High-Energy Beam Welding Joint Part with Segmented Flow Paths
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Solution Overview
Problem
High-energy beam welding methods fail to account for flow paths at butt portions, potentially blocking or narrowing them, leading to fluid leakage and compromised joint strength in metal structures.
Innovation Solution
A manufacturing method involving two-stage welding where a high-energy beam is applied at a shallow depth to prevent fusion around flow paths and at a deeper depth to secure joint strength, ensuring air-tightness and preventing fluid leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is performed over the entire circumference of the butt portion to secure joint strength, then the joint strength between metal pieces is improved, but the flow path may be narrowed or blocked due to fusion around the flow path
Solution Approach 1:
The welding process is divided into two distinct stages: temporary welding at a first depth that avoids the flow path coupling, and main welding at a second depth that ensures joint strength. This segmentation allows each welding stage to serve a specific purpose without compromising the flow path.
Solution Approach 2:
Different welding depths are applied to different functional zones: a shallower depth is used in the region where the flow path coupling exists to prevent fusion, while a deeper welding depth is applied in other regions to ensure adequate joint strength. This local differentiation of welding parameters resolves the contradiction between joint strength and flow path integrity.
2Strength
If welding depth is increased to ensure joint strength, then the joint strength between metal pieces is improved, but the flow path coupling may be fused causing leakage
Solution Approach 1:
Temporary welding is performed first at a controlled depth that does not reach the flow path coupling, establishing a preliminary bond between the metal pieces. This preliminary action secures the components in position while preserving the flow path coupling, preventing subsequent leakage issues.
Solution Approach 2:
The welding depth parameter is changed between two stages: a first welding depth that is insufficient to reach the flow path coupling (preventing fusion), and a second welding depth that is sufficient to ensure joint strength. This parameter change allows the system to achieve both protection of the flow path and adequate joint strength.
3Reliability
If welding is performed at shallow depth to protect flow path, then the flow path is protected from fusion, but the joint strength may be insufficient
Solution Approach 1:
The welding process is segmented into two stages with different depth parameters. The first stage uses a shallow depth to protect the flow path coupling from fusion, while the second stage uses a deeper penetration to ensure adequate joint strength. This segmentation allows both requirements to be satisfied by different portions of the welding process.
Solution Approach 2:
The welding is performed in two periodic stages: temporary welding followed by main welding. Each stage serves a different function - the first stage protects the flow path while providing initial bonding, and the second stage reinforces the joint strength. This periodic application of welding at different depths resolves the contradiction between flow path protection and joint strength.
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 effectively secures joint strength and prevents fluid leakage by controlling the welding depth to protect flow paths and maintain structural integrity.
Implementation Method 1
a plurality of metal pieces (base materials) are occasionally welded to each other using a high-energy beam such as an electron beam and a laser beam
Data Source
AI summary
A manufacturing method for a joint part in which a first metal piece and a second metal piece are joined to each other by performing welding by irradiating a high-energy beam to a joint surface on which the first metal piece and the second metal piece face each other, the first metal piece including a first flow path for passage of a fluid provided at a specific depth from a surface on a side exposed to the high-energy beam, the second metal piece including a second flow path for passage of the fluid provided at a specific depth from the surface on the side exposed to the high-energy beam, and the first flow path and the second flow path being coupled to each other on the joint surface.