Welding Insert Structure for Joining Dissimilar Materials
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Solution Overview
Problem
Existing electric resistance welding techniques are limited to assembling parts made of the same material, and there is a need for a method to efficiently join parts of different materials like steel, aluminum, magnesium, and composite materials, which is essential for lightweight vehicle construction, energy efficiency, and structural reinforcement.
Innovation Solution
An insert with a docking portion, peripheral rim, and body part that allows translation under pressure, enabling the peripheral rim to bear against the first part and the body part to be welded to the second part, while thermal decoupling means prevent heat transfer during welding, allowing for the assembly of parts with different materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electric resistance welding is used to assemble parts, then the assembly is mechanically efficient and economical, but it is limited to assembling parts made of the same material
Solution Approach 1:
The patent introduces a welding insert as an intermediary component between two parts made of different materials. This insert enables electric resistance welding to join dissimilar materials (such as steel and aluminum) by serving as a mediator that can be welded to both materials, thereby overcoming the limitation of traditional spot welding which only works with identical materials.
Solution Approach 2:
The welding insert is divided into distinct functional segments: a head part with a docking portion for receiving the welding electrode, a peripheral rim for bearing against the first part, and a body part extending through the first part to be welded to the second part. This segmentation allows each part to perform its specific function optimally in the multi-material assembly process.
2Object-affected harmful factors
If thermal decoupling means are used to protect the first part from heat, then the first part is protected from heat damage, but the welding operation becomes more complex
Solution Approach 1:
The peripheral rim acts as a thermal intermediary that bears against the first part to protect it from heat damage during welding. By positioning this rim between the heat source and the first part, it serves as a thermal barrier that prevents heat transfer while maintaining the simplicity of the overall insert design.
Solution Approach 2:
The insert incorporates thermal decoupling means at specific locations where heat protection is most needed. The peripheral rim is strategically positioned to provide local thermal protection to the first part, applying the principle of local quality by protecting only the areas most susceptible to heat damage rather than the entire assembly.
3Ease of operation
If the docking portion is released to allow translation, then the body part can move to initiate welding, but the connection means must be designed to allow controlled movement
Solution Approach 1:
The connection means are designed to transition from a static connected state to a dynamic movable state during the welding operation. The docking portion is initially connected to the peripheral rim, but can be released to allow translation of the body part toward the second part. This dynamic behavior enables controlled movement while maintaining operational simplicity.
Solution Approach 2:
The peripheral rim is designed to bear against the first part before the body part bears against the second part, creating a preliminary action that tensions the first part. This preliminary bearing action prepares the assembly for the subsequent welding operation by ensuring proper positioning and tensioning before the actual welding occurs.
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 effectively tensions the first part and facilitates the welding of dissimilar materials, enhancing the robustness and thermal insulation of the assembly, enabling the use of diverse materials in vehicle construction.
Implementation Method 1
the peripheral rim, intended to bear against the first part
Implementation Method 2
assembly of two parts and assembly method using this insert... by electric resistance welding... docking portion, intended to receive a welding electrode... distal end intended to be welded to the second part
Implementation Method 3
The thermal decoupling means make it possible to protect the first part from the heat released during the welding operation
Data Source
AI summary
The inserts includes ahead part including a docking portion intended to receive a welding electrode, a peripheral rim, intended to bear against the receiving part, and a body part intended to extend through the first part, the body part having a distal end intended to be welded to the second part. The docking portion is connected to the peripheral rim by connection means configured to allow the translation of the docking portion and of the body part with respect to the peripheral rim under the effect of a distal pressure exerted on the docking portion during the operation of assembling the first and second parts.