Friction Stir Welding Probe Recess Geometry for Better Material Stirring
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Solution Overview
Problem
The existing friction stir welding tools with constant width outer circumferential recesses have a limited capacity to take in softened material, which can lead to inadequate stirring and suboptimal welding quality.
Innovation Solution
The friction stir welding tool features outer circumferential recesses with increasing width towards the front end of the probe, allowing for a greater volume of softened material to be taken in and efficiently stirred, enhancing welding quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If outer circumferential recesses have constant width over entire length, then tool structure is simple, but volume of softened material that can be taken in is small
Solution Approach 1:
The outer circumferential recesses are designed with non-uniform width, where the width varies along the length of the recesses. Specifically, the width is smaller near the proximal end and larger near the distal end, allowing different sections of the recesses to serve different functions in material accommodation and stirring efficiency
2Productivity
If outer circumferential recesses have constant width, then manufacturing is simple, but stirring efficiency of softened material is insufficient
Solution Approach 1:
The recess width is optimized locally at different positions: narrower width at the proximal end for structural integrity and easier manufacturing, and wider width at the distal end for enhanced material stirring efficiency, creating a gradient structure that balances manufacturing ease with functional performance
3Manufacturing precision
If outer circumferential recesses have constant width, then tool design is simple, but welding quality is suboptimal
Solution Approach 1:
The varying width design of the outer circumferential recesses optimizes material flow and stirring at different locations, with the wider distal end section providing enhanced material accommodation and mixing capability, directly improving weld quality through better material homogenization
4Force
If outer circumferential recesses have constant width, then tool structure is simple, but pressing force required is high
Solution Approach 1:
The non-uniform recess width distribution, with narrower proximal end and wider distal end, optimizes the mechanical leverage and material flow characteristics, reducing the pressing force required while maintaining effective material stirring and welding performance
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 design increases the efficiency of material stirring and improves welding quality by accommodating more softened material, while also reducing the required pressing force on the workpiece, thus enhancing the durability of the tool.
Implementation Method 1
material softened by friction heat of the probe
Data Source
AI summary
A friction stir welding tool includes a probe having a front end surface and an outer circumferential surface. The probe has, formed therein, outer circumferential recesses extending to the front end surface along a rotation axis. The friction stir welding tool rotates the probe about the rotation axis and embeds the probe inside a workpiece during rotation of the probe to thereby weld the workpiece. The width of the outer circumferential recesses is increased toward a front end of the probe.