Movable Backing System for Friction Stir Welding Gap Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing friction agitation welding systems lack a precise and efficient method to clamp plate-shaped workpieces, leading to suboptimal welding quality due to issues like shrinking, bulging, and lateral opening forces, especially in aircraft structures with limited interior accessibility and varying workpiece thicknesses.
Innovation Solution
A movable backing system comprising an upper and lower unit with rollers and a connecting means, such as a strip or fiber, to precisely clamp and align workpieces, using coupling mechanisms like springs to equalize thickness tolerances and prevent detrimental forces during welding, allowing for one-side welding and improved accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional clamping methods are used for friction stir welding, then the welding process can be performed, but welding quality deteriorates due to shrinking, bulging, and lateral opening forces
Solution Approach 1:
The movable backing system is positioned and clamps the workpieces before the friction stir welding process begins. This preliminary clamping action prevents detrimental effects such as shrinking, bulging, or lateral opening forces during welding by maintaining proper alignment and gap control from the start of the operation.
Solution Approach 2:
The movable backing system acts as an intermediary device between the workpieces and the welding tool. It provides the necessary clamping and alignment functions, mediating the forces and pressures during welding to prevent harmful effects on weld quality.
2Strength
If rigid interior backing is used, then structural support is provided, but accessibility is reduced and the system cannot accommodate varying workpiece thicknesses
Solution Approach 1:
The backing system is designed to be movable rather than fixed, allowing it to adapt to different workpiece thicknesses and configurations. The movable units can be positioned and adjusted as needed, providing structural support when required while maintaining accessibility and flexibility for various welding scenarios including one-side welding.
Solution Approach 2:
The movable backing system allows for changes in positioning and clamping parameters to accommodate workpieces of different thicknesses. By adjusting the position and force applied by the movable units, the system maintains effective structural support across varying workpiece dimensions without requiring a fixed rigid backing structure.
3Manufacturing precision
If precise gap control is implemented, then welding quality improves, but the clamping and alignment procedure becomes more complex
Solution Approach 1:
The movable backing system replaces complex mechanical alignment and gap control mechanisms with a simpler movable clamping structure. By using movable units that can be positioned and secured, the system achieves precise gap control without requiring elaborate mechanical alignment procedures, thereby improving welding quality while maintaining operational simplicity.
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 system enables superior welding quality by maintaining precise gaps, preventing adverse forces, and facilitating easier clamping and alignment, even for workpieces of different thicknesses, enhancing the overall welding process, particularly beneficial for aircraft structures.
Implementation Method 1
The coupling means may provide a defined force between the upper and lower rollers to equalize thickness tolerances between sheets to be welded
Implementation Method 2
the upper unit comprises at least an upper roller and the lower unit comprises at least a lower roller to define the position of the plate-shaped workpieces to be welded
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to a movable backing system (1) to clamp plate-shaped backing workpieces (W) for friction agitation welding and friction stir welding and to a friction agitation or stir welding system. The movable backing system (1) comprises an upper unit (20) to be arranged above the backing workpieces (W) to support the backing workpieces (W), a lower unit (30) to be arranged below the backing workpieces (W) to support the backing workpieces (W), and a connecting means (40) connecting the upper and the lower unit (30) to be arranged in a gap between the backing workpieces (W) to be welded.