Solid-Phase Metal Bonding With Local Electric Interface Heating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional solid phase welding methods face challenges in accurately controlling welding temperature, particularly in lowering it, and in achieving strong joints without sliding metallic materials, which complicates the apparatus and limits applicability.
Innovation Solution
A method involving local heating of the weld interface with external means while applying pressure equal to or greater than the yield strength of the materials, using electric heating to rapidly raise the temperature only in the vicinity of the interface, and controlling current density to minimize heat affected zones and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction welding or linear friction welding is used to join high strength metallic materials, then the joint strength is improved, but the welding temperature becomes difficult to control and the apparatus complexity increases
Solution Approach 1:
The patent replaces the mechanical friction-based heating system with an electric heating system. Instead of using friction between moving parts to generate heat, the invention uses electric heating elements to directly heat the welding interface, enabling precise temperature control while maintaining high joint strength
Solution Approach 2:
The patent changes the heating mechanism from mechanical friction to electric heating, allowing independent control of temperature parameters. This enables the welding temperature to be precisely adjusted and maintained within optimal ranges for different high strength materials, resolving the temperature control difficulty
2Strength
If friction welding is used to achieve strong joints, then the joint strength is improved, but the apparatus complexity and sliding mechanism requirements increase
Solution Approach 1:
The patent eliminates the complex sliding and rotation mechanisms required for friction welding by substituting them with a stationary electric heating system. The welding process is achieved through electric heating combined with pressure application, removing the need for intricate mechanical movement components
Solution Approach 2:
The patent extracts and removes the sliding mechanism from the welding system. By separating the heating function from the mechanical friction process, the invention simplifies the apparatus to essential components: electric heating elements, pressure application mechanism, and control system
3Strength
If rapid heating and cooling is applied in friction welding to achieve high strength joints, then the joint strength is improved, but the heat affected zone expands and material deformation increases
Solution Approach 1:
The patent applies heating locally at the welding interface through electric heating elements positioned directly at the joint. This localized heating minimizes the heat affected zone by concentrating thermal energy only where needed, preventing excessive material deformation while achieving strong joints
Solution Approach 2:
By replacing friction-based heating with electric heating, the patent enables more precise spatial and temporal control of heat input. This substitution allows for controlled heating rates and better heat distribution, reducing the expansion of the heat affected zone while maintaining joint strength
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
Enables precise control of welding temperature, reduces the welding temperature, and achieves strong, high-strength joints with minimal heat affected zones, simplifying the apparatus and enhancing applicability.
Implementation Method 1
raising a temperature of the vicinity of the interface to be welded to a welding temperature by an external heating means
Implementation Method 2
using electric heating to rapidly raise the temperature only in the vicinity of the interface
Implementation Method 3
applying a pressure equal to or greater than a yield strength of the one material to be welded and/or the other material to be welded
Data Source
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 to achieve a solid phase welding of the metallic materials. 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.