Welding Element for Dissimilar Material Suspension Connection
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Solution Overview
Problem
The existing connections between vibration dampers and add-on parts in wheel suspensions face challenges in achieving a reliable and strong link, especially under unfavorable installation space conditions, and often require mutually weldable materials, which limits the design flexibility and effectiveness.
Innovation Solution
A connection method that uses a welding element mechanically connected to an add-on part and welded to a contact region of dissimilar materials, allowing for a welded connection without requiring mutual weldability, utilizing a contact region with a smaller wall thickness and enabling forged parts like steel to be used, along with materials like aluminum or plastics, through methods like friction welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If screw connections are used to connect the vibration damper to the add-on part, then the connection can be established with dissimilar materials, but the clamping length is limited and settling characteristics problems arise
Solution Approach 1:
A welding element is introduced as an intermediary component between the add-on part and the contact region. The welding element is mechanically connected to the add-on part and welded to the contact region, enabling connection of dissimilar materials (such as aluminum vibration damper and steel add-on part) while achieving reliable and stable connection without the limitations of screw connections
2Strength
If forged steel yokes are used to connect the vibration damper to the wheel mounts, then strong connection is achieved, but the installation space requirements increase
Solution Approach 1:
The connection system is segmented into three distinct components: the add-on part (e.g., steel yoke), the welding element (e.g., aluminum collar or sleeve), and the contact region on the vibration damper. This segmentation allows each component to be optimized independently, enabling the use of smaller, space-efficient designs while maintaining strong connection through the welding element that is mechanically connected to the add-on part and welded to the contact region
3Adaptability or versatility
If dissimilar materials are used for the add-on part and contact region, then design flexibility is enhanced, but mutual weldability is lost
Solution Approach 1:
The welding element serves as a material intermediary that bridges dissimilar materials. For example, an aluminum welding element can be mechanically connected to a steel add-on part and welded to an aluminum contact region on the vibration damper. This intermediary approach enables the use of dissimilar materials (steel and aluminum) while maintaining welding feasibility, as the welding element is selected to be weldable to the contact region material
Solution Approach 2:
The welding element and contact region are designed to be made from the same material or weldable material partners (e.g., both aluminum or both steel), ensuring homogeneous material compatibility for welding. This homogeneity principle is applied to the welding element-contact region interface, while the add-on part can be made from a different material, thus achieving both design flexibility and welding feasibility
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 provides a strong and reliable connection with a high residual pre-load, enabling optimal linkage of add-on parts to vibration dampers, even in constrained spaces, and allows for the use of non-mutually weldable materials, enhancing the structural integrity and adaptability of the connection.
Implementation Method 1
allowing for a welded connection without requiring mutual weldability, utilizing a contact region with a smaller wall thickness and enabling forged parts like steel to be used, along with materials like aluminum or plastics, through methods like friction welding
Data Source
AI summary
An assembly for a wheel suspension includes a vibration damper and an add-on part. The vibration damper includes a contact region on which the add-on part is configured to rest and wherein the contact region is configured to receive a force transmitted thereon. A welding element is mechanically connected to the add-on part and welded to the contact region. The contact region and the welding element include the same material or weldable material partners and the add-on part and the contact region are formed from dissimilar and not mutually weldable materials.