manufacturing a welded component, where at least one material piece is positioned between metal pieces to be welded together. At least one protrusion (5,13,23,33,43) is achieved to at least one of the metal pieces (3,4;11,12;21,22;31,32;41,42) to be welded together, and at least one opening (2,14,24,34,44) is achieved to at least one material piece (1,15,25,35,45) which is positioned between the metal pieces (3,4;11,12;21,22;31,32;41,42) to be welded and isolated (16,17;26;36) from the metal pieces to be welded. At least one part of the protrusion (5,13,23,33,43) in one of those metal pieces to be welded together is taken through the opening (2,14,24,34,44) in order to have mechanical contact through the upper end of the protrusion (5,13,23,33,43) with the second metal piece to be welded. Welding (37,38,39) of the metal pieces together is carried out by focusing the weld effect to the surface of the second metal piece which is in connection with the protrusion to the first metal piece to be welded. The invention also relates to the use of the component.