CN102049591B - Dissimilar metal spot welding system of light metal and coated steel and welding method thereof - Google Patents
Dissimilar metal spot welding system of light metal and coated steel and welding method thereof Download PDFInfo
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- CN102049591B CN102049591B CN 201010613175 CN201010613175A CN102049591B CN 102049591 B CN102049591 B CN 102049591B CN 201010613175 CN201010613175 CN 201010613175 CN 201010613175 A CN201010613175 A CN 201010613175A CN 102049591 B CN102049591 B CN 102049591B
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Abstract
The invention provides a dissimilar metal spot welding system of light metal and coated steel and a welding method thereof, wherein the system comprises a CMT (cold metal transfer) arc welding system, an air bottle, a robot control module, a robot and a clamping device; the arc welding system is connected to the robot control module and used for transmitting a welding control signal; the air bottle is communicated with the CMT arc welding system; the robot control module is connected to the robot for transmitting a control signal of the movement of the robot. In the invention, a spot melting soldering joint is formed between light metal and coated steel to realize the spot connection of the light metal and the coated steel; the serious deformation of the joint during continuous seam welding is solved while the connecting quality of dissimilar metal is ensured; traditional vehicle body part joints primarily using resistance spot welding process are not influenced; and the design and manufacture costs of vehicle bodies are greatly reduced.
Description
Technical field
What the present invention relates to is the device and method in a kind of metal welding techniques field, specifically dissimilar metal spot welding system and the welding method thereof of a kind of light metal and clad steel sheet.
Background technology
Be subject to the favor of each large automobile production manufacturer much smaller than steel owing to the density of the light alloy materials such as aluminium, magnesium, yet the overall mechanical property of advanced steel still is better than light alloy material, therefore adopt many materials syndeton of light-alloy and advanced high-strength steel to become the preferred option of automotive light weight technology, this just relates to xenogenesis connection between light-alloy and the steel.
Because the fusing point between the aluminum steel, thermal coefficient of expansion and electric conductivity difference are huge and easily form during melting welding hard mutually crisp---intermetallic compound, so be difficult to form well behaved joint.A kind of mechanical cold forming process that forms firm interlock-semitubular rivet self-piercing riveting, problem that the method has existed when effectively having avoided the foreign material melting of making between rivet and the plate abroad proposed.Yet joint easily cracks even embrittlement during the low elongation light alloy materials such as riveted joint Birmasil and magnesium alloy; And when the riveted joint steel, because the high distortion of steel strength is difficult, needs larger rivet force, need on the one hand to increase rivet value in order to avoid rivet serious pier occurs slightly and cracking, on the other hand the equipment property indices is also proposed requirements at the higher level, thereby increased the link cost of vehicle body.Laser Welding of Aluminum Alloys and steel can effectively be controlled the thickness of intermetallic compound, and strength of joint easily meets the demands, but need energy and the plate gap of strict control laser beam, cause process costs very high.Friction stir welding has lower energy input, the less advantages such as distortion, relatively is suitable for welding aluminium.But when adopting this method, the shape of joint is very restricted, and for complex-shaped body of a motor car, is difficult to guarantee assembly precision between the sheet part by anchor clamps, is welded in application in the body of a motor car thereby greatly limited agitating friction.
Find through the retrieval to prior art, Fronius company proposes a kind of cold metal transfer (Cold Metal Transfer that is called, abbreviation CMT) technology of arc welding, and realized being connected between aluminium sheet and the galvanized steel plain sheet by the CMT melt-brazing method, it is aluminium sheet fusing in the welding process, and steel plate does not melt, and realizes that by the welding wire solder aluminium alloy is connected connection with galvanized steel.Because the CMT method realizes the transition of metal drop by the mechanical pumpback of welding wire, greatly reduce with the technology of arc welding phase specific heat input of routine, therefore can effectively reduce the thickness of compound between the aluminum steel interface metal, thereby guaranteed the mechanical property of joint, become a kind of aluminium alloy and method of attachment of steel xenogenesis that has application prospect.But there is following defective in the CMT melt-brazing method: (1) at present the method only is used for the seam weldering, because the thermal expansion coefficient difference of aluminium alloy and steel is larger, there is larger welding deformation in joint; When (2) seam welds, be necessary for lap joint between aluminium alloy and the steel plate, this has proposed challenge to traditional vehicle body parts design, is difficult to apply.
