CN102126064A - Light metal and bare steel plate spot-welding method based on bulk forming solder - Google Patents
Light metal and bare steel plate spot-welding method based on bulk forming solder Download PDFInfo
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Abstract
The invention relates to a light metal and bare steel plate spot-welding method based on a bulk forming solder in the technical field of metal welding. The method comprises the following steps of: drilling a technology hole on a light metal plate, shaping the solder and embedding the solder into the technology hole; overlapping and clamping the light metal plate provided with the hole and the solder on a bare steel plate, and making a welding gun with a welding wire vertical to the metal plate and aligned with the center of the technology hole; and introducing protective gas into a position to be welded in advance, igniting electric arcs in a cold metal transfer (CMT) mode, combusting, filling a space between the technology hole and the solder, melting the boundary of the solder and the hole, and brazing with the lower-layer steel plate through the solder to form a melt-brazed joint. By adopting cold metal transfer arc welding, the spot melt-brazed joint is formed between the light metal and the bare steel plate, spot connection is realized between the light metal and steel, the differential metal connecting quality is ensured and the manufacturing cost of vehicle bodies is greatly reduced.
Description
Technical field
What the present invention relates to is the method in a kind of metal welding techniques field, specifically is the optimization dissimilar metal spot welding method of a kind of light metal and naked steel plate.
Background technology
Be subjected to the favor of each big automobile production manufacturer much smaller than steel owing to the density of light metal materials such as aluminium, magnesium, yet the overall mechanical property of advanced steel still is better than light metal material, therefore adopt many materials syndeton of light metal and advanced high-strength steel to become the light-weighted preferred option of automobile, this xenogenesis that just relates between light metal and the steel connects.
Because light metal is huge with fusing point, thermal coefficient of expansion and electric conductivity difference between the steel 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---the semitubular rivet self-piercing riveting that forms firm interlock between rivet and the plate, problem that this method has existed when effectively having avoided the foreign material melting of making abroad proposed.Yet joint is easy to generate crackle even embrittlement during low elongation light metal material such as riveted joint Birmasil and magnesium alloy; And when the riveted joint steel, because the high distortion difficulty of steel strength needs bigger rivet force, need on the one hand to increase rivet value in order to avoid the thick and cracking of serious pier takes place rivet, on the other hand the every performance indications of equipment are also proposed requirements at the higher level, thereby increased the link cost of vehicle body.Laser weld aluminium alloy and steel can effectively be controlled the thickness of intermetallic compound, and strength of joint meets the demands easily, but need the energy and the plate gap of strict control laser beam, cause the technology cost very high.Friction stir welding has lower energy input, 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 limited agitating friction greatly.
Find through retrieval prior art, Fronius proposes a kind of cold metal transition (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 being connected of aluminium alloy and galvanized steel by the welding wire solder.Because the CMT method realizes the transition of metal drop by the mechanical pumpback of welding wire, technology of arc welding specific heat input reduction greatly mutually with 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) this method at present only is used for the seam weldering, because the thermal expansion coefficient difference of aluminium alloy and steel is bigger, there is bigger 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; (3) this method only is applicable to being connected of galvanized steel plain sheet and aluminium alloy, can not obtain good joint for naked steel plate.
Summary of the invention
The present invention is directed to the prior art above shortcomings, a kind of light metal and naked steel plate spot welding method based on the bulk forming solder is provided, make that with the weldering of cold metal transferred arc a molten soldered fitting is put in formation between light metal and the naked steel plate, 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 generation gross distortion and naked steel plate can't be connected the problem that obtains good joint with light metal material, and be connected to main vehicle body parts joint design with resistance spot welding process and do not exert an influence, thereby greatly reduce the design and the manufacturing cost of vehicle body to traditional.
The present invention is achieved by the following technical solutions:
The present invention relates to a kind of solder bulk forming flush mounting, comprise: drift, patrix, blank holder and counterdie, wherein: drift is fixedlyed connected with patrix and is socketed in the blank holder, and light metal plate with holes and solder place on the counterdie, drift, patrix, blank holder and the coaxial setting of counterdie.
Described drift provides downward pressure in the solder extrusion process, screw thread has been attacked in inside, so that be connected with patrix.
The end of described patrix is fixedlyed connected with drift by screw thread, in the solder extrusion process, forms die cavity with counterdie and light metal plate with holes, makes extruded solder be full of die cavity inside.
