Friction Stir Additive Rivet Formation for Consistent Weld Joints
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Friction stir additive manufacturing tools often produce inconsistent and rough welds, and the installation of rivets can cause structural deformities, necessitating improved methods for joining parts with higher quality welds and surface finishes.
Innovation Solution
A method involving a friction stir additive manufacturing tool that deposits filler material along a weld line between two work-pieces, including through holes, to form high-quality welds and integrated stiffeners or in-situ rivets, while minimizing material waste and reducing the need for post-joining rivet installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional friction stir additive manufacturing tools are used to join parts, then the joining process can be completed, but the weld profiles and surfaces formed are inconstant, rough, and uncontrolled
Solution Approach 1:
The patent applies preliminary action by pre-forming through-holes in the work-pieces before the friction stir additive manufacturing process. These through-holes are strategically positioned to receive filler material that forms rivet-like structures during welding. This preliminary preparation enables the filler material to be deposited in controlled locations, creating consistent weld profiles and preventing rough, uncontrolled surfaces while maintaining joint strength.
2Strength
If rivets are installed to strengthen weld lines, then the connection between parts is improved, but structural deformities are created in parts
Solution Approach 1:
The patent merges the welding process with rivet formation into a single integrated operation. The friction stir additive manufacturing tool simultaneously creates the weld joint and deposits filler material into the through-holes to form in-situ rivets. This combination eliminates the need for separate rivet installation that would cause structural deformities, while the rivets are formed within the material flow during welding, preserving structural integrity.
Solution Approach 2:
The through-holes serve as intermediaries that guide the filler material to specific locations where rivet-like structures are needed. Rather than installing rivets separately (which causes deformities), the holes act as channels that direct the filler material deposition, allowing rivet formation to occur naturally during the welding process without external intervention that would disrupt the part structure.
3Strength
If filler material is deposited into through holes during welding, then in-situ rivets are formed to strengthen joints, but the process complexity increases
Solution Approach 1:
The friction stir additive manufacturing tool is designed with multi-functionality, serving both as a welding device and a material deposition device. The same tool that creates the weld joint also deposits filler material into the through-holes to form rivets. This universal tool eliminates the need for separate riveting equipment and operations, reducing overall process complexity despite the advanced capabilities required of the single tool.
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 approach results in consistent, high-quality welds and reduced material costs, improved mechanical performance, and the ability to join dissimilar materials without material degradation, enhancing structural integrity and manufacturing efficiency.
Implementation Method 1
friction stir additive manufacturing tool
Implementation Method 2
advancing a friction stir additive manufacturing tool across the top surface of the first work-piece and the top surface of the second work-piece along a weld line
Implementation Method 3
depositing a filler material along the weld line and into a plurality of through holes formed in either or both of the first work-piece and the second work-piece
Data Source
AI summary
A method of joining a first work-piece to a second work-piece is provided. Each of the first work-piece and the second work-piece include a top surface, an opposed bottom surface, and a side surface connecting the top surface and the opposed bottom surface. In one aspect, the method includes positioning the side surface of the first work-piece adjacent to the side surface of the second work-piece, and advancing a friction stir additive manufacturing tool across the top surface of the first work-piece and the top surface of the second work-piece along a weld line between the first work-piece and the second work-piece. As the friction stir additive manufacturing tool advances along the weld line, a filler material is deposited along the weld line and into a plurality of through holes formed in either or both of the first work-piece and the second work-piece. Each of the plurality of through holes includes a first opening on the top surface, a second opening on the opposed bottom surface, and a passageway through the work-piece between the first opening and the second opening. The method further includes joining the first work-piece and the second work-piece together.