Integrated Probe-Anvil Bonding for Dissimilar Metal Laminates
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Solution Overview
Problem
Existing methods for joining three or more metallic members made of dissimilar materials, such as resistance welding and friction stir bonding, require multiple steps, diverse equipment, and result in reduced bonding strength and increased production costs and environmental impact.
Innovation Solution
A bonding device and method that combines resistance welding and friction stir bonding using a single device with an anvil and probe that serves as electrodes for both processes, allowing simultaneous operation to reduce equipment and production line length, and enhance bonding strength by using friction stir spot welding and resistance spot welding techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple bonding techniques are combined to join three or more dissimilar metallic members, then bonding reliability is improved, but the number of steps and equipment increases
Solution Approach 1:
The patent combines resistance welding and friction stir bonding into a single integrated device. The bonding device includes both a resistance welding unit with electrodes and a friction stir bonding unit with a probe, allowing both processes to be performed in one piece of equipment rather than requiring separate devices for each bonding technique.
Solution Approach 2:
The bonding device is designed to perform multiple functions: it can perform resistance welding between the first and intermediate members, friction stir bonding between the intermediate and second members, and simultaneously heat-treat the resistance welding nugget. This multi-functional approach eliminates the need for multiple separate bonding devices.
2Reliability
If multiple bonding techniques are combined to join three or more dissimilar metallic members, then bonding reliability is improved, but production time and facility length increase
Solution Approach 1:
The bonding device performs resistance welding and friction stir bonding simultaneously in a continuous operation. The probe rotates and applies friction stir bonding to the intermediate and second members while the electrodes simultaneously perform resistance welding between the first and intermediate members, eliminating sequential processing time.
Solution Approach 2:
The friction stir bonding process generates heat that is utilized preliminarily to facilitate the resistance welding process. The heat from friction stir bonding pre-heats the intermediate member, reducing the energy required for resistance welding and enabling simultaneous operation of both processes.
3Object-affected harmful factors
If adhesive agents are used to prevent electrolytic corrosion in resistance welding, then corrosion resistance is improved, but bonding strength stability deteriorates
Solution Approach 1:
The patent replaces the chemical bonding method (adhesive agents) with mechanical bonding methods. Friction stir bonding creates a mechanical interlock through material stirring and flow, while resistance welding creates a metallurgical bond through localized melting and solidification, eliminating the need for adhesive agents and their associated reliability issues.
4Use of energy by moving object
If friction stir bonding is used to join dissimilar metallic members, then energy consumption is reduced, but the range of effectively stirred material is limited
Solution Approach 1:
The bonding device segments the joining process by using friction stir bonding for joining the intermediate member to the second member (dissimilar materials), and resistance welding for joining the first member to the intermediate member. This segmentation allows each process to be optimized for its specific material combination, expanding the overall versatility of the system.
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 solution reduces processing time, equipment costs, and environmental impact while improving bonding strength by integrating resistance welding and friction stir bonding, minimizing the generation of brittle intermetallic compounds and maintaining nugget toughness through controlled heat application.
Implementation Method 1
Friction stir bonding is a process for bonding metallic plate members to one another by utilizing frictional heat generated by a probe rotating while plunging into the members
Implementation Method 2
an electric power supply electrically connected to the anvil and the probe to conduct electric current through the laminated assembly via the anvil and the probe
Data Source
AI summary
A bonding device for joining together a first member (3), an intermediate member (4), and a second member (3) which are layered as a laminated assembly includes a probe (12, 41, 52), an anvil (11), a drive mechanism (14) configured to rotate the probe around the central axial line and move the probe toward and away from the second member along the central axial line, and an electric power supply (15) electrically connected to the anvil and the probe to conduct electric current through the laminated assembly via the anvil and the probe.