Metal Opening Repair Using Hot-Worked Bonded Inserts

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Solution Overview

Problem

Existing methods for filling openings in metal objects, such as tubes, often result in heat-affected zones, which weaken the material and are not suitable for repairing metal workpieces with various configurations.

Innovation Solution

A method involving a metallically bondable insert that is heated to a hot working temperature and subjected to engagement and translocation motions to create a metallic bond with the workpiece, eliminating heat-affected zones by forming a uniform crystalline microstructure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional heating and filling methods are used to fill openings in metal workpieces, then the opening can be filled, but heat-affected zones are created that weaken the tube

Engineering Contradiction:

Improveease of filling openingVSAvoidstrength of tube

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent applies parameter changes by heating both the insert and opening wall surface to a specific hot working temperature range, transforming the material state to enable plastic deformation and metallic bonding without creating heat-affected zones. This temperature-controlled parameter change allows the filling process to proceed while maintaining material strength.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces conventional thermal welding or brazing processes with a mechanical bonding process. By applying engagement motion and translocation motion to force the insert into the opening while both surfaces are heated to hot working temperature, the method creates a metallic bond through mechanical deformation and interlocking rather than through heat-affected zone formation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If solid state welding is used to join metal tubes, then heat-affected zones are avoided and a uniform crystalline structure is achieved, but substantial heat and force are required and it has not been utilized for repairing metal workpieces with various configurations

Engineering Contradiction:

Improveuniformity of crystalline structureVSAvoidapplicability to various workpiece configurations

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent segments the bonding process into distinct phases: heating the insert and opening surface to hot working temperature, applying engagement motion to establish contact, and then applying translocation motion to force the insert into the opening. This segmentation allows the method to be adapted to various workpiece configurations while maintaining the benefits of solid-state bonding.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces dynamic motion elements - engagement motion and translocation motion - that allow the bonding process to adapt to different workpiece geometries. The insert can be engaged and translocated along various paths depending on the opening configuration, making the method versatile for repairing tubes, plates, and other metal workpieces with different shapes and sizes.

Inventive Principle:

Principle #15Dynamics

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 effectively bonds the insert with the workpiece without creating heat-affected zones, resulting in a strong, uniformly structured repair that maintains the material's integrity.

Implementation Method 1

The opening wall surface is heated in a first non-oxidizing atmosphere to a hot working temperature, at which hot working temperature the opening wall surface is plastically deformable. Also, the insert engagement surface is heated in a second non-oxidizing atmosphere to the hot working temperature, at which hot working temperature the insert engagement surface is plastically deformable.

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

the insert is also subjected to a translocation motion, to move the insert at least partially into the opening, for engaging the insert engagement surface with the opening wall surface while the insert is subjected to the engagement motion, to cause plastic deformation of the opening wall surface and of the insert engagement surface as they engage each other, for at least partially creating a metallic bond between the insert and the workpiece

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 3

The insert and the workpiece are allowed to cool, to solidify the insert and the workpiece together.

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS11597032B2Method and system for modifying metal objects

Publication Date: 2023.03.07 CHENG PAUL PO

AI summary

A method of at least partially filling an opening in a workpiece made of metal, the opening being at least partially defined by one or more opening walls having one or more opening wall surfaces. The method includes providing an insert bondable with the workpiece, the insert having one or more insert engagement surfaces formed for engagement with the opening wall surface. The opening wall surface and the insert engagement surface are heated to a hot working temperature. The insert is subjected to an engagement motion, to move the insert engagement surface relative to the opening wall surface. While the insert is subjected to the engagement motion, the insert is also subjected to a translocation motion to move the insert at least partially into the opening, for engaging the insert engagement surface with the opening wall surface, for at least partially creating a metallic bond between the insert and the workpiece.