Solid-Phase Metal Bonding with Local Heating and No Sliding
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Solution Overview
Problem
Existing friction welding methods face limitations in controlling welding temperature, are limited to specific material compositions, and require complex apparatuses, leading to complications and reduced applicability.
Innovation Solution
A solid phase welding method that applies pressure to the interface of metallic materials to control welding temperature by focusing on deformation resistance, using electric heating to raise temperature locally and discharge flashes, with controlled pressure and current density to form a stable bond without sliding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If friction welding is performed by repeatedly moving one member in contact with the other member on the same trajectory, then welding can be achieved, but the apparatus becomes complicated and large due to the need for sliding mechanisms
Solution Approach 1:
The patent replaces the mechanical sliding system with a stationary contact system. Instead of moving one member relative to the other through complex mechanical mechanisms, the invention uses a pressurizing mechanism to apply axial force while maintaining stationary contact between the members, substituting mechanical motion with a combination of pressure and localized heating
Solution Approach 2:
The invention extracts the essential welding function from the complex sliding mechanism. By separating the pressure application function from the motion function, the patent removes the need for complex sliding mechanisms while retaining the core welding capability through stationary contact and controlled deformation
2Strength
If high pressure is applied during friction welding to achieve bonding, then welding strength is improved, but the welding temperature becomes difficult to control and may exceed desired levels
Solution Approach 1:
The patent changes the controlling parameter for welding temperature from pressure alone to a combination of pressure and time. By applying pressure in stages and controlling the duration of pressure application, the invention achieves both strong bonding and controlled temperature, preventing excessive heat generation while maintaining welding strength
Solution Approach 2:
The invention uses periodic or staged pressure application rather than continuous high pressure. The pressurizing mechanism applies pressure in controlled stages, allowing temperature management while achieving the necessary bonding strength through cumulative deformation and contact
3Adaptability or versatility
If conventional friction welding methods are used, then welding can be achieved, but the method is limited to specific material compositions and cannot be applied to high carbon steel materials
Solution Approach 1:
The patent creates a universal welding method that can be applied to various material compositions including high carbon steel. The stationary contact friction welding approach with controlled pressure and heating mechanisms removes material-specific limitations, making the process applicable to a broader range of materials while maintaining welding quality
Solution Approach 2:
The invention adjusts welding parameters such as pressure magnitude, heating rate, and contact time to accommodate different material compositions. This parameter flexibility allows the same welding method to be successfully applied to various materials including high carbon steel, which was previously incompatible with conventional friction welding
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
Accurate temperature control and reduced welding temperature achieve a stable bond without sliding, simplifying apparatus design and expanding applicability to various metallic materials.
Implementation Method 1
applies pressure to the interface of metallic materials to control welding temperature by focusing on deformation resistance
Implementation Method 2
using electric heating to raise temperature locally
Implementation Method 3
discharge flashes, with controlled pressure and current density to form a stable bond
Implementation Method 4
solid phase welding method that applies pressure to the interface of metallic materials to control welding temperature
Data Source
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AI summary
To provide a solid phase welding method and a solid phase welding apparatus which are possible to accurately control the welding temperature, to lower the welding temperature and, in addition, to achieve a solid phase welding of the metallic materials to be welded to each other without sliding them. The present invention provides a solid phase welding method for metallic materials comprising, a first step of forming an interface to be welded by abutting end portions of one material to be welded and the other material to be welded and applying a pressure in a direction substantially perpendicular to the interface to be welded, a second step of raising a temperature of the vicinity of the interface to be welded to a welding temperature by an external heating means, wherein the pressure is set to equal to or more than the yield strength of the one material to be welded and/or the other material to be welded at the welding temperature.