Solid-State Insert Welding for Tube Repair Without Heat-Affected Zones
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Solution Overview
Problem
Existing methods for solid state welding often result in heat-affected zones, which weaken the welded tubes, and are not suitable for repairing or modifying metal workpieces with various configurations.
Innovation Solution
A method involving the use of an insert and a workpiece, where both are heated to a hot working temperature and subjected to an engagement motion to create a metallic bond without melting, eliminating heat-affected zones and allowing for uniform crystalline structure formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional welding methods are used to fill openings in tubes, then the openings can be filled, but heat-affected zones are created that weaken the tube
Solution Approach 1:
The patent applies parameter changes by heating the insert and workpiece to a hot working temperature (e.g., 0.5-0.8 times the melting temperature) to enable plastic deformation and metallic bonding without melting. This temperature parameter change allows the opening to be filled while avoiding the heat-affected zones that weaken conventional welding, as the controlled heating and rapid cooling produce a uniform crystalline structure that maintains or enhances tube strength.
2Strength
If solid state welding is used to join tubes, then heat-affected zones are avoided, but substantial heat and force are required and it cannot be used for repairing or modifying various workpiece configurations
Solution Approach 1:
The patent applies preliminary action by pre-heating the insert and workpiece to the hot working temperature before the insert is engaged with the workpiece. This preliminary heating prepares the materials for plastic deformation and metallic bonding, enabling the process to be applied to various workpiece configurations (tubes, plates, shapes) without requiring substantial force during the actual joining operation, thus improving versatility while maintaining strong bonds.
Solution Approach 2:
The patent changes the temperature parameter to a hot working temperature range that enables plastic deformation and metallic bonding. This parameter change allows the process to adapt to different workpiece configurations and materials, as the heated materials become more formable and bondable, eliminating the limitation of conventional solid state welding that requires substantial force and is restricted to specific geometries.
3Ease of manufacture
If conventional welding is used to fill openings, then the openings are filled, but the welded areas are weakened due to heat-affected zones
Solution Approach 1:
The patent applies parameter changes by controlling the temperature to a hot working range and managing the heating duration to achieve metallic bonding without creating extensive heat-affected zones. The rapid cooling after engagement produces a uniform crystalline structure in the bonded area, ensuring high reliability and integrity of the filled opening while maintaining the opening filling capability.
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 bonds the insert and workpiece without creating heat-affected zones, resulting in a strong, uniformly crystalline microstructure that is resistant to damage.
Implementation Method 1
An insert heated portion and a remainder segment heated portion are heated to a hot working temperature, at which they are plastically deformable
Implementation Method 2
an insert engagement surface of the insert is pressed against the opening wall surface, for plastic deformation of the insert heated portion and of the remainder segment heated portion, creating a metallic bond
Implementation Method 3
The insert and the remainder segment are allowed to cool, to bond the insert and the remainder segment together
Data Source
AI summary
A method of securing an insert in a preselected region of a workpiece. An opening wall is formed in the workpiece with an opening wall surface defining an opening to produce a remainder segment of the workpiece. The opening encompasses or coincides with the preselected region. An insert is provided to fit in the opening. An insert heated portion and a remainder segment heated portion are heated to a hot working temperature, at which they are plastically deformable. While the insert is subjected to an engagement motion, to move the insert relative to the remainder segment, an insert engagement surface of the insert is pressed against the opening wall surface, for plastic deformation of the insert heated portion and of the remainder segment heated portion, creating a metallic bond between the insert and the remainder segment. The insert and the remainder segment are allowed to cool, to bond them together.