SBIR Phase 1: A Novel Joining Process for Tubular Structures in Automotive and Aerospace Applications

这个小型企业创新研究(SBIR)第一阶段项目探索了使用一种新发明的基于电磁理论的新型材料连接工艺作为一种可靠且经济的管状结构焊接方法的可行性。该项目将进行研究和工程，以解决新焊接技术的商业实施和传播的下列关键技术障碍：(1)对工艺的全面了解和表征；(2)系统设备和焊接程序的设计和优化的有效方法；(3)特殊焊头设计和制造，以便在生产环境中快速装卸工件；(4)可集成到汽车装配线中的自动化焊接系统的工业系统原型设计，以及(5)工艺和性能规格。该技术的成功开发将对汽车底盘和空间框架应用中的液压成型管状结构的装配工艺产生革命性的影响。它还将促进使用铝和钢的混合车身结构设计，并使不同材料(如钛)能够连接到航空航天和电子应用的高温合金。一种新的每年数百万美元的特种管连接工艺预计将在大约5年内完成。

This Small Business Innovation Research (SBIR) Phase I project explores the feasibility of using a newly invented novel materials joining process based on electromagnetic theory as a reliable and economic method to weld tubular structures. The project will conduct research and engineering that will address the following critical technical hurdles for the commercial implementation and dissemination of the new welding technology: (1) A comprehensive understanding and characterization of the process; (2) An effective methodology for design and optimization of the system apparatus and welding procedure; (3) Special weld head design and manufacturing to allow for quick loading and unloading the workpiece in the production environment; (4) Industrial system prototyping for an automated welding system that can be integrated in automotive assembly line, and (5) Process and performance specifications. The successful development of such technology would revolutionize the assembly process of the hydroformed tubular structures in automotive chassis and space frame applications. It will also promote the hybrid automotive body structure design that uses both aluminums and steels, and enable joining of different materials such as titanium to superalloys for aerospace and electronic applications. A new multi-million dollar/year specialty tube joining process is expected in about 5 years.