Reinforced Friction Plug Welds via Extruded Land
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Solution Overview
Problem
Friction plug welds often exhibit weld strength properties along the line of fusion that are less than desired, particularly in applications like closing termination holes on circumferential friction stir welds, where the strength of the friction plug weld is inferior to the friction stir weld.
Innovation Solution
A method and apparatus for forming reinforced friction plug welds by creating a weld land that surrounds the plug, increasing the weld strength through a combination of frictional heat and forging, which enhances the load-carrying capability without significantly increasing time or material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If friction plug welding is used to close termination holes or repair castings, then the joining time is short and heat input is limited, but the weld strength along the line of fusion is less than desired
Solution Approach 1:
The welding process is divided into two distinct stages: first, friction welding to join the plug to the substrate, and second, forge welding under compressive load to strengthen the fusion line. This segmentation allows each stage to optimize for its specific function, maintaining short overall cycle time while achieving high weld strength through the dedicated forge welding phase.
Solution Approach 2:
The friction welding phase performs preliminary joining to establish the basic weld, creating a initial bond between the plug and substrate. This preliminary action enables the subsequent forge welding to focus solely on strengthening the fusion line without needing to perform the initial joining function, thereby maintaining productivity while improving strength.
2Adaptability or versatility
If friction plug welding is used for repairs and filling holes, then the process is efficient and versatile, but the load carrying capability is insufficient compared to friction stir welds
Solution Approach 1:
The process changes physical parameters during welding: first generating heat through friction to plasticize the materials, then applying compressive load and maintaining rotation to forge the materials together. This parameter transformation from thermal to mechanical dominance creates a reinforced weld structure with enhanced load carrying capability while preserving the versatility of friction plug welding for various applications.
Solution Approach 2:
The weld creates a composite structure consisting of the original substrate material and the plug material that are metallurgically bonded through the combined friction and forge welding process. This composite weld structure, with its refined grain structure from the forge welding phase, achieves load carrying capability comparable to or exceeding the base material while maintaining the adaptability of the friction plug welding process.
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 reinforced friction plug welds demonstrate improved strength and consistency, enabling higher load-bearing capacities and allowing for more effective repairs and structural integrity in various applications, including aerospace, marine, and automotive industries.
Implementation Method 1
Friction welding is a type of solid-state welding process that generates heat through mechanical friction between a moving workpiece and a stationary component
Implementation Method 2
a lateral force that plastically displaces and fuses the materials
Data Source
AI summary
A hole in a metal workpiece is filled by friction plug welding. The weld between the workpiece and the plug is reinforced by a weld land in the workpiece that surrounds one end of the plug. The weld land is formed by extruding a portion of the plug into a cavity in an anvil used in the welding process.