Thin Metal Hollow Structure Tooling for Friction Weld Shape Control
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Solution Overview
Problem
Existing friction welding techniques face challenges in assembling thin metal parts into hollow structures like airfoils and tail fins, as they struggle with maintaining part shape, managing axial and lateral forces, and achieving consistent weld quality due to the small thickness and dimensions involved.
Innovation Solution
The use of tooling that includes an anvil and shape-holder members to clamp and hold preformed parts in position, with deformable clamping means and lateral grip members to manage forces and maintain shape, allowing for efficient friction welding of thin metal parts into hollow structures with small wall thickness and volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional clamping or spool techniques are used to hold thin metal parts for friction welding, then the parts can be positioned for welding, but the tooling becomes complex and cannot effectively maintain part shape and manage forces for hollow structures with small dimensions
Solution Approach 1:
The tooling is divided into two separate frames positioned on opposite sides of the hollow structure, with each frame providing independent clamping and shape-holding functions. This segmentation allows complex functions to be distributed across modular components, making the overall system more manageable while maintaining high reliability for weld quality
Solution Approach 2:
The anvil is positioned inside the hollow structure formed by the thin metal parts, while the frames and clamping means are positioned outside. This nested arrangement allows the tooling to effectively manage forces and maintain part shape without adding external complexity, as the internal anvil provides stable support from within the hollow structure
2Shape
If thin metal parts with small thickness are used to create hollow structures, then the structures achieve desired lightweight and compact properties, but the parts become difficult to hold in shape and manage forces during welding
Solution Approach 1:
The anvil positioned inside the hollow structure provides counter-support to balance the axial and lateral forces generated during friction welding of thin metal parts. This internal support structure acts as a counterweight system that prevents deformation while maintaining the lightweight nature of the thin-walled hollow structure
Solution Approach 2:
The tooling transitions from traditional external-only clamping to a three-dimensional arrangement with the anvil inside the hollow structure and frames outside. This spatial dimensionality change allows forces to be managed from multiple directions simultaneously, effectively maintaining shape while handling thin parts
3Ease of manufacture
If the tooling is simplified to reduce complexity, then ease of manufacture improves, but the ability to effectively clamp and hold parts for consistent weld quality in small dimensions deteriorates
Solution Approach 1:
Each frame is designed to perform multiple functions simultaneously: providing structural support, enabling clamping of parts, and maintaining shape during welding. This multi-functionality reduces the need for separate specialized components, simplifying manufacture while preserving the precision required for consistent weld quality in small-dimensional hollow structures
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 solution enables robust, reliable, and consistent friction welding of thin metal parts into hollow structures by effectively managing forces and heat, ensuring the desired shape and quality of the weld, even in small dimensions, while minimizing tool complexity and operation steps.
Implementation Method 1
The bead of welding is obtained in the welding zone as a result of the parts heating under the effect of the friction applied locally thereto by the welding pin
Data Source
AI summary
The invention relates to tooling for holding parts in position to enable them to be friction welded together in order to construct a hollow structure, the tooling comprises: a framework made up of two frames for receiving the parts for welding together in their positions for forming the hollow structure, the parts comprising preformed parts and an intermediate section; shape-holder members for holding the hollow structure, associating backing thrust members and lateral grip members for gripping the outsides of the preformed parts; anvils suitable for being placed inside the set of preformed parts beside the section; and clamping means operable to take up a clamping position in which they cause opposing thrust to be applied against the anvil and the inside face of a preformed part, its part itself bears against the shape-holder members.