Welding Auxiliary Joining Part for Non-Weldable Material Connections
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Solution Overview
Problem
Current methods for connecting components of non- or poorly weldable materials with weldable materials are time-consuming and complex, often resulting in poor mechanical loadability and lifetime due to small contact surfaces and waste material contamination during the welding process.
Innovation Solution
A mechanical-thermal setting-welding process using a welding auxiliary joining part made of weldable material, which is driven into the non-weldable component with a combined mechanical and thermal load, deformed to form a welding head, and then welded to a weldable component, eliminating the need for pre-punching and minimizing waste material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a welding auxiliary joining part with a small contact surface is used, then the welding process can be performed, but the mechanical loadability and lifetime are reduced
Solution Approach 1:
The welding auxiliary joining part is deformed from a linear shape into a three-dimensional welding head with increased surface area. This dimensional transformation allows the same component to provide both structural function and adequate welding contact surface, resolving the contradiction between maintaining mechanical loadability and increasing contact area.
Solution Approach 2:
The geometric parameters of the welding auxiliary joining part are changed through deformation, transforming it from a simple insert to a formed welding head with optimized surface area, shape, and structural properties. This parameter change enables adequate contact surface while maintaining mechanical integrity.
2Ease of manufacture
If pre-punching is performed to insert the welding auxiliary joining part, then the insertion is facilitated, but waste material is produced and the process becomes more complex
Solution Approach 1:
The welding auxiliary joining part is pre-formed with an insertion tip geometry that enables direct insertion into the component without requiring pre-punching. This preliminary shaping of the joining part itself eliminates the need for separate punching operations and prevents waste material generation.
Solution Approach 2:
The welding auxiliary joining part is designed with self-insertion capability through its tip geometry, allowing it to be directly inserted into the component without external assistance from punching tools or pre-prepared holes. The joining part serves its own insertion function.
3Reliability
If a multi-step process is used to deform the shank laterally after welding, then a force-fit connection is achieved, but the process becomes time-consuming and complex
Solution Approach 1:
The deformation process is merged with the welding process itself. The welding auxiliary joining part is deformed under combined mechanical and thermal load during the welding operation, achieving both the welding connection and the force-fit connection in a single integrated process step rather than separate operations.
Solution Approach 2:
The welding auxiliary joining part is made of weldable material that can undergo deformation under combined mechanical and thermal load. This material property enables the joining part to be both welded and deformed in a single process, achieving multiple functions simultaneously.
4Productivity
If the tip of the welding auxiliary joining part is used for welding, then the connection is achieved, but the small contact surface prolongs the welding procedure
Solution Approach 1:
The welding contact surface is transformed from a small tip area to a larger three-dimensional welding head surface. This dimensional change increases the contact area available for welding, enabling faster heat distribution and shorter welding cycles while maintaining connection quality.
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 provides a faster, more reliable connection with increased mechanical loadability and lifetime by forming a larger welding surface without waste material contamination, allowing for efficient connection of disparate materials like plastics and metals.
Implementation Method 1
driving of a welding auxiliary joining part into the at least one first component with a combined mechanical-thermal load of at least the welding auxiliary joining part
Implementation Method 2
welding the welding auxiliary joining part to the at least one second component so that the at least one first component and the at least one second component are connected to each other
Data Source
AI summary
A welding auxiliary joining part is disclosed in the shape of a stud having a head, a shank and a tip. The welding auxiliary joining part is driven in by means of a mechanical-thermal setting method into a component of non- or poorly weldable material. During the driving in, a welding head is created due to mechanical deformation so that the component may be connected subsequently via the welding auxiliary joining part to a further component of weldable material by means of welding.