The present invention relates to a kind of arc welding system, comprise: CMT electric arc welding system, welding wire, naked steel plate, gas cylinder, robot switch board, robot and clamping device, wherein: the CMT electric arc welding system links to each other with the robot switch board and transmits the welding control signal, welding wire is loaded in the CMT electric arc welding system, the gas cylinder that is filled with argon gas is communicated with the CMT electric arc welding system, the robot switch board links to each other with robot and the transferring robot motion control signal, and clamping device clamps light metal plate with holes and naked steel plate in welding process.
Described CMT electric arc welding system comprises: welding gun, wire-feed motor, host power supply and tank for coolant, and wherein: welding gun links to each other with wire-feed motor, host power supply and tank for coolant, and is contained in the end of robot; Wire-feed motor is controlled by host power supply, and the welding wire that is mounted in it splashes in the hole of light metal plate as filling metal molten by welding gun, forms joint with mother metal and solder fusion; Tank for coolant provides power supply and control signal by host power supply, cooling CMT electric arc welding system in welding process; Host power supply links to each other with the robot switch board with input, output signal in the transmission welding process.
The artificial industrial machinery arm of described machine, the weight capacity and the radius of clean-up satisfy the arc welding requirement, have six axles that rotatablely move, and drive the welding gun that is contained in the 6th in welding process, make its accurately center of location light metal plate holes.
The present invention includes following steps:
The first step, welding material preliminary treatment: after getting some fabrication holes on the light metal plate, solder is embedded in the fabrication hole by the bulk forming mode.
Described bulk forming embeds and is meant: the cylindrical solder of bulk is placed the hole of light metal plate, and the bottom surface contacts with the counterdie surface, its axis alignment counterdie axis, and the driving blank holder is pressed in the light metal plate on the counterdie; Drift drives patrix and moves downward, and the extruding solder is to predefined stroke stop motion, block cylindrical solder after extruding, be bowl structure and with light metal plate mechanical connection with holes.
Described fabrication hole is cylindrical or the truncated cone-shaped structure.
Described solder is cylindrical zinc, tin, copper or nickel-base alloy piece, has plasticity and toughness preferably, can improve wetability in welding process, forms joint with welding wire, mother metal fusion.
Described bowl structure is made up of end and shank, and wherein: the top of shank obtains the snap ring structure through extruding, and the diameter of end and thickness all greater than the diameter and the thickness of snap ring structure, are realized by end and snap ring structure and light metal plate mechanical connection.
Second overlapping being positioned on the naked steel plate of light metal plate with holes that goes on foot, will be equipped with solder also clamps, and will have the vertical setting with the metallic plate face of welding gun of welding wire and the center in Alignment Process hole;
The parent metal of described naked steel plate is mild steel, high-strength steel, advanced high-strength steel or super-high strength steel etc.
The 3rd the step, after the welding position feeds protective gas in advance, adopt default welding current, weldingvoltage and wire feed rate and frequency with ignite space in electric arc, burning and fill process hole and the solder of CMT bond pattern, melt the border in solder and hole simultaneously, and realize soldering by solder with the steel plate of lower floor, form molten soldered fitting; Extinguish arcs and continuation feed protective gas and prevent the joint oxidation.Robot drives the position that welding gun moves to next preset holes, realizes that the molten pricker spot welding of all the other points connects.
Described CMT pattern is meant: realize the transition of metal drop by the mechanical pumpback of welding wire, comparing the sweating heat input can reduce greatly with the arc welding droplet transfer mode of routine, therefore can effectively reduce the thickness of light metal and steel combination interface intermetallic compound.
The present invention compared with prior art has the following advantages: the present invention changes spot welding into by stitching weldering continuously, greatly reduce influence because of the different distortion butt joint quality that produce of two kinds of material thermal expansion coefficients, and solder is settled, building mortion simply is easy to realize, the efficient height, makes the possibility that is connected to become of light metal and the naked steel plate of no coating.Compare with self-piercing riveting mechanical connection technology, punching and solder cost are low, and to not influencing based on the vehicle body parts design method of resistance spot welding process for a long time, are easy to apply.It is low to the particularly important is this method input heat, can effectively control the thickness of compound between light metal and steel plate interface metal, and solder has improved the wetability in the welding process, and process stabilization, weld defect are few, and joint is attractive in appearance and have a good mechanical performance.
