Friction Stir Welding Tool Shoulder for Complex Geometry Access
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Solution Overview
Problem
Friction stir welding tools face limitations in accessibility and flexibility, restricting the ability to weld complex geometries like containers to the corners, scarf joints, and flange seams, and require additional material treatment due to continuous shoulder contact with workpieces.
Innovation Solution
A welding tool with a molding shoulder that adapts to specific welding situations, allowing improved accessibility and enabling the formation of previously unattainable connections by separating the connection region from surroundings, allowing for molding of edges and surfaces during the welding process without additional materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the shoulder is designed as a conventional welding tool component, then the welding process is simple, but the accessibility to complex geometries is restricted
Solution Approach 1:
The shoulder is segmented into multiple independent molding elements that can be selectively activated or deactivated. Each molding element can be independently positioned and oriented, allowing the shoulder to adapt to various complex geometries while maintaining a modular structure that doesn't overly complicate the overall device.
Solution Approach 2:
The shoulder incorporates dynamically adjustable molding elements that can change their position, orientation, or shape during the welding process. This dynamic capability enables the shoulder to access and mold complex geometries such as container corners and scarf joints, transforming a static component into an adaptable tool.
2Ease of operation
If the shoulder continuously contacts the workpiece, then the welding process is stable, but the freedom of movement in three dimensions is restricted
Solution Approach 1:
The continuous shoulder contact is segmented into discrete contact points through multiple independent molding elements. This segmentation allows certain elements to maintain stable contact with the workpiece while others remain free to move, providing both stability and freedom of movement simultaneously.
Solution Approach 2:
The shoulder employs dynamically controllable contact elements that can adjust their contact status with the workpiece. Some elements maintain continuous contact for process stability, while others can be retracted or positioned to allow three-dimensional movement and access to difficult geometries.
3Adaptability or versatility
If the shoulder is adapted for specific welding situations, then the accessibility is improved, but the device complexity increases
Solution Approach 1:
The shoulder is designed as a universal tool with multiple molding elements that can perform various functions depending on the welding situation. The same shoulder structure can be used for different geometries and joint types by activating different combinations of molding elements, eliminating the need for multiple specialized shoulders.
Solution Approach 2:
The shoulder incorporates dynamically configurable molding elements that can be programmed or adjusted for specific welding situations. This dynamic adaptability allows a single shoulder design to handle multiple welding scenarios, from container corners to scarf joints, without requiring complex mechanical changes for each application.
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
Enables the welding of complex geometries like edge joints, containers to the corners, and flange seams with reduced material excess, simplifying the process and eliminating the need for subsequent treatment of welded seams by improving accessibility and securing workpiece edges with precise molding.
Implementation Method 1
the connection region between the shoulder of the welding tool and the workpieces heats up to just below the melting point of the material of the workpieces
Implementation Method 2
the workpieces become soft and plasticize, such that a mixing of the materials of the workpieces being connected is possible in the connection region
Implementation Method 3
a pressure difference is created between the forward region of the welding tool and the rearward end thereof, as a result of the rotary movement of the probe, such that plasticized material is transported around the probe, mixes, and therefore contributes to the formation of the welded seam
Data Source
AI summary
A welding method for connecting at least two workpieces at a connection region by means of friction stir welding using a welding tool having a probe and a shoulder. The method includes rotating the probe around a rotation axis, wherein the connection region is softened by friction heat provided by the probe during said friction stir welding to form a welded seam at the connection region. The method also includes molding, simultaneously with forming the welded seam, at least one of a bevel, a rounding and a chamfer on an edge of the connection region using the shoulder, wherein the shoulder is configured to separate the connection region from the surroundings.