Summary of the invention
The present invention is directed to the prior art above shortcomings, dissimilar metal spot welding system and the welding method thereof of a kind of light metal and clad steel sheet are provided, by between light metal and clad steel sheet, forming the some melt-brazed joint, realize that light metal is connected with the point of steel, when guaranteeing the dissimilar metal quality of connection, having solved continuous seam weldering makes joint produce the problem of gross distortion, and be connected to main vehicle body parts joint design with resistance spot welding process and do not exert an influence traditional, thereby greatly reduce the Design and manufacture cost of vehicle body.
The present invention is achieved by the following technical solutions:
The present invention relates to the dissimilar metal spot welding system of a kind of light metal and clad steel sheet, comprise: CMT electric arc welding system, gas cylinder, robot control module, robot and clamping device, wherein: electric arc welding system links to each other with the robot control module and transmits the welding control signal, gas cylinder is communicated with the CMT electric arc welding system, the robot control module links to each other with robot, the control signal of transferring robot motion.
Described CMT electric arc welding system comprises: welding gun, wire-feed motor, welding wire, host power supply and tank for coolant, wherein: welding gun respectively with wire-feed motor, host power supply and tank for coolant link to each other, and welding gun is fixedly installed on the end of robot, wire-feed motor links to each other with host power supply and receives control instruction, welding wire is arranged in wire-feed motor and splashes into the fabrication hole of light metal plate with holes and form joint with the mother metal fusion as filling metal after the welding gun heat fused, tank for coolant is connected with host power supply and receives control instruction and be connected with the CMT electric arc welding system, cooling CMT electric arc welding system in welding process, host power supply links to each other with the robot control module with the input/output signal in the transmission welding process.
Described light metal plate with holes is provided with one and is the fabrication hole of cylindrical or truncated cone-shaped structure.
Described steel plate is clad steel sheet, and its parent metal is mild steel, high-strength steel, advanced high-strength steel or super-high strength steel etc., and coating is zinc, tin, copper or nickel alloy plating layer, and thickness of coating is the 5-50 micron;
Described gas cylinder built-in protective gas is for welding process provides inert protective atmosphere.
Described machine people is the industrial machinery arm that has six axles that rotatablely move, and weight capacity and the radius of clean-up satisfy the arc welding requirement, drives the welding gun that is contained in the 6th axle in welding process, makes its accurately center of location light metal plate holes.
The present invention relates to the welding method of said system
1) gets some fabrication holes at the light metal plate in advance;
2) overlapping being positioned on the clad steel sheet and by clamping device of light metal plate with holes clamped, contact between the metallic plate up and down;
3) robot drives the welding gun motion and makes welding wire in the welding gun vertical with metal plate and aim at the center of the fabrication hole of light metal plate with holes;
4) robot control module sends the control signal that welding process begins and opens in advance logical protective gas of gas cylinder to CMT arc welding host power supply, forms protective gas atmosphere at light metal plate with holes;
5) welding gun is by CMT arc welding host power supply control, under the CMT arc mode, with the striking current set and the voltage electric arc that ignites;
6) electric arc is adjusted to welding current, the weldingvoltage of setting, with wire feed rate and the welding of welding wire pumpback frequency of setting, welding is realized by border, melting process hole and upper strata aluminium sheet in wire melting fill process hole, realizes soldering by coating and lower floor's clad steel sheet;
7) after welding finished, welding current decayed to the receipts arc current, the fabrication hole on the light-alloy plate filled up fully and surfacing after arc extinction, keep passing into protective gas to prevent the joint oxidation;
8) robot drives position and the repeating step 3 that welding gun moves to next preset holes) to step 7) operation, realize dissimilar metal spot welding.