Description of drawings
Fig. 1 is a process unit schematic diagram of the present invention.
Fig. 2 is solder shaping back shape figure of the present invention
Fig. 3 is a technology of arc welding method schematic diagram of the present invention
Fig. 4 is a welding system schematic diagram of the present invention.
Fig. 5 settles the building mortion fundamental diagram for solder of the present invention.
Fig. 6 is cold metal transferred arc weldering process fundamental diagram of the present invention
The specific embodiment
Below embodiments of the invention are elaborated, present embodiment is being to implement under the prerequisite with the technical solution of the present invention, provided detailed embodiment and concrete operating process, but protection scope of the present invention is not limited to following embodiment.
Embodiment 1
Shown in Fig. 1,2,3,4, present embodiment comprises solder shaping flush mounting and arc welding system.
Wherein solder shaping flush mounting comprises: drift 1, patrix 2, blank holder 3, counterdie 4.Wherein: drift 1 is fixedlyed connected with patrix 2 and is socketed in the blank holder 3, and light metal plate 5 with holes and solder 6 place on the counterdie 4, drift 1, patrix 2, blank holder 3 and counterdie 4 coaxial settings.
Described drift 1 provides downward pressure in solder 6 extrusion process, screw thread has been attacked in inside, so that be connected with patrix 2.
The end of described patrix 2 is fixedlyed connected with drift 1 by screw thread, in the extrusion process of solder 6, forms die cavity with counterdie 4 and light metal plate with holes 5, makes extruded solder 6 be full of die cavity inside.
Wherein electric arc welding system comprises: CMT electric arc welding system 10, welding wire 11, naked steel plate 12, gas cylinder 13, robot switch board 14, robot 15, clamping device 16, wherein: CMT electric arc welding system 10 links to each other with robot switch board 14 and transmits the welding control signal, welding wire 11 is loaded in the CMT electric arc welding system 10, the gas cylinder 13 that is filled with argon gas is communicated with CMT electric arc welding system 10, robot switch board 14 links to each other with robot 15 and transferring robot 15 motion control signals, and clamping device 16 clamps light metal plate 5 with holes and naked steel plate 12 in welding process.
Described CMT electric arc welding system comprises: welding gun 17, wire-feed motor 18, host power supply 19 and tank for coolant 20, and wherein: welding gun 17 links to each other with wire-feed motor 18, host power supply 19 and tank for coolant 20, and is contained in the end of robot 15; Wire-feed motor 18 is by host power supply 19 controls, and the welding wire 11 that is mounted in it splashes in the hole of light metal plate 5 as filling metal molten by welding gun 17, forms joint with mother metal and solder 6 fusions; Tank for coolant 20 provides power supply and control signal by host power supply 19, cooling CMT electric arc welding system 10 in welding process; Host power supply 19 links to each other with input, output signal in the transmission welding process with robot switch board 14.
Described robot 15 is the industrial machinery arm, and weight capacity is 5kg, and the radius of clean-up is 1444mm, has six axles that rotatablely move, and drives the welding gun 17 that is contained in the 6th in welding process, makes its accurately center of location light metal plate 5 holes.
The upper strata light metal plate 5 of present embodiment is aluminium alloy AA6061-T6, the naked steel plate 12 of lower floor is low carbon steel plate GMW2, panel thickness coupling: 1mm+1.2mm, aluminium alloy plate 5 usefulness mechanical grinding modes are removed the oxide layer on surface, remove the greasy dirt of metal sheet surface with acetone reagent, welding wire 11 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 course of work is shown in Fig. 5 (a)～(f) and Fig. 6 (a)～(h):
The first step, welding material preliminary treatment: after getting fabrication hole on the aluminium alloy plate 5, solder 6 shapings are embedded in the fabrication hole.
Described shaping embeds and is meant: the cylindrical solder 6 of bulk is placed the hole of aluminium alloy plate 5, and the bottom surface contacts with counterdie 4 surfaces, its axis alignment counterdie 4 axis, and driving blank holder 3 is pressed in aluminium alloy plate 5 on the counterdie 4; Drift 1 drives patrix 2 and moves downward, and extruding solder 6 is to predefined stroke stop motion, block cylindrical solder 6 after extruding, be bowl structure and with aluminium alloy plate 5 mechanical connections with holes.
Described fabrication hole is cylindrical, diameter 6.5mm.
