AN APPARATUS FOR MICRO-FRICTION STIR WELDING OF DISSIMILAR MATERIALS

Abstract

The present invention relates to an apparatus for micro-friction stir welding of dissimilar materials. The apparatus features a specially contoured probe with a variable taper and a concave-shoulder geometry, both designed to optimize heat generation, material flow, and mixing during welding. Made from wear-resistant materials, such as tungsten carbide, the apparatus minimizes wear and extends tool life. The improved design reduces the formation of defects such as voids and intermetallic compounds, resulting in stronger and more reliable welds. The apparatus is adaptable to a wide range of dissimilar material combinations, enhancing its applicability in various industrial sectors that require high precision and reliability in welding operations, including aerospace, automotive, and electronics.

Specification

Description:[001] The present invention relates to a novel design for a tool used in micro-friction stir welding (micro-FSW), particularly for welding dissimilar materials. The invention aims to improve welding performance, reduce defects, and enhance compatibility between materials with varying properties.
BACKGROUND OF THE INVENTION
[002] The following description provides the information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[003] Micro-friction stir welding (micro-FSW) is a solid-state joining process widely used in industries where precise joining of small-scale components is critical, such as electronics, aerospace, and medical devices. The welding of dissimilar materials presents unique challenges due to differences in melting points, thermal expansion, and metallurgical compatibility.
[004] E , Claims:1. An apparatus for micro-friction stir welding of dissimilar materials, comprising:
a probe having a variable taper, wherein the variable taper is configured to optimize material flow between dissimilar materials during the welding process; and
a shoulder with a concave surface, wherein the concave surface is configured to facilitate heat generation and control flash formation, wherein the probe and shoulder are cooperatively configured to enhance material mixing, reduce defect formation, and extend tool life during the welding of dissimilar materials.
2. The apparatus as claimed in claim 1, wherein the probe comprises helical flutes, the helical flutes being configured to enhance material mixing and ensure uniform distribution of dissimilar materials during the welding process.
3. The apparatus as claimed in claim 1, wherein the probe is made from a wear-resistant material selected from the group consisting of tungsten carbide, tool steel, and ceramics, thereby reducing tool wear and increasing the durabili

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