Intermediate Metal Joining for Incompatible Workpieces

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Solution Overview

Problem

Existing methods of solid state welding are not suitable for connecting metal elements that are stationary or made of different alloys that are not directly bondable with each other.

Innovation Solution

A method involving an intermediate metallic element that is bondable with both the extension and stub elements, using heating elements to heat the elements to a hot working temperature for plastic deformation and bonding, while maintaining a non-oxidizing atmosphere to facilitate bonding without filler material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If solid state welding is used to connect metal workpieces, then bonding strength is improved, but the method is not suitable for stationary workpieces or workpieces made of different alloys

Engineering Contradiction:

Improvebonding strengthVSAvoidapplicability to stationary workpieces and different alloys

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

An intermediate element is introduced between the stub element and extension element to enable bonding. This intermediate element is selectively bondable to both the first metal of the stub element and the second metal of the extension element, serving as a mediator that overcomes the incompatibility between different alloys and enables connection of stationary workpieces.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The bonding process utilizes controlled heating to raise the intermediate element and adjacent workpiece portions to a hot working temperature range, enabling plastic deformation and bonding. The parameters of temperature and mechanical stress are changed in a controlled sequence to achieve bonding without requiring the workpieces to be movable or directly compatible.

Inventive Principle:

Principle #35Parameter changes

2Strength

If heating elements are used to heat workpieces to hot working temperature for plastic deformation, then bonding capability is improved, but oxidation risk increases

Engineering Contradiction:

Improvebonding capabilityVSAvoidoxidation risk

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

A non-oxidizing atmosphere is provided during the heating and bonding process to protect the heated portions of the workpieces and intermediate element from oxidation. This creates an inert environment that allows the hot working temperature range to be maintained without the harmful oxidative effects that would otherwise occur.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Adaptability or versatility

If intermediate element is used to connect incompatible metals, then bonding versatility is improved, but process complexity increases

Engineering Contradiction:

Improvebonding versatility for incompatible metalsVSAvoidprocess complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The intermediate element serves as a selective intermediary that is bondable to both the stub element and extension element. This approach provides versatility for connecting incompatible metals while maintaining a relatively simple process structure, as the intermediate element's selective bondability eliminates the need for complex multi-step bonding procedures or specialized equipment for each metal combination.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 strong, uniform bonding of metal elements with good axial, radial, and circumferential integrity, eliminating notches and irregularities, and enabling connection of incompatible metals without the need for filler material.

Implementation Method 1

The heating elements are energized, to provide hot portions at each of the exposed end, the first end, the second end, and the inner end

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

Once the hot portions at each of exposed end, the first end, the second end, and the inner end are heated to a hot working temperature at which each of the exposed end, the first end, the second end, and the inner end are all respectively subject to plastic deformation

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS11577295B2System and method for connecting metal workpieces

Publication Date: 2023.02.14 CHENG PAUL PO

AI summary

A method of forming an assembly in which a metal extension element is connected with a metal stub element, by an intermediate element. The intermediate element extends between first and second ends. The intermediate element is positioned to locate its first end spaced apart from the stub element. An inner end of the extension element is spaced apart from the second end of the intermediate element. Heating elements are located between the elements, to heat the proximal portions of the elements to a hot working temperature, at which the heated portions are subject to plastic deformation. The heating elements are removed, and while the intermediate element is rotating, the first end is urged against the stub element to bond the intermediate element with the stub element. While the extension element is rotating, the inner end is urged against the second end to bond the extension element and the intermediate element.