The present invention compared with prior art has the following advantages: the present invention changes spot welding into by stitching weldering, greatly reduces the impact because of the different thermal deformation butt joint quality that produce of bi-material thermal coefficient of expansion.Compare with the self-piercing riveting Mechanical joining technique, punching and the cost of welding wire are very low, and the vehicle body parts method for designing based on resistance spot welding process is not for a long time affected, and are easy to apply.The particularly important is the method and can effectively control the thickness of compound between light metal and steel plate interface metal, joint has superior mechanical property.
Description of drawings
Fig. 1 is process schematic diagram of the present invention.
Fig. 2 is system schematic of the present invention.
Fig. 3 is the inventive method fundamental diagram.
Fig. 4 is technological parameter curve map of the present invention.
The specific embodiment
The below elaborates to embodiments of the invention, and the present embodiment is implemented under take technical solution of the present invention as prerequisite, provided detailed embodiment and concrete operating process, but protection scope of the present invention is not limited to following embodiment.
Embodiment 1
As shown in Figure 2, the present embodiment comprises: CMT electric arc welding system 1, welding wire 2, light metal plate 3 with holes, steel plate 4, gas cylinder 5, robot control module 6, robot 7, clamping device 8.Wherein: CMT electric arc welding system 1 links to each other with robot control module 6 and transmits the welding control signal, welding wire 2 is loaded in the CMT electric arc welding system 1, light metal plate 3 with holes, steel plate 4 are fixed on the clamping device 8, gas cylinder 5 is communicated with CMT electric arc welding system 1, robot control module 6 links to each other with robot 7, the control signal of transferring robot 7 motions.
Described CMT electric arc welding system comprises: welding gun 9, wire-feed motor 10, host power supply 11 and tank for coolant 12, and wherein: welding gun 9 links to each other with wire-feed motor 10, host power supply 11 and tank for coolant 12, and is contained in the end of robot 7; Wire-feed motor 10 is by host power supply 11 controls, and the welding wire 2 that is mounted in it splashes in the hole of light metal plate 3 as filling metal molten by welding gun 9, forms joint with the mother metal fusion; Tank for coolant 12 provides power supply and control signal by host power supply 11, cooling CMT arc welding 1 system in welding process; Host power supply 11 links to each other with robot control module 6 with input, output signal in the transmission welding process.
Described light metal plate 3 with holes, the fabrication hole on it is cylindrical, diameter is 6.5mm.
Described steel plate is clad steel sheet 4, is zinc plated mild carbon steel.
Described gas cylinder 5 in-built argon gas are as protective gas, for welding process provides inert protective atmosphere.
Described robot 7 is the industrial machinery arm, and weight capacity is 5kg, has six axles that rotatablely move, and the radius of clean-up is 1444mm, drives the welding gun 9 that is contained in the 6th axle in welding process, makes its accurately center of location light metal plate 3 holes.
The upper strata light metal plate 3 of the present embodiment is aluminium alloy AA6061-T6, lower floor's galvanized steel plain sheet 4 is zinc plated mild carbon steel plate HDG-GMW2, panel thickness coupling: 1mm+1.2mm, aluminium alloy plate 3 usefulness mechanical grinding modes are removed the oxide layer on surface, remove the greasy dirt of metal sheet surface with acetone reagent, welding wire 2 materials are A1Si5, and diameter is 1.2mm.
Technological parameter: welding current is 127A, voltage 15.3V, and wire feed rate 6.0m/min, arc length is modified to-30%, and welding wire pumpback frequency 70Hz adopts argon gas as protective gas, and its flow is 15L/min, and be 0.8s weld interval.
