Multi-Spot Vaporizing Foil Welding for Simultaneous Automotive Joints
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Solution Overview
Problem
Current collision welding methods, such as resistance spot welding, are costly and inefficient for producing multiple contemporaneous welds, especially in smaller scale industry settings like the automotive industry, and existing vaporizing foil actuator welding (VFAW) methods can only complete one weld at a time without reconfiguration.
Innovation Solution
A multiple spot vaporizing foil actuator welding system that includes a target sheet layer secured to a stabilizing component, with standoff components and an electrically insulating layer, and a vaporizable component sheet layer with varying geometry to optimize vaporization and control the timing and location of welds, allowing for simultaneous multiple welds without increasing current or voltage requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If resistance spot welding is used to produce multiple contemporaneous welds, then the welding process can join metal surfaces, but the current load and cost increase additively for each additional weld
Solution Approach 1:
The vaporizable component sheet layer is divided into multiple vaporizing subsections, each corresponding to a specific weld location. When electrical energy is applied, these subsections vaporize independently to propel separate portions of the flier sheet layer into the target sheet layer, enabling multiple contemporaneous welds without additive current increases.
Solution Approach 2:
Multiple weld operations are merged into a single simultaneous process. By configuring the vaporizable component sheet layer with multiple vaporizing subsections that can be activated together, the system performs multiple collision welds in one operation, achieving productivity improvement without proportional energy increase.
2Speed
If traditional collision welding with explosives is used, then high-velocity impact welds can be achieved, but the process is constrained to larger scales and requires intensive materials
Solution Approach 1:
The mechanical system of explosives and heavy machinery is replaced with an electrical-thermal system. Electrical energy vaporizes the conductive material in the vaporizable component sheet layer, and the resulting gas pressure propels the flier sheet layer at collision welding speeds, eliminating the need for explosive materials and complex mechanical acceleration systems.
Solution Approach 2:
The conductive material in the vaporizable component sheet layer undergoes a phase transition from solid to gas when electrical energy is applied. This phase transition generates rapid gas expansion that creates the high pressure pulse needed to accelerate the flier sheet layer to collision welding speeds, replacing the need for explosive chemical reactions.
3Reliability
If single spot VFAW welding is used, then collision welding advantages are maintained, but only one weld can be completed at a time without reconfiguration
Solution Approach 1:
The vaporizable component sheet layer is segmented into multiple vaporizing subsections, each capable of independent vaporization to create a collision weld. This segmentation allows multiple welds to be performed simultaneously in a single process cycle while maintaining the reliability and quality characteristics of individual collision welds.
Solution Approach 2:
The vaporizable component sheet layer is designed to perform multiple functions within a single process cycle. By incorporating multiple vaporizing subsections that can be activated simultaneously, the system maintains the collision welding mechanism's reliability while enabling multi-spot welding capability, making the process universally applicable to various welding configurations.
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 cost-effective and efficient completion of multiple contemporaneous welds by controlling the vaporization process to accelerate the flier sheet to speeds greater than the speed of sound, maintaining the advantages of collision welding while scaling up the process for industrial applications.
Implementation Method 1
the thin metal conductor may be heated to above its energy of sublimation before it has time to melt. Consequently, the thin metal conductor vaporizes directly from its solid state into a rapidly expanding gas
Implementation Method 2
the transformation of the solid metallic conductor directly into its gaseous state results in the formation of a rapidly expanding and energetic vapor capable of generating the high forces required to propel a flier sheet into a target metal material at the speeds necessary to complete a collision weld
Implementation Method 3
the welding occurs consequent of the removal of the surface oxide layers from both component metals, such that the fresh layers of each respective material may be brought into contact so as to produce a metallurgical bond
Data Source
AI summary
A multiple spot vaporizing foil actuator weld (VFAW) system includes a target sheet layer secured relative to a stabilizing component, such that standoff components may be arranged sandwichably between the target and a flier sheet layer. An electrically insulating layer separates the flier from a vaporizing component sheet layer, which may comprise at least two vaporizing subsections configured to have less conductive material than at least three dividing subsections that separate the vaporizing subsections. The geometry and/or other features of the vaporizing subsections may be varied to optimize the vaporization. A second electrically insulated stabilizing component may sandwichably secure the above components between the first stabilizing component in order to control the forces generated in the VFAW process. The method involves loading the vaporizable component sheet layer with electrons via applied voltage such that the vaporizing subsections sublimate. The rapidly expanding gas particles accelerate the flier, completing the weld.