Thermal-Sprayed Aluminum Joining Layer for Fast Pressure Welding
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Solution Overview
Problem
Current methods for joining components, such as steel and aluminum, in vehicle bodywork are inefficient in terms of cycle time and investment costs, and often require complex processes to achieve sufficient stiffness and strength.
Innovation Solution
A method involving the application of an adhesive layer via thermal spraying on a joining region of an aluminum die-cast component, followed by pressure welding, specifically resistance spot welding, which eliminates the need for additional materials and reduces weight and costs, while achieving a strong and efficient connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional joining methods (riveting, clinching, screwing) are used to connect steel and aluminum components, then mechanical strength and stiffness requirements are met, but cycle time increases and investment costs rise
Solution Approach 1:
The invention changes the material parameter by using an aluminum-compatible adhesive layer instead of conventional steel-based joining methods. This allows direct pressure welding between aluminum components without requiring complex multi-step processes, thereby reducing cycle time while maintaining mechanical strength requirements
Solution Approach 2:
The invention extracts the steel intermediate layer from the joining process by using an aluminum-compatible adhesive layer. This eliminates the need for complex steel-to-aluminum joining procedures and enables simpler, faster pressure welding processes that meet mechanical strength requirements
2Strength
If conventional joining methods are used to ensure sufficient connection strength, then mechanical requirements are satisfied, but construction complexity increases
Solution Approach 1:
The invention applies homogeneity by using an aluminum-compatible adhesive layer that matches the base material properties. This creates a homogeneous aluminum-aluminum connection system that is simpler to construct than dissimilar metal joins, while still satisfying connection strength requirements through the adhesive layer's design
3Reliability
If additional materials such as welding wire are used during pressure welding, then filling gaps and ensuring connection quality improves, but costs increase and weight increases
Solution Approach 1:
The invention applies self-service by designing the adhesive layer with self-fill capability through its specific material properties and layer configuration. The aluminum-compatible adhesive automatically fills gaps and ensures connection quality without requiring additional welding wire or filler materials, thereby reducing weight while maintaining reliability
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 method enables rapid cycle times and low investment costs while providing a strong, efficient connection between dissimilar materials, optimizing mechanical requirements and reducing complexity in the joining process.
Implementation Method 1
generating at least in regions an adhesive layer on the joining region by means of a thermal spraying method
Implementation Method 2
adhere to the component surface primarily as a result of mechanical interlocking
Implementation Method 3
The welding spot between the electrodes is heated to the required temperature by means of the flow of current
Implementation Method 4
fastening a second component to the adhesive layer by joining by means of pressure welding
Implementation Method 5
A further preferred welding method is inter alia capacitor discharge welding
Data Source
AI summary
A method for joining components includes providing a first component where the first component is an aluminum die-cast component and has a joining region for disposing and fastening a second component, generating at least in regions an adhesive layer on the joining region by a thermal spraying method, and fastening the second component to the adhesive layer by joining by pressure welding.