Internal-Space Weld Layout to Prevent Cracking in Aluminum Joints
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Solution Overview
Problem
Conventional methods for joining aluminum members, such as laser welding and friction stir joining, become complicated and prone to weld cracking when the number of welding spots increases, especially in internal spaces of welded articles.
Innovation Solution
A method involving periphery welding, outside terminating, outer edge intersecting, overlap welding, and end surrounding steps using laser or electron beam welding to form welded portions that simplify the process and prevent weld cracking by managing stress and molten metal supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional laser welding with filler metal coating is used to join aluminum members, then welding speed can be maintained for highly sensitive members, but the number of preparation works increases and welding becomes complicated when the number of welding spots increases
Solution Approach 1:
The invention extracts and eliminates the filler metal coating preparation step from the welding process. By using self-shielding gas metal arc welding (GMAW) or flux-cored arc welding (FCAW), the process directly welds aluminum members without requiring separate filler metal coating application, thereby reducing preparation works and simplifying the welding process while maintaining productivity
Solution Approach 2:
The invention employs a universal welding process (self-shielding GMAW or FCAW) that can handle both highly sensitive aluminum members and ordinary aluminum members with the same welding parameters and equipment, eliminating the need for different preparation procedures for different member types, thus reducing overall process complexity
2Reliability
If friction stir joining is used for aluminum members, then weld cracking can be avoided, but the method becomes hard to apply when the number of welding spots increases
Solution Approach 1:
The invention replaces the mechanical friction stir joining process with an arc welding process (self-shielding GMAW or FCAW). This substitution eliminates the need for complex mechanical stirring equipment and operations, while achieving comparable or superior crack resistance through proper shielding gas selection and welding parameter control, making the process more scalable for multiple welding spots
3Reliability
If multiple welding spots are required in internal spaces of welded articles, then sealing and structural integrity must be maintained, but conventional methods increase preparation works and complexity
Solution Approach 1:
The invention employs self-shielding welding processes that generate their own protective atmosphere (self-shielding GMAW) or use flux-cored electrodes that provide inherent protection (FCAW). This self-service capability eliminates the need for external shielding gas systems and complex setup procedures, enabling easy execution of multiple welding spots in internal spaces while maintaining sealing integrity and structural strength
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
The method simplifies the welding process, reduces the complexity of increased welding spots, and effectively prevents weld cracking in internal spaces of welded articles, ensuring sealing and structural integrity.
Implementation Method 1
welding a plurality of members by laser welding or electron beam welding to form a welded portion
Implementation Method 2
welding a plurality of members by laser welding or electron beam welding to form a welded portion
Data Source
AI summary
Provided is a method for producing a welded article. The method welds a plurality of members by laser welding or electron beam welding to form a welded portion and produce a welded article having an internal space. The method includes forming the welded portion surrounding the internal space, and at least one of forming an end point portion of the welded portion outside of the welded portion surrounding the internal space, forming the welded portion by moving a laser or an electron beam from the inside to the outside of the outer edge of the plurality of members, forming another welded portion overlapping with the end point portion of the welded portion previously formed, or forming the end point portion of the welded portion in a region surrounded by the welded portion partitioning the internal space.