Electromagnetic Pulse Friction Stir Lock Welding for Stronger Plate Joints
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Solution Overview
Problem
Existing lock welding technologies, such as ultrasonic vibration-aided electromagnetic lock welding, face challenges in forming strong mechanical connections between metal plates without rivets, as they lack a heat source and struggle to achieve ideal plastic deformation, leading to suboptimal connection strength and potential damage.
Innovation Solution
An electromagnetic pulse-aided friction stir lock welding device and method that uses high-speed stirring and rotating needles to form a nugget between metal plates, followed by a pulsed magnetic field to create a mechanical lock structure, with real-time thermal imaging to ensure the nugget meets design requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ultrasonic vibration-aided electromagnetic lock welding is used to connect metal plates without rivets, then the lightweight and cost benefits are achieved, but the plastic deformation of plates is difficult and the connection strength is insufficient
Solution Approach 1:
The invention introduces frictional heating to change the thermal parameter of the metal plates, raising the temperature to enhance plastic deformation capability. This thermal parameter change enables the material to deform more easily under the stirring needle, forming a proper mechanical lock structure that improves connection strength
Solution Approach 2:
The invention employs periodic reciprocating motion of the stirring needle combined with rotational motion. This periodic action creates cyclic heating and cooling zones that promote material flow and deformation, enabling effective plastic deformation and mechanical lock formation that enhances connection strength
2Strength
If high-speed stirring and rotating is used to form nugget between metal plates, then plastic deformation and mechanical lock structure are improved, but the device complexity increases
Solution Approach 1:
The invention merges multiple functions into a single stirring needle component: it serves as both the heating element (through frictional heating) and the forming tool (through reciprocating and rotational motion). This consolidation achieves plastic deformation and mechanical lock formation without requiring separate heating devices and forming mechanisms, thus limiting the increase in device complexity
Solution Approach 2:
The stirring needle generates its own heating effect through friction with the metal plates during high-speed rotation and reciprocating motion. This self-heating mechanism eliminates the need for external heating systems, reducing device complexity while still achieving the necessary plastic deformation for mechanical lock structure formation
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 approach enhances the mechanical properties and connection strength of the lock welding structure, offering high accuracy, ease of control, efficiency, and simplicity by inducing plastic deformation through frictional heating and utilizing magnetic field forces for a stable lock welding configuration.
Implementation Method 1
Electromagnetic coils are symmetrically arranged on the side wall of the settling tank, and the electromagnetic coils are connected with a power supply circuit
Implementation Method 2
Plastic metal is generated around a stirring needle while welding spots are formed by stirring and rotating at high speed
Data Source
AI summary
The present invention discloses an electromagnetic pulse-aided friction stir lock welding processing device and method, which comprises an upper die body and a lower die body. The upper end of the lower die body is provided with a frustum-shaped settling tank. The lower end of the upper die body is provided with a tip inserted into the settling tank, an outer wall of the tip is fitted with an inner wall of the settling tank, a gap for placing parts to be processed is arranged between the upper die body and the lower die body.