Laser-Welded Joining Structure for Dissimilar Material Interlayers
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Solution Overview
Problem
Conventional joining methods for metal materials of the same type with a difficult-to-weld material interposed between them often result in reduced thickness and weakened joining strength due to excessive drawing during press work, which compromises the integrity of the weld.
Innovation Solution
A joining structure and method where a spacer formed from a filler material with a central portion protruding more than the outer peripheral portion is inserted into a through portion of a third material, allowing for laser welding between the first and second metal members without reducing their thickness, and the third material is compressed and fixed between them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If press work is performed to form protrusions by drawing, then the gap between first and second materials is reduced, but the materials are partially drawn too much causing reduced thickness and weakened joining strength
Solution Approach 1:
A spacer made of filler material is introduced as an intermediary component between the first and second metal materials. The spacer is inserted into a through portion formed in the third material, allowing the gap to be reduced through the spacer's protruding structure rather than by drawing the metal materials themselves. This mediator approach enables gap reduction while preserving the original thickness and strength of the metal materials.
Solution Approach 2:
The invention changes the material parameter by using filler material for the spacer instead of forming protrusions directly from the metal materials. The spacer's central portion protrudes more than the outer peripheral portion, creating a tapered shape that reduces the gap while the material parameter change (using filler material) prevents the thickness reduction and strength loss associated with excessive drawing.
2Adaptability or versatility
If the third material is interposed between the first and second members, then joining of different material types is enabled, but the gap becomes too large for laser welding
Solution Approach 1:
The spacer acts as a mediator that bridges the gap created by the interposed third material. By inserting the spacer into the through portion of the third material, the effective gap for welding is reduced to a level suitable for laser welding, while still maintaining the adaptability of joining different material types through the third material layer.
Solution Approach 2:
The solution addresses the gap issue by introducing a dimensional element - the spacer with its protruding central portion creates a three-dimensional structure within the through portion. This dimensional approach allows the gap to be reduced in the welding direction while maintaining the overall structure that enables different material type joining.
3Length of moving object
If protrusions are formed by drawing with narrow clearance, then the gap is reduced, but the materials are partially drawn too much forming thinner portions
Solution Approach 1:
Instead of forming protrusions directly from the metal materials through drawing, the invention uses a spacer made of filler material as an intermediary. The spacer is formed with the required protruding shape and then inserted into the through portion, eliminating the need for narrow clearance drawing and preventing the formation of thinner portions in the metal materials.
Solution Approach 2:
The invention uses composite material construction where the spacer is made of filler material rather than the same metal material. This composite approach allows the protruding structure to be formed without the thickness reduction problems associated with drawing metal materials, as the filler material can be formed into the desired shape through other manufacturing processes.
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 joining of metal materials of the same type with a different type without reducing their thickness, maintaining the strength of the metal components and ensuring effective compression and fixation of the interposed material.
Implementation Method 1
a spacer formed of a filler material that is joined to a surface of the second member which faces the first member
Implementation Method 2
the first member is welded to at least the spacer, in a state where the spacer is inserted into the through portion
Data Source
AI summary
A first member and a second member are formed of metal materials of the same type and a third member is formed of a material of a different type that is difficult to weld to the first member and the second member. The first member and the second member are laser welded to each other such that respective regions of the first member and the second member which correspond to the spacer are welded via a through hole with the third member interposed therebetween. The spacer is formed of a filler material jointed to the second member by arc welding and is formed such that a central portion protrudes toward the first member more than an outer peripheral portion.