Described solder 6 is cylindrical zinc-containing alloy piece, and diameter is 5mm, and height is 3.5mm, has plasticity and toughness preferably, can improve wetability in welding process, forms joint with welding wire 11, mother metal fusion.
Described bowl structure is made up of end 7 and shank 8, wherein: the top of shank obtains snap ring structure 9 through extruding, the diameter of end 7 and thickness are realized the mechanical connection by end 7 and snap ring structure 8 and aluminium alloy plate 5 all greater than the diameter and the thickness of snap ring structure 9.
Second aluminium alloy plate with holes 5 overlapping being positioned on the naked steel plate 12 that go on foot, will be equipped with solder 6 also clamp, and will have the vertical setting with the metallic plate face of welding gun 17 of welding wire 11 and the center in Alignment Process hole;
The parent metal of described naked steel plate 12 is a mild steel.
The 3rd the step, after the welding position feeds protective gas in advance, adopt pre-set welding current, weldingvoltage and wire feed rate and frequency with ignite space in electric arc, burning and fill process hole and the solder 6 of CMT bond pattern, melt the border in solder 6 and hole simultaneously, and realize solderings by solder 6 with the steel plate 12 of lower floor, form molten soldered fitting; Extinguish arcs and continuation feed protective gas and prevent the joint oxidation.
Described CMT pattern is meant the CMT method that Austrian Fronius company proposes, this method realizes the transition of metal drop by the mechanical pumpback of welding wire 11, comparing the sweating heat input can reduce greatly with the arc welding droplet transfer mode of routine, therefore can effectively reduce the thickness of aluminium alloy and steel combination interface intermetallic compound.
Weld under this welding parameter condition, the zinc element in the solder has improved the wetability of aluminium on steel, has obtained good welding point.The smooth symmetry of joint pattern, nothing is splashed, pore, weld defects such as crackle are few.Postwelding adopts universal testing machine to stretch, and joint can reach higher shear strength.
Embodiment 2
The upper strata light metal plate 5 of present embodiment is aluminium alloy AA6061-T6, the naked steel plate 12 of lower floor 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 5 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 course of work is shown in Fig. 5 (a)～(f) and Fig. 6 (a)～(h):
The first step, welding material preliminary treatment: after getting some fabrication holes on the aluminium alloy plate 5, solder 6 shapings are embedded in the fabrication hole.
Described shaping embeds and is meant: the cylindrical solder 6 of bulk is placed the hole of aluminium alloy plate 5, and the bottom surface contacts with counterdie 4 surfaces, its axis alignment counterdie 4 axis, and driving blank holder 3 is pressed in aluminium alloy plate 5 on the counterdie 4; Drift 1 drives patrix 2 and moves downward, and extruding solder 6 is to predefined stroke stop motion, block cylindrical solder 6 after extruding, be bowl structure and with aluminium alloy plate 5 mechanical connections with holes.
Described fabrication hole is cylindrical, diameter 6.5mm.
Described solder 6 is cylindrical zinc-containing alloy piece, and diameter is 5mm, and height is 3.5mm, has plasticity and toughness preferably, can improve wetability in welding process, forms joint with welding wire 11, mother metal fusion.
Described bowl structure is made up of end 7 and shank 8, wherein: the top of shank obtains snap ring structure 9 through extruding, the diameter of end 7 and thickness are realized the mechanical connection by end 7 and snap ring structure 8 and aluminium alloy plate 5 all greater than the diameter and the thickness of snap ring structure 9.
Second aluminium alloy plate with holes 5 overlapping being positioned on the naked steel plate 12 that go on foot, will be equipped with solder 6 also clamp, and will have the vertical setting with the metallic plate face of welding gun 17 of welding wire 11 and the center in Alignment Process hole;
The parent metal of described naked steel plate 12 is a mild steel.
The 3rd the step, after the welding position feeds protective gas in advance, adopt pre-set welding current, weldingvoltage and wire feed rate and frequency with ignite space in electric arc, burning and fill process hole and the solder 6 of CMT bond pattern, melt the border in solder 6 and hole simultaneously, and realize solderings by solder 6 with the steel plate 12 of lower floor, form molten soldered fitting; Extinguish arcs and continuation feed protective gas and prevent the joint oxidation.Robot 15 drives the position that welding gun 17 moves to next preset holes, realizes that the molten pricker spot welding of all the other points connects.
