Retractable Friction Stir Tool Tip for Keyhole-Free Welding
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Solution Overview
Problem
Current friction stir-welding tool holders leave a keyhole feature after use and are limited to welding large, thick work pieces, failing to accommodate varying work piece sizes and shapes effectively.
Innovation Solution
The Swappable Retractable Tool Tip (SRTT) system, which includes interchangeable tool tips and shoulders, utilizes compressed air to retract the tool tip and fill the keyhole, allowing for adaptation to different work piece sizes and shapes through adjustable geometries and dimensions, enabling welding of both small and large work pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional friction stir-welding tool holder is used, then large, thick work pieces can be welded, but a keyhole feature is left after tool removal and the tool cannot accommodate small or varying work piece sizes
Solution Approach 1:
The tool holder is divided into separate functional components: a fixed shoulder portion and a retractable tool tip portion. The tool tip can be retracted independently from the shoulder, allowing the shoulder to fill the keyhole while the tip is withdrawn. This segmentation enables the tool to both weld effectively and eliminate keyholes by separating the welding function from the filling function.
Solution Approach 2:
The tool tip is made dynamically retractable through a mechanism that allows it to move relative to the fixed shoulder. This dynamic capability enables the tool tip to be pulled back after welding, allowing the shoulder to fill the keyhole. The system transitions from a static tool design to a dynamic one where components can move independently to achieve multiple objectives.
2Adaptability or versatility
If a fixed geometry tool holder is used, then welding of large work pieces is possible, but the tool cannot adapt to small or varying work piece sizes and shapes
Solution Approach 1:
The tool holder is segmented into interchangeable components including different tool tip geometries and shoulder configurations. This allows selection of appropriate tool combinations for different work piece sizes and shapes without redesigning the entire tool system. The segmented design enables modular adaptation to various welding applications.
Solution Approach 2:
The tool holder system is designed with universal features that can accommodate multiple work piece types. The fixed shoulder portion can work with various tool tip geometries, and the retractable mechanism provides universal applicability across different welding scenarios. This multi-functionality allows a single tool holder system to handle small, large, and varying work piece geometries.
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 SRTT system effectively welds various work pieces of different shapes and thicknesses while eliminating the keyhole feature, providing a versatile solution for friction stir welding by allowing tool tip and shoulder interchangeability and adjustable dimensions.
Implementation Method 1
utilizes compressed air to retract the tool tip and fill the keyhole
Implementation Method 2
friction stir-welding tool holders allows for large scale and large work pieces to be welded together through friction stir welding
Data Source
AI summary
Systems and techniques are directed to a Swappable Retractable Tool Tip (SRTT), which is designed as a next generation of friction stir welding tools and retractable tool tips. The disclosed SRTT may be “swappable,” having different types of retractable tool tips that can be assembled and employed as a part of the SRTT. A SRTT system can include at least: a blank tool holder, a piston, and a retractable tool tip. In operation, the blank tool holder allows air to flow to cause movement of the piston and the retractable tool tip. For example, compressed air can push up on the piston and the retractable tool tip, retracting it into a “home” position inside of the blank tool holder. Also, the SRTT can include springs that push down on the piston and the retractable tool tip, extending the tip into an “extended” position outside of the blank tool holder.