Projected Welding Stud Surface for Thin-Sheet Joint Strength
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Solution Overview
Problem
Existing welding elements face challenges in achieving a strong and flexible connection across varying sheet thicknesses, particularly with aluminum alloys, as the same welding elements cannot be used for both thin and thick sheets without compromising the strength of the weld.
Innovation Solution
A welding stud with a head featuring regularly distributed pointed projections on its surface, arranged in parallel rows and separated by intersecting grooves, which allows for adaptable welding characteristics and prevents penetration welding, especially designed for thin sheets, and can be manufactured through cold-forming processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the same welding element is used for both thin and thick sheets, then device complexity is reduced, but the strength of the weld joint deteriorates for specific thicknesses
Solution Approach 1:
The welding surface features localized pointed projections distributed across the surface, creating areas of concentrated melting capability. This local structural variation enables the same welding element to adapt to different sheet thicknesses by controlling where and how the material melts, thereby maintaining weld joint strength across varying thicknesses while using a single universal welding element design.
2Productivity
If welding is performed on thin sheets with standard elements, then productivity is maintained, but the risk of perforation increases
Solution Approach 1:
The pointed projections on the welding surface fundamentally change the thermal distribution parameters during welding. By concentrating heat at the projection tips, the melting process becomes more controlled and localized, preventing excessive heat penetration that would cause perforation in thin sheets. This parameter change allows maintaining high welding productivity while eliminating the perforation risk through improved heat distribution control.
3Adaptability or versatility
If the welding surface is modified with projections, then adaptability to different sheet thicknesses is improved, but manufacturing complexity increases
Solution Approach 1:
The welding surface is segmented into multiple discrete pointed projections rather than a continuous complex geometry. This segmentation simplifies the manufacturing process, as projections can be created through standard embossing or forming techniques applied to the welding element. The segmented projection pattern provides adaptability to different sheet thicknesses while keeping the manufacturing process relatively simple and cost-effective.
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
This solution enables a cost-effective, flexible, and strong welding connection that maintains or increases the strength of the weld across different sheet thicknesses, preventing penetration welding and ensuring even melting, thus providing a reliable attachment method for both thin and thick metal sheets.
Implementation Method 1
The geometry also makes it possible to prevent the risk of through-welding in thin sheets... welding the welding element to the workpiece by melting at least part of the protrusions
Implementation Method 2
arc stud welding process belongs to the arc pressure welding processes... welding the welding element to the workpiece by melting
Data Source
Figure 1~2
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Figure 5
AI summary
Welding element (10) which is suitable for being joined to a workpiece using a welding process, comprising: - a head (14) 14 with a welding surface (22) and a holding surface (24) facing away from the welding surface (22), - a shaft-shaped anchor section (12) which extends between a first end region (18) and a second end region (20) along a longitudinal axis (Xa), wherein the first end region (18) is connected to the holding surface (24), wherein the welding surface (22) has several regularly distributed pointed projections (26).