Solid-State Welding Load Control for Surface Impurity Removal
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Solution Overview
Problem
Existing solid state welding methods fail to effectively remove impurities from surface-treated metals, leading to reduced joining quality due to the presence of plating layers or similar treatments on metal surfaces.
Innovation Solution
A solid state welding apparatus comprising a pair of compression bars and electrodes, controlled by a controller to apply varying loads and pass current through the workpieces, allowing for the removal of impurities by passing current through protrusions formed on the metal surfaces, thereby addressing the issue of impurity presence during the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plating layer or surface treatment is present on metal surfaces, then the metal surface is protected or treated, but impurities are introduced that reduce joining quality
Solution Approach 1:
The patent applies preliminary action by removing impurities from the metal surface before the actual welding process. The compression bars apply compressive force to the workpieces prior to welding, which causes protrusions to form on the metal surfaces. These protrusions are then removed through material transfer during the welding process, ensuring that impurities are eliminated before the main joining operation occurs.
Solution Approach 2:
The patent converts the harmful effect of surface treatments into a beneficial process. The plating layer or surface treatment that initially introduces impurities is transformed into a mechanism for generating protrusions through compressive force. These protrusions, when removed via material transfer during welding, effectively eliminate the impurities while simultaneously preparing the surface for high-quality joining.
2Manufacturing precision
If compressive force is applied to form protrusions on metal surfaces, then impurities can be removed through material transfer, but the process complexity increases
Solution Approach 1:
The patent merges the impurity removal function with the welding process itself. The compression bars that apply compressive force to form protrusions are the same components used for the welding operation. The material transfer that removes impurities occurs during the welding process, eliminating the need for separate impurity removal equipment or steps.
Solution Approach 2:
The compression bars serve multiple functions: they apply compressive force to form protrusions, maintain contact between workpieces during welding, and facilitate material transfer to remove impurities. This multi-functionality reduces device complexity while achieving effective impurity removal and high-precision joining.
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 apparatus effectively removes impurities from the metal surfaces, ensuring high-quality joining by passing current through the central portion of the workpieces, preventing impurities from remaining and enhancing the strength of the welded interface.
Implementation Method 1
passes a current through the pair of electrodes to remove an impurity on a metal surface
Implementation Method 2
The controller controls the pair of compression bars to cause a first load to act on each of the first and second workpieces
Data Source
AI summary
A solid state welding apparatus comprises a pair of compression bars, a pair of electrodes disposed around the pair of compression bars, respectively, and a controller. The controller controls the pair of compression bars to cause a first load to act on each of the first and second workpieces, subsequently controls the pair of compression bars to subject compressive force to load removal to cause a second load smaller than the first load to act on the first and second workpieces, and subsequently passes a current through the pair of electrodes to remove an impurity on a metal surface.