Metal Joint Reinforcement Cladding for Zinc-Safe Body Structures
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Solution Overview
Problem
Existing methods for reinforcing metal components in motor-vehicle bodies using additive manufacturing face challenges such as local destruction of the zinc layer and decreased strength due to heat-induced microcrystalline structure alterations, which affect the structural integrity and weight optimization of the components.
Innovation Solution
The method involves applying a multi-level metal cladding with a coarse base cladding and fine cladding including stiffening micro-ribs, followed by a local zinc overlay and quenching step using additive manufacturing, to create structural joints with high strength and reduced weight, adaptable to current production lines with lower energy costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additive manufacturing technology is used to apply metal cladding to reinforce metal components, then the strength and structural integrity of the component is improved, but the zinc layer on the metal surface is locally destroyed due to heat generation
Solution Approach 1:
A protective sacrificial zinc overlay is applied to the metal component surface before the additive manufacturing process. This preliminary zinc layer absorbs the thermal damage during cladding application, preventing destruction of the original protective zinc coating on the component. The sacrificial layer is then removed after the process, leaving the original zinc layer intact.
Solution Approach 2:
The sacrificial zinc overlay acts as an intermediary layer between the heat source (additive manufacturing process) and the original zinc coating. It mediates the thermal interaction by absorbing the harmful heat effects, thereby protecting the original zinc layer from destruction while allowing the cladding process to proceed.
2Ease of manufacture
If heat is applied during additive manufacturing to melt metal powders, then the metal cladding is successfully formed, but the microcrystalline structure of the metal sheet is altered leading to decreased strength
Solution Approach 1:
The metal sheet rapidly skips through the heat-affected zone during the additive manufacturing process, minimizing the duration of thermal exposure. This rapid transit reduces the time for microcrystalline structure alteration, thereby preserving the strength characteristics of the base metal while still enabling successful cladding formation.
Solution Approach 2:
The additive manufacturing process uses periodic pulsed energy input rather than continuous heating. This periodic action allows brief intervals for heat dissipation, preventing excessive thermal accumulation that would alter the microcrystalline structure, while still achieving sufficient melting for cladding formation during the pulse periods.
3Strength
If traditional manufacturing methods are used to produce motor-vehicle bodies, then structural strength is maintained, but the vehicle weight increases and production costs rise
Solution Approach 1:
Instead of uniformly thick metal sheets throughout the vehicle body, the invention applies localized metal cladding only at specific reinforcement zones where structural strength is needed. This creates local quality variations - thicker material where required for strength, thinner material elsewhere - thereby reducing overall vehicle weight while maintaining necessary structural integrity.
Solution Approach 2:
The invention creates a composite structure combining the base metal sheet with the additive-manufactured metal cladding. This composite construction allows optimization of material distribution, using material only where structurally necessary, thereby reducing weight compared to traditional uniform thickness designs while maintaining strength requirements.
4Reliability
If multiple electrical resistance welding spots are applied to frame the motor-vehicle body, then structural integrity is ensured, but the manufacturing time and energy consumption increase
Solution Approach 1:
The invention merges the reinforcement function with the welding process itself by applying metal cladding directly at the welding locations during the additive manufacturing process. This combines two separate operations (welding and reinforcement) into one integrated process, eliminating the need for additional reinforcement steps and reducing overall manufacturing time and energy consumption.
Solution Approach 2:
The additive manufacturing system performs multiple functions simultaneously: it applies the metal cladding for structural reinforcement and creates the welding joint in one process. This multi-functionality eliminates the need for separate reinforcement operations, thereby improving productivity while maintaining structural integrity.
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 approach enables the creation of motor-vehicle structures with enhanced strength and reduced weight, requiring fewer electrical resistance welding spots, and allows the use of thinner sheets with reduced cycle times and energy consumption, while maintaining structural integrity and preventing zinc layer destruction.
Implementation Method 1
an energy source is used, such as a laser or plasma beam, to selectively melt layers of metal powders, or metal wires, of various sizes, so as to form layer above layer of a metal 'cladding'
Implementation Method 2
it also comprises a local quenching step obtained by feeding a cold fluid over the cladding, immediately after the cladding application step
Implementation Method 3
the method comprises the step of performing an electrical resistance welding spot between said components
Data Source
AI summary
A structural joint between two components of metal material is obtained by carrying out an electrical resistance welding spot between said components and subsequently performing a step of applying a cladding of metal material by an additive manufacturing technology. In one example, after a first step of applying a coarse base cladding, a second step of applying a fine cladding is carried out, again by additive manufacturing technology. The fine cladding can include a distribution of stiffening micro-ribs above the base cladding. The same method can also be applied to a single sheet metal component, rather than to a welded joint.