Metal working – Method of mechanical manufacture – Impeller making
Patent
1994-03-02
1995-11-28
Ramsey, Kenneth J.
Metal working
Method of mechanical manufacture
Impeller making
2281145, 228119, 164 80, 164108, B23K 2012
Patent
active
054696178
DESCRIPTION:
BRIEF SUMMARY
The invention relates to friction forming.
In friction welding as is well known, two members generally circular in the form of rods or tubes are pressed together while undergoing relative rotation such that the abutting ends are heated and in due course are displaced from the common interface. With continued relative movement and applied load a plasticised layer develops in the common interface which continues to be regularly extruded forming a flash or collar about the components. With tubes, the flash develops on the inside as well as the outside surfaces. By arresting the relative rotation while maintaining or even increasing the applied load between the components the plasticised layer is partially extruded from the interfacial region while a consolidated forge type weld is completed between the components. It is noted that the plasticised material forming the flash or collar about the components being joined does not contribute significantly per se to the joint formed and is often machined or cut off to leave a nominally flush finish. This friction technique is also used in a stud to plate configuration where in general it is preferable to develop plasticised material from both the plate substrate as well as the stud. With dissimilar materials the plasticised layer is developed principally from the material with the lower hot strength, although in general a solid phase bond is formed.
Attempts have been made in the past to utilize the flash which is inevitably formed during the friction welding process. For example, D. R. Andrews and M. J. Gilpin in an article entitled "Friction Forming--A Preliminary Study" in the Metallurgist and Materials Technologist, July 1975, pages 355-358 describe a form of hot forging using a frictional process to develop heat in the material to be forged in order to shape the component by using a die to shape flash formed when a component is urged against a friction plate. It is suggested that this process could be used for the shaping of bolts, pump impellers, valve stems and the like. This process has never been commercialised and is of limited use in simply providing a die to accommodate and shape the flash which is produced.
In accordance with the present invention, a method of forming a plug-like member comprises placing a consumable member in a bore of a substrate; causing relative movement between the consumable member and the substrate while urging them together to generate frictional heat and form a plasticised region which progresses along the consumable member in a direction opposite to the urging direction, allowing the plasticised material to solidify so as to form the plug like member having an outer surface conforming to the inner surface of at least part of the bore; and either leaving the plug-like member in situ or, following formation of the complete plug-like member, removing the substrate.
We have devised a new technique which has a wide variety of applications in which plug-like members of a variety of constitutions can be formed as will be explained below.
The invention should be contrasted with the hot forging and shaping technique described above. The invention is not concerned with simply accommodating and shaping the flash which is produced but causes the consumable member to be fully plasticised across the bore of the workpiece resulting in a generally uniform and integrated structure. It is a characteristic of the invention that the frictional plane rises up the consumable member whereas in the Andrews et al approach the plane is substantially fixed. Furthermore, as explained below, most of the applications being mentioned involve leaving a plug-like member in situ whereas in the hot forging process the intention is to separate the friction plate and die from the material.
The plasticised material will develop at a rate faster than the feed rate of the consumable member. The consumable member is forced into the configuration of the surrounding cavity or bore to entrap the new plasticised material as it is being formed to result in a plug in the c
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patent: 4592120 (1986-06-01), Egan et al.
patent: 5262123 (1993-11-01), Thomas et al.
Dawes Christopher J.
Dolby Richard E.
Jones Stephen B.
Lilley Roger H.
Nicholas Edward D.
Novack Martin M.
Ramsey Kenneth J.
The Welding Institute
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