Friction Stir Welded Enclosure Joint With Bow Wave Recess
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Friction stir welding techniques are not effective for welding thin-gauge metal covers to metal bases in electronic device enclosures, often resulting in a 'bow wave' that creates gaps and defects in the weld, compromising the hermetic seal.
Innovation Solution
Incorporating a bow wave reduction feature in the base design, such as recesses in the sidewall, to absorb excess cover material and prevent the formation of a bow wave during friction stir welding, ensuring a consistent and high-quality weld.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If friction stir welding is used to join thin-gauge metal covers to metal bases, then welding automation and productivity are improved, but weld quality deteriorates due to bow wave formation causing gaps and defects
Solution Approach 1:
The base is pre-formed with a recess feature before the friction stir welding process. This recess is specifically designed to accommodate and absorb the bow wave that will form during welding, preventing it from causing gaps or defects in the final weld joint.
Solution Approach 2:
The recess acts as an intermediary structure between the bow wave and the weld joint. It provides a designated space for the displaced metal to occupy, preventing the bow wave from interfering with the quality of the weld itself.
2Productivity
If friction stir welding is applied to thin-gauge metal covers, then manufacturing efficiency is improved, but weld consistency deteriorates due to material displacement causing gaps
Solution Approach 1:
The recess is incorporated into the base design before welding begins. This pre-planned feature ensures that the bow wave has a predetermined space to occupy, maintaining consistent weld quality across multiple production cycles.
Solution Approach 2:
The invention changes the geometric parameters of the base by adding a recess feature. This modification alters the available space during welding, allowing the bow wave to be contained without compromising weld consistency.
3Device complexity
If traditional friction stir welding is used on thin-gauge metal, then process simplicity is maintained, but seal reliability deteriorates due to bow wave induced defects
Solution Approach 1:
The recess is formed as part of the base manufacturing process before assembly and welding. This preliminary action ensures that the base is ready to accommodate the bow wave without requiring additional steps or modifications during the welding process itself.
Solution Approach 2:
The recess is placed specifically at the location where the bow wave will form during welding. This localized feature provides targeted accommodation for the displaced metal, ensuring seal reliability at the critical weld joint area without affecting the rest of the structure.
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 bow wave reduction feature allows for the formation of reliable, high-quality friction stir welds that maintain a hermetic seal, reducing the likelihood of wrinkles or folds and ensuring efficient sealing of electronic device enclosures.
Implementation Method 1
Friction stir welding is a technique that is known to be useful in various industrial welding applications
Implementation Method 2
Friction stir welding techniques can be most effectively and reliably used for welding together two metal pieces
Data Source
AI summary
Described are enclosures that include a friction stir weld, including electronic device enclosures, and precursors thereof that contain a metal base that includes a recess and a metal cover that in an assembled condition form a joint at which a friction stir weld can be produced, as well as methods for producing a friction stir weld at a joint of such an assembly; the base includes at least one bow wave reduction feature.