The present embodiment technical process technical process such as Fig. 3 (a)～(h) and shown in Figure 4:
1) gets the fabrication hole that cylindrical diameter is 6.5mm at aluminium alloy plate 3 in advance;
2) aluminium alloy plate 3 overlapping being positioned on the clad steel sheet 4 and by clamping device are clamped, contact between the metallic plate up and down;
3) robot 7 drives welding guns 9 motions and makes welding wire 2 in the welding gun 9 vertical with metal plate and aim at the center of the fabrication hole of aluminium alloy plate 3 with holes;
4) robot control module 6 sends the control signal that welding process begins and opens in advance logical protective gas of gas cylinder 5 to CMT arc welding host power supply 11, forms protective gas atmosphere near the fabrication hole of aluminium alloy plate 3 with holes;
5) in advance behind the logical protective gas certain hour (GPr=0.1s), welding gun 9 is by 11 controls of CMT arc welding host power supply, under the CMT arc mode, take striking current (size is as 135% of welding current), the voltage electric arc that ignites;
6) ignite electric arc after the I-S section, electric current is through decay (SL section), welding current, weldingvoltage and wire feed rate and the welding wire pumpback frequency welding of CMT electric arc welding system 1 to set,, the burning and the fill process hole, the border of melt-off pore simultaneously, and realize soldering with the steel plate 4 of lower floor by coating;
7) after reaching predefined weld interval (I section), welding current decays to through the SL section and receives arc current (size is 50% of welding current), fabrication hole on the aluminium alloy plate 3 filled up fully and surfacing after (I-E section) arc extinction, continue the protective gas (GPo=0.5s) of logical certain hour to prevent the joint oxidation;
Weld under this welding parameter condition, the zinc element on the galvanized steel plain sheet has improved the wetability of aluminium on steel, has obtained good welding point.The smooth symmetry of joint pattern, without splashing, the weld defects such as pore, crackle are few.Postwelding adopts universal testing machine to stretch, and joint draws cuts that intensity is the highest can to reach 3.364KN; And self-piercing riveting technique (SPR) adopts same material and thickness of slab, draw to cut intensity and be up to 2.704KN, so this process can reach higher intensity.The zinc coat at the galvanized steel plain sheet back side has kept the Corrosion Protection of steel plate without scaling loss simultaneously.
Embodiment 2
The upper strata light metal plate 3 of the present embodiment is aluminium alloy AA6061-T6, lower floor's galvanized steel plain sheet 4 is high-strength steel DP780, panel thickness coupling: 1mm+2mm, the aperture is 6.5mm, centre-to-centre spacing between the Kong Yukong is 20mm, aluminium alloy plate 3 usefulness mechanical grinding modes are removed the oxide layer on surface, remove the greasy dirt of metal sheet surface with acetone reagent.
Technological parameter: welding wire 2 materials are A1Si5, and diameter is 1.2mm, and welding current is 144A, voltage 16.4V; wire feed rate 6.5m/min, arc length is modified to-30%, welding wire pumpback frequency 70Hz; adopt argon gas as protective gas, its flow is 15L/min, and be 0.8s weld interval.
The present embodiment technical process technical process such as Fig. 3 (a)～(h) and shown in Figure 4:
1) in advance at aluminium alloy plate 3 fabrication hole that to get some cylindrical diameters be 6.5mm;
2) aluminium alloy plate 3 overlapping being positioned on the clad steel sheet 4 and by clamping device are clamped, contact between the metallic plate up and down;
3) robot 7 drives welding guns 9 motions and makes welding wire 2 in the welding gun 9 vertical with metal plate and aim at the center of the fabrication hole of aluminium alloy plate 3 with holes;
4) robot control module 6 sends the control signal that welding process begins and opens in advance logical protective gas of gas cylinder 5 to CMT arc welding host power supply 11, forms protective gas atmosphere near the fabrication hole of aluminium alloy plate 3 with holes;
5) in advance behind the logical protective gas certain hour (GPr=0.1s), welding gun 9 is by 11 controls of CMT arc welding host power supply, under the CMT arc mode, take striking current (size is as 135% of welding current), the voltage electric arc that ignites;
6) ignite electric arc after the I-S section, electric current is through decay (SL section), welding current, weldingvoltage and wire feed rate and the welding wire pumpback frequency welding of CMT electric arc welding system 1 to set,, the burning and the fill process hole, the border of melt-off pore simultaneously, and realize soldering with the steel plate 4 of lower floor by coating;
7) after reaching predefined weld interval (I section), welding current decays to through the SL section and receives arc current (size is 50% of welding current), fabrication hole on the aluminium alloy plate 3 filled up fully and surfacing after (I-E section) arc extinction, continue the protective gas (GPo=0.5s) of logical certain hour to prevent the joint oxidation;
8) robot 7 drives position and the repeating step 3 that welding guns 9 move to next preset holes) to step 7) operation, realize dissimilar metal spot welding.
