Solid-State Welding Load Control for Plating 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 the metal surfaces.
Innovation Solution
A solid state welding apparatus comprising a pair of compression bars and electrodes, controlled by a controller, which applies a first load to form protrusions on the metal workpieces, subjects the load to removal, and passes a current through the electrodes to remove impurities from the metal surface, allowing for effective impurity removal and subsequent joining in a solid state.
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 the plating layer acts as an impurity and reduces joining quality
Solution Approach 1:
The patent applies preliminary action by removing the plating layer (impurity) from the metal surface before the actual solid state welding process. The compression bars are designed to first press and remove the plating layer, then proceed with the welding operation, ensuring the surface is clean and ready for high-quality joining.
Solution Approach 2:
The compression bars are segmented into multiple pressing portions that can independently contact and process different areas of the metal surface. This segmentation allows the system to effectively remove impurities from various locations simultaneously and provides flexibility in handling different workpiece configurations.
2Manufacturing precision
If compression force is applied to remove impurity, then impurity removal effectiveness improves, but excessive compression may damage the workpiece
Solution Approach 1:
The compression bars are designed with dynamic pressing portions that can adjust their contact pressure and area. The pressing portions are configured to apply concentrated force for effective impurity removal while the overall system controls the total compression force to prevent workpiece damage. The dynamic adjustment allows optimization between removal effectiveness and workpiece protection.
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 surface, preventing their retention during the joining process and ensuring high-quality solid state welding by passing the current through the central portion of the workpieces, thus enhancing the joining quality.
Implementation Method 1
passes a current through the pair of electrodes to remove an impurity on a metal surface
Data Source
Figure 1
Figure 2~2(F)
Figure 3~3(F)
AI summary
A solid state welding apparatus (1) comprises a pair of compression bars (11) and (12) that presses a first surface-treated metal workpiece (W10) and a second surface-treated metal workpiece (W20) on sides opposite in a direction of a thickness of the workpieces, a pair of electrodes (21) and (22) disposed around the pair of compression bars (11) and (12), respectively, and a controller (30). The controller (30) controls the pair of compression bars (11) and (12) to cause a first load to act on each of the first and second workpieces (W10) and (W20), subsequently controls the pair of compression bars (11) and (12) 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 (W10) and (W20), and subsequently passes a current through the pair of electrodes (21) and (22) to remove an impurity on a metal surface.