Wavy Butt Weld Boundary for Higher-Strength Metal Plate Joints
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Solution Overview
Problem
Existing butt welding techniques often result in insufficient joining strength between metal plates due to a straight welding boundary line, leading to potential fractures and poor welding when the area of the joint is inadequate, and increasing the number of butt portions is limited by design constraints.
Innovation Solution
The use of a wavy or curved welding boundary line that extends beyond a straight line connecting the ends of the weld, increasing the joint area and preventing displacement of non-welded portions during thermal expansion, thereby enhancing joining strength without increasing the number of butt portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a straight welding boundary line is used in butt welding, then the welding process is simple, but the joining strength is insufficient and the joint area is inadequate
Solution Approach 1:
The welding boundary line is designed as a curved or wavy line instead of a straight line. This curvature increases the length of the welding boundary, thereby increasing the joint area and improving joining strength while maintaining manufacturing simplicity through standardized curved boundary designs
2Strength
If the number of butt portions is increased to improve joining strength, then the joining strength increases, but the design complexity increases and design limitations are reached
Solution Approach 1:
Instead of increasing the number of butt portions (one-dimensional solution), the invention extends the welding boundary line in the two-dimensional plane to increase joint area. This dimensional approach allows achieving higher joining strength without adding more connection points or increasing structural complexity
3Area of stationary object
If the joint area is increased by adding more butt portions, then the joining strength improves, but the manufacturing complexity and design constraints increase
Solution Approach 1:
The welding boundary line is designed as a curved or wavy line instead of a straight line. This curvature increases the length of the welding boundary, thereby increasing the joint area and improving joining strength while maintaining manufacturing simplicity through standardized curved boundary designs
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 significantly improves the joining strength between metal plates by increasing the joint area and reducing the likelihood of poor welding, while also allowing for varying plate thicknesses and easier removal from bending dies without interference.
Implementation Method 1
displacement in non-welded portions due to thermal expansion
Data Source
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AI summary
A metal member (1, 11) includes a first plate (2, 12), and a second plate (3, 13) abutting against and welded to the first plate (2, 12) in at least one butt portion (SI, S2, S3). In the butt portion (S1, S2, S3), a length from a first end (P1, P11, P13) to a second end (P2, P12, P14) of a welding boundary line (L1, L11, L13) between the first plate (2, 12) and the second plate (3, 13) is longer than a length of a straight line (L2, L14) connecting the first end (P1, P11, P13) to the second end (P2, P12, P14) of the welding boundary line (L1, L11, L13).