Welding Joining Part With Clamping Ring for Poorly Weldable Materials
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Solution Overview
Problem
Existing welding auxiliary joining parts face challenges in reliably pressing into components made of poorly weldable materials like aluminum or plastic, often resulting in material displacement and compressive stresses that hinder the welding process.
Innovation Solution
A welding auxiliary joining part with a specifically designed element head featuring a continuous circumferential clamping ring and optional additional rings, which are strategically positioned to clamp the punch shaft without obstructing penetration, ensuring a secure and sealing connection by controlling material flow and displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a ring bead is arranged at the radial outer rim of the element head underside to compress material towards the center, then deep penetration of the welding auxiliary joining part into the aluminum component is supported, but the shaft and element head protrude beyond the free surface of the component and hinder future welding processes
Solution Approach 1:
The element head is designed with a conical shape that transitions from a larger diameter at the top to a smaller diameter at the bottom, where the ring bead is positioned. This dimensional transition allows the element head to provide sufficient material compression and penetration support while maintaining a smaller profile at the bottom, preventing excessive protrusion and improving welding accessibility.
2Reliability
If multiple rigid continuous circumferential stamping rings are pressed into the component surface for selective sealing, then corrosion protection and sealing are improved, but material congestion generates compressive stresses that counteract penetration and adversely affect the joining process
Solution Approach 1:
Instead of using multiple rigid stamping rings distributed around the element head, a single ring bead is positioned specifically at the radial outer rim of the element head underside. This localized design provides sealing functionality at the critical interface between the element head and component, while avoiding the material congestion and compressive stresses generated by multiple distributed rings.
3Strength
If the element head is designed to extend radially beyond the punch shaft to provide clamping, then secure connection is improved, but material displacement increases and creates compressive stresses at the component surface
Solution Approach 1:
The ring bead is designed with specific dimensional parameters including a controlled radial extent and a height that allows it to extend slightly beyond the element head underside. The radial extent is limited to provide adequate clamping force while the height is optimized to prevent excessive material displacement. These parameter adjustments balance connection strength with stress reduction.
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 solution enables easy and reliable pressing of the welding auxiliary joining part into components, reducing material displacement and compressive stresses, thereby enhancing the welding process and ensuring a stable connection between components of different weldability.
Implementation Method 1
by pressing the clamping ring (40) into the first component (A), a material portion of the first component (A) is displaced radially inwards, so that the punch shaft (10) is clamped by the displaced material
Implementation Method 2
In resistance welding, a high current flow is generated in the welding auxiliary joining part, so that in the contact area between the welding auxiliary joining part and at least one second component a melting of material is created
Implementation Method 3
a melting of material is created and thus a welding connection between the welding auxiliary joining part and the second component
Data Source
AI summary
A welding auxiliary joining part with which a welding connection, more particularly a resistance welding connection, can be established between a first component A made of a poorly weldable material and a second component made of weldable material. The welding auxiliary joining part is distinguished by a cylindrical punch shaft that can be punchingly pressed into the first component A approximately rotation-free. The punch shaft has an element head at the head underside of which only one continuous circumferential clamping ring is arranged that projects axially in the direction of the punch shaft.