Other embodiment of 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, does not have weld defect such as splash.Post welding distortion is little, and upper and lower two-layer plate keeps smooth substantially, compares with the seam weldering, does not have obviously crooked.Therefore adopt this process can reduce to be connected the distortion of workpiece greatly.
Claims (9)
1. the optimization dissimilar metal spot welding method of a light metal and naked steel plate is characterized in that, may further comprise the steps:
The first step, welding material preliminary treatment: after getting some fabrication holes on the light metal plate, solder is embedded in the fabrication hole by the bulk forming mode;
Second overlapping being positioned on the naked steel plate of light metal plate with holes that goes on foot, will be equipped with solder also clamps, and will have the vertical setting with the metallic plate face of welding gun of welding wire and the center in Alignment Process hole;
The 3rd step, after tape welding connects the position and feeds protective gas in advance, adopt default welding current, weldingvoltage and wire feed rate and frequency with ignite space in electric arc, burning and fill process hole and the solder of CMT bond pattern, melt the border in solder and hole simultaneously, and realize soldering by solder with the steel plate of lower floor, form molten soldered fitting; Extinguish arcs and continuation feed protective gas and prevent the joint oxidation, and robot drives the position that welding gun moves to next preset holes, realize that the molten pricker spot welding of all the other points connects.
2. the optimization dissimilar metal spot welding method of light metal according to claim 1 and naked steel plate, it is characterized in that, described shaping embeds and is meant: the hole that the cylindrical solder of bulk is placed the light metal plate, the bottom surface contacts with the counterdie surface, its axis alignment counterdie axis, and the driving blank holder is pressed in the light metal plate on the counterdie; Drift drives patrix and moves downward, and the extruding solder is to predefined stroke stop motion, block cylindrical solder after extruding, be bowl structure and with light metal plate mechanical connection with holes.
3. the optimization dissimilar metal spot welding method of light metal according to claim 1 and naked steel plate is characterized in that described fabrication hole is cylindrical or the truncated cone-shaped structure.
4. the optimization dissimilar metal spot welding method of light metal according to claim 1 and naked steel plate is characterized in that, described solder is cylindrical zinc, tin, copper or nickel-base alloy piece.
5. the optimization dissimilar metal spot welding method of light metal according to claim 1 and naked steel plate, it is characterized in that, described bowl structure is made up of end and shank, wherein: the top of shank obtains the snap ring structure through extruding, the diameter of end and thickness all greater than the diameter and the thickness of snap ring structure, are realized by end and snap ring structure and light metal plate mechanical connection.
6. solder shaping flush mounting according to the described method of claim 1, it is characterized in that, comprise: drift, patrix, blank holder and counterdie, wherein: drift is fixedlyed connected with patrix and is socketed in the blank holder, light metal plate with holes and solder place on the counterdie with the coaxial setting of blank holder, drift, patrix, blank holder and the coaxial setting of counterdie.
7. arc welding system according to the described method of claim 1, it is characterized in that, comprise: CMT electric arc welding system, welding wire, steel plate, gas cylinder, robot switch board, robot and clamping device, wherein: electric arc welding system links to each other with the robot switch board and transmits the welding control signal, welding wire is loaded in the CMT electric arc welding system, the gas cylinder that is filled with argon gas is communicated with the CMT electric arc welding system, the robot switch board links to each other with robot and the transferring robot motion control signal, and clamping device clamps light metal plate with holes and naked steel plate in welding process.
8. arc welding system according to claim 7, it is characterized in that, described CMT electric arc welding system comprises: welding gun, wire-feed motor, host power supply and tank for coolant, and wherein: welding gun links to each other with wire-feed motor, host power supply and tank for coolant, and is contained in the end of robot; Wire-feed motor is controlled by host power supply, and the welding wire that is mounted in it splashes in the hole of light metal plate as filling metal molten by welding gun, forms joint with mother metal and solder fusion; Tank for coolant provides power supply and control signal by host power supply, cooling CMT electric arc welding system in welding process; Host power supply links to each other with the robot switch board with input, output signal in the transmission welding process.
9. arc welding system according to claim 8, it is characterized in that, the artificial industrial machinery arm of described machine, the weight capacity and the radius of clean-up satisfy the arc welding requirement, have six axles that rotatablely move, in welding process, drive the welding gun that is contained in the 6th, make its accurately center of location light metal plate holes.
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