Resistance Welding with External Pressurization for Dissimilar Metals
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Solution Overview
Problem
Existing methods for resistance welding dissimilar metals, such as non-ferrous and ferrous metals, often result in inadequate fusion zones and frequent welding defects due to high heat input and pushing up of the element during the welding process.
Innovation Solution
A resistance welding method involving an element with a head and shaft portion made of ferrous metal, where the shaft is contacted with a non-ferrous member, and both are sandwiched and pressurized by electrodes with an external pressurizing jig to prevent the element from being pushed up during welding, allowing for a desired fusion zone formation with lower heat input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If large heat input is applied to form a desired fusion zone, then the fusion zone strength is improved, but welding defects frequently occur
Solution Approach 1:
The invention changes the pressure parameter by introducing external pressurization during the welding process. By applying pressure to the non-ferrous metal member while welding, the method enables formation of a desired fusion zone with relatively low heat input, thereby reducing welding defects while maintaining fusion zone strength
Solution Approach 2:
The invention applies preliminary pressurization to the non-ferrous metal member before and during the welding process to counteract the upward pushing force that occurs when the metal melts and flows. This preliminary anti-action prevents element displacement and ensures proper fusion zone formation without requiring excessive heat input
2Ease of manufacture
If the rivet is pushed upward by the heat-softened or melted first member flowing into the groove portion, then the joining process is simplified, but the formation of a desired fusion zone between the rivet and the second member is hindered
Solution Approach 1:
The invention applies preliminary pressurization to the non-ferrous metal member to counteract the upward pushing force that occurs when the metal melts and flows. This prevents the element from being pushed upward, maintaining manufacturing simplicity while ensuring proper fusion zone formation between the element and the second member
3Ease of operation
If the second component around the button component is warped upward, then the joining process becomes easier, but the button component is easily pushed upward during welding and formation of a desired fusion zone is inhibited
Solution Approach 1:
The invention applies preliminary pressurization to the non-ferrous metal member to counteract the upward warping and pushing forces that occur during welding. This prevents the button component from being pushed upward, maintaining operational ease while ensuring proper fusion zone 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
The method effectively forms a high-strength fusion zone between ferrous metal elements and non-ferrous metal members with reduced risk of welding defects by controlling the pressure and heat input, ensuring reliable joint formation.
Implementation Method 1
melting the first member by energization of the pair of electrodes while maintaining pressurization with the pair of electrodes and the external pressurizing jig
Data Source
AI summary
A resistance welding method for joining together a first member and a second member with an element including a head portion and a shaft portion. The method includes: contacting the shaft portion with the first member to stack the element, the first member, and the second member in this order; sandwiching and pressurizing the element, the first member, and the second member with a pair of electrodes while pressurizing at least one of the element or the first member with an external pressurizing jig disposed around at least one electrode of the pair of electrodes that is closer to the element; and melting the first member by energization of the pair of electrodes while maintaining pressurization with the pair of electrodes and the external pressurizing jig so that the element penetrates the first member to weld the element and the second member together.