Rolling Powder Alloy Case Design for Bondability
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Solution Overview
Problem
Conventional methods for manufacturing aluminum powder alloy using hot press deformation result in brittleness due to the inclusion of reinforcement materials, leading to adhesion issues between metal vessel components during electric-pressure sintering, which can cause separation and hinder the rolling process.
Innovation Solution
A case for rolling powder alloy is designed with a rectangular frame and lid members where at least one peripheral edge of the lid members has a peripheral wall standing upright along the outer peripheral surface of the side constituent member, ensuring adhesion between the side and lid members through outer and inner peripheral surfaces, preventing incomplete bonding and the need for weld bead removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal powder is contained between the frame member and lid member during electric-pressure sintering, then the metal vessel can be assembled, but the bondability decreases and separation occurs
Solution Approach 1:
The invention divides the contact interface between the frame member and lid member into two distinct surfaces: a flat contact surface for sintering bonding and a peripheral wall surface for mechanical support. This segmentation prevents metal powder from interfering with the bonding interface while maintaining structural integrity during assembly and processing.
2Reliability
If welding is performed to reinforce adhesion between frame member and lid member, then bondability improves, but weld bead removal is required which increases work and may damage the lid member
Solution Approach 1:
The invention extracts the adhesion-reinforcement function from the welding process and transfers it to the peripheral wall structure. The peripheral wall standing upright along the outer peripheral surface provides mechanical support and prevents separation without requiring welding, thereby eliminating the need for weld bead removal and reducing processing complexity.
3Ease of manufacture
If conventional metal vessel structure is used, then assembly is simple, but component separation occurs during rolling due to poor adhesion
Solution Approach 1:
The invention adds a vertical dimension by creating a peripheral wall that stands upright along the outer peripheral surface of the frame member. This three-dimensional structure provides mechanical interlocking and support in addition to the horizontal sintering bond, preventing separation during rolling while maintaining assembly simplicity.
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 design enhances bondability and maintains flatness without the intervention of metal powder, reducing the risk of component separation and damage during rolling, thus enabling the production of high-quality aluminum powder alloy with reduced processing complexity.
Implementation Method 1
it has a problem to make it into a desired shape based on the conventional processing method... by means of an electric-pressure sintering between the frame member 110 and the lid member 112
Data Source
AI summary
An object of this invention is to provide a case for rolling powder alloy without failures at the time of rolling. The case for rolling powder alloy (1) is formed like a shape of box and comprises a side constituent member (10) forming like a rectangular frame in a combination of two members (10a, 10a) and surrounding a side surface of metal powder, an upper lid constituent member (11) mounting on one opening of the side constituent member (10) and covering an upper surface of the metal powder, and a lower lid constituent member (12) mounting on the other opening of the side constituent member (10) and covering a lower surface of the metal powder. The peripheral edges of the upper lid constituent member (11) and the lower lid constituent member (12) are, respectively, provided with a peripheral wall (11b, 12b) standing upright along an outer peripheral surface of the side constituent member, and the side constituent member (10) is inserted into a space surrounded by the peripheral wall (11b, 12b). According to such case for rolling powder alloy, the aluminum powder alloy can be easily manufactured without failures at the time of rolling.