Workpiece Composite Joining With Local Thickness Reduction
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Solution Overview
Problem
Existing methods for joining metal sheets with significant thickness differences or unfavorable material pairings, such as aluminum and steel, face challenges in thermal joining and require complex structural designs or joining methods, limiting the freedom of design in producing workpiece composites for mass production.
Innovation Solution
A method involving a thermal joining process where one workpiece is provided with an indentation at the joining portion to reduce thickness, allowing for reliable joining of workpieces with large thickness differences by creating a uniform thickness at the joining location, and optionally using a combination of welding and brazing to form an integral connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If thermal joining methods are used to join metal sheets with great differences in thickness, then joining of workpieces with different thicknesses is achieved, but joining reliability deteriorates due to thermal distortion and material transfer issues
Solution Approach 1:
The invention applies preliminary action by creating an indentation in the thicker workpiece before performing the thermal joining process. This pre-prepared geometric feature compensates for the thickness difference, allowing the thinner workpiece to be properly positioned and joined without excessive thermal distortion or material transfer issues. The indentation is formed in advance to optimize the joining conditions.
Solution Approach 2:
The invention applies local quality by creating a localized thickness reduction (indentation) only in the specific joining region of the thicker workpiece, while the rest of the workpiece maintains its original thickness. This localized modification allows for reliable joining at the critical joining zone without compromising the overall structural integrity and thickness requirements of the workpiece.
2Reliability
If complex structural design measures are used to achieve workpiece composites with specific local reinforcements, then joining feasibility is improved, but device complexity increases
Solution Approach 1:
The invention applies segmentation by dividing the workpiece into distinct regions: the main body with original thickness and the localized indentation region. This segmentation allows the thicker workpiece to maintain its overall strength while having a specific localized area prepared for joining, simplifying the design compared to complex structural measures.
Solution Approach 2:
The invention applies local quality by creating a localized thickness reduction only in the joining region, rather than modifying the entire workpiece structure. This localized approach simplifies the overall design while achieving the necessary joining feasibility, avoiding complex structural design measures.
3Ease of manufacture
If conventional thermal joining is used without thickness reduction, then manufacturing simplicity is maintained, but susceptibility to edge cracking increases
Solution Approach 1:
The invention applies preliminary action by forming the indentation before the thermal joining process. This pre-prepared geometry reduces stress concentration at the joining zone during welding, thereby reducing susceptibility to edge cracking while maintaining manufacturing simplicity through an integrated process approach.
Solution Approach 2:
The invention applies preliminary anti-action by creating the indentation in advance to counteract the harmful effects of thermal distortion and stress concentration that would otherwise lead to edge cracking during the joining process. This preventive measure reduces cracking susceptibility before the actual joining occurs.
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 reliable joining of workpieces with thickness differences greater than 0.6 mm, improves joining of difficult material pairings, reduces susceptibility to edge cracking, and allows for the use of previously unutilized weld forms, enhancing design freedom and reducing material transfer issues.
Implementation Method 1
In the case of welding, the material of the parts to be connected by a joining process is heated to above the liquidus temperature. The molten phases of the two workpieces mix and solidify after cooling to form an integral connection.
Implementation Method 2
In the case of brazing, a molten phase is produced by melting a braze material. The workpieces themselves are not heated to above the liquidus temperature or are only melted superficially. As in the case of welding, an integral connection of the workpieces is produced after solidifying.
Data Source
AI summary
A workpiece composite and a method for producing the workpiece composite having at least two workpieces are provided. A first workpiece and a second workpiece are positioned relative to each other, and an integral connection between the end face of the first workpiece and the second workpiece is formed in a joint section by way of a thermal joining method. Prior to forming the integral connection, the first workpiece is provided with an indentation or embossing, which adjoins the end face, at least in the joint section, whereby the thickness of the first workpiece is reduced in the region of the end face.