SBIR Phase I: Joining of Dissimilar Materials Using Rivet-Weld Technology

SBIR 第一阶段：使用铆焊技术连接异种材料

• 批准号: 1345675
• 负责人: Tae Hyung Kim
• 金额: $ 14.92万
• 依托单位: Optimal Process Technologies, LLC
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2014
• 资助国家: 美国
• 起止时间: 2014-01-01 至 2014-09-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1345675&HistoricalAwards=false
• 关键词: SBIR; Phase; Joining; Dissimilar; Materials

This Small Business Innovation Research (SBIR) Phase I project will establish the technical feasibility and demonstrate the commercial potential of a new rivet-weld technology for joining dissimilar materials in manufacturing light weight vehicle structures for sustainable transportation. Reducing vehicle weight has been a primary goal of the automotive and aircraft manufacturers in order to improve fuel efficiency and reduce pollution. An effective approach to weight reduction is to create optimized multi-material structures by tailoring different materials to the specific areas of a structure according to their properties. The challenge in producing such multi-material structures lies in materials joining since traditional welding techniques cannot be applied to joining such dissimilar materials due to limitations of weldability. A hybrid technology that combines the advantages of self-piercing riveting and resistance spot welding was invented. The intellectual merits of the project are (1) a new joining technology to enable the joining of aluminum to high strength steels and the creation of innovation joint configurations such as sheet to tube joining, (2) computational method for optimizing the rivet designs tailored for the specific material and joint configurations, and (3) algorithms for controlling the rivet-weld process.The broader impact/commercial potential of this project is to enable design and construction of light weight structures such as automotive bodies. It has been established that every 10% reduction in vehicle weight will result in an improvement in fuel efficiency between 6~8%. With the increasing interest in full electric and hybrid electric vehicles, reduced vehicle weight will translate to smaller batteries and longer driving range for each charge. All these will lead to reduced energy consumptions and emissions. In addition, the rivet-weld technology will allow manufacturers to produce multi-material structure using existing assembly plant infrastructure. The rivet weld machines can be adopted onto welding robots or stationary machines on the assembly lines with minimum reconfiguration.

该小型企业创新研究（SBIR）第一阶段项目将建立技术可行性，并展示一种新的铆接焊接技术的商业潜力，用于在制造可持续运输的轻型车辆结构中连接异种材料。减轻车辆重量是汽车和飞机制造商的主要目标，以提高燃料效率并减少污染。减轻重量的一种有效方法是通过根据不同材料的特性将不同材料定制到结构的特定区域来创建优化的多材料结构。生产这种多材料结构的挑战在于材料连接，因为传统的焊接技术由于可焊性的限制而不能应用于连接这种不同的材料。发明了一种结合自冲铆接和电阻点焊优点的混合技术。该项目的智力优势是（1）一种新的连接技术，可以将铝连接到高强度钢上，并创造创新的连接配置，如板管连接，（2）优化针对特定材料和连接配置定制的铆钉设计的计算方法，以及（3）用于控制铆接-焊接过程的算法。该项目的更广泛的影响/商业潜力是能够设计和建造轻质结构，例如汽车车身。已经确定的是，车辆重量每减少10%将导致燃料效率提高6~ 8%。随着人们对全电动和混合动力汽车的兴趣越来越大，车辆重量的减轻将转化为更小的电池和每次充电更长的行驶里程。所有这些都将导致减少能源消耗和排放。此外，铆接焊接技术将允许制造商使用现有的装配工厂基础设施生产多材料结构。铆钉焊接机可用于焊接机器人或装配线上的固定机器，只需最小的重新配置。