Other embodiment of the present embodiment is identical with embodiment 1.
Under this technological parameter condition, multiple spot series spot welding joint pattern is smooth attractive in appearance, and technology stability is good, without the weld defect such as splashing.Post welding distortion is little, and upper and lower two-layer plate keeps smooth substantially, compares with the seam weldering, without obviously crooked.Therefore adopt this process can greatly reduce to be connected the distortion of workpiece.
Claims (4)
1. the welding method of the dissimilar metal spot welding system of a light metal and clad steel sheet, it is characterized in that, this system comprises: the CMT electric arc welding system, gas cylinder, the robot control module, robot and clamping device, wherein: electric arc welding system links to each other with the robot control module and transmits the welding control signal, gas cylinder is communicated with the CMT electric arc welding system, the robot control module links to each other with robot, the control signal of transferring robot motion, described CMT electric arc welding system comprises: welding gun, wire-feed motor, welding wire, host power supply and tank for coolant, wherein: welding gun respectively with wire-feed motor, host power supply and tank for coolant link to each other, and welding gun is fixedly installed on the end of robot, wire-feed motor links to each other with host power supply and receives control instruction, welding wire is arranged in wire-feed motor and splashes into the fabrication hole of light metal plate with holes and form joint with the mother metal fusion as filling metal after the welding gun heat fused, tank for coolant is connected with host power supply and receives control instruction and be connected with the CMT electric arc welding system, cooling CMT electric arc welding system in welding process, host power supply links to each other with the robot control module with the input/output signal in the transmission welding process, said method comprising the steps of:
1) gets some fabrication holes at the light metal plate in advance;
2) overlapping being positioned on the clad steel sheet and by clamping device of light metal plate with holes clamped, contact between the metallic plate up and down;
3) robot drives the welding gun motion and makes welding wire in the welding gun vertical with metal plate and aim at the center of the fabrication hole of light metal plate with holes;
4) robot control module sends the control signal that welding process begins and opens in advance logical protective gas of gas cylinder to CMT arc welding host power supply, forms protective gas atmosphere at light metal plate with holes;
5) welding gun is by CMT arc welding host power supply control, under the CMT arc mode, with the striking current set and the voltage electric arc that ignites;
6) electric arc is adjusted to welding current, the weldingvoltage of setting, with wire feed rate and the welding of welding wire pumpback frequency of setting, welding is realized by border, melting process hole and light metal plate in wire melting fill process hole, realizes soldering by coating and lower floor's clad steel sheet;
7) after welding finished, welding current decayed to the receipts arc current, the fabrication hole on the light metal plate filled up fully and surfacing after arc extinction, keep passing into protective gas to prevent the joint oxidation;
8) robot drive welding gun moves to the position of next preset holes and repeats step 3) to the operation of step 7), realizes dissimilar metal spot welding.
2. method according to claim 1 is characterized in that, the parent metal of described clad steel sheet is mild steel, high-strength steel, advanced high-strength steel or super-high strength steel, and coating is zinc, tin, copper or nickel alloy plating layer, and thickness of coating is the 5-30 micron.
3. method according to claim 1 is characterized in that, described gas cylinder built-in protective gas.
4. method according to claim 1 is characterized in that, described machine people is the industrial machinery arm that has six axles that rotatablely move.
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