CN1084654C - 同步冷却的摩擦搅动焊接 - Google Patents

同步冷却的摩擦搅动焊接 Download PDF

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CN1084654C
CN1084654C CN97113488A CN97113488A CN1084654C CN 1084654 C CN1084654 C CN 1084654C CN 97113488 A CN97113488 A CN 97113488A CN 97113488 A CN97113488 A CN 97113488A CN 1084654 C CN1084654 C CN 1084654C
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soldering set
welding
weld
waste heat
friction stir
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凯文·J·科利根
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • B29C65/0681—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding created by a tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B23K20/123—Controlling or monitoring the welding process
    • B23K20/1235—Controlling or monitoring the welding process with temperature control during joining
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B23K20/1245—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding characterised by the apparatus
    • B23K20/1255—Tools therefor, e.g. characterised by the shape of the probe
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/349—Cooling the welding zone on the welding spot
    • B29C66/3494—Cooling the welding zone on the welding spot while keeping the welding zone under pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • B29C66/81429—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth comprising a single tooth
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/818—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
    • B29C66/8181—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects
    • B29C66/81811—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects of the welding jaws
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/818—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
    • B29C66/8181—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects
    • B29C66/81811—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects of the welding jaws
    • B29C66/81812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects of the welding jaws the welding jaws being cooled from the outside, e.g. by blowing a gas or spraying a liquid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81411—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81421—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave
    • B29C66/81422—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave being convex
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/816—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the mounting of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8167—Quick change joining tools or surfaces

Abstract

对于难以焊接的材料，提供了一种在非常高的焊接速度下获得表面粗糙度大大降低的焊缝的摩擦搅动焊接方法和装置。该方法包括在焊接加工期间冷却搅动焊接焊具，由此减小被软化金属粘附到焊具旋转焊杆和台肩上的倾向。该装置包括带内部空间或外套的焊具，在焊接期间，通过它们冷却剂被吸入，以移走热量冷却焊具。在另一实施例中，此装置包括一将冷却剂喷射到焊接焊具远端外表面上的装置，由此，从焊具和周围工件上移走热量。

Description

同步冷却的摩擦搅动焊接
本发明涉及摩擦搅动焊接的一种方法和装置，尤其是，按照本发明可以去除在摩擦搅动焊接过程中所产生的余热，从而得到较平滑的焊接表面。
摩擦搅动焊接(FSW)是一种较新的焊接工艺，其用于将诸如金属、塑料和其它在所施加的摩擦热下软化和混合的材料的工件连接到一起，以形成一整体连接。在专利公开号WO 93/10935、WO 95/26254，和美国专利5,460,317中，可以发现有关FSW装置和工艺的详细描述，这里将它们都作为参考文献。在图1A和1B中显示了一种FSW的实用装置，如图所示，以板10A′和10B′为例的两个工件被对准，以便要被焊接到一起的板的边缘以直接接触的方式被固定到垫板12′上。一FSW焊具W在其末端有一台肩14′和从台肩的中心向下延伸的非熔化焊杆16′。当旋转焊具W′同板10B′和10A′间的界面接触时，旋转焊杆16′被迫与两个板的材料接触，如图所示。焊杆在材料内的旋转和台肩与材料上表面之间的摩擦在焊接焊具和板界面之间产生大量的摩擦热。这些热量软化了旋转焊杆和台肩附近的板材，引起材料混合，然后变硬，形成一焊缝。焊具沿板10A′和10B′间界面纵向移动，从而沿板间界面形成一细长焊缝。焊接焊具的台肩14′防止变软的材料从板上向上逸出，并强迫材料进入焊缝。当完成焊接时，焊接焊具处于收起位置。
对某些材料，用现有技术的摩擦搅动焊接方法焊接能得到平滑焊缝，但对于不可挤压的铝合金，由于材料粘附到焊接焊具的台肩和焊杆上，严重地限制了最大主轴速度。对这些合金来说，例如铝合金7075，2014，2090，和2024，当主轴速度增大时，输入到焊缝的热量相应地增加，焊缝的上表面的表面组织由于变得粗糙而降级。在更高的主轴速度和更高的输入热量下，铝材就粘附、聚集在焊接焊具的台肩上，从焊接表面的边上撕去材料。对长焊缝来说，这种情况能引起过度的聚集，以致于不可能进行连续焊接。而且，过热的焊接焊具有时能从焊接表面的中心撕去部分表面材料，在焊缝的上表面产生一“鱼鳞”的外表，其沿焊缝的长度方向逐渐地恶化。对某些应用方面，这样一个粗糙的焊接表面是不合要求的，它需要额外机械加工，以获得光滑的表面。粗糙表面经常提供疲劳裂纹的产生点，因此一般是不希望的，特别是被用在能引起疲劳情况下的焊接工件，例如在施加交变载荷的条件下。对大多数应用而言，需要一种能产生不需后续的机加工就具有较低的表面粗糙度及均匀、光滑表面组织的焊缝的FSW方法。
本发明提供了一种对于诸如不可挤压铝合金那样难以焊接材料进行摩擦搅动焊接的方法和装置，它能获得比现有摩擦搅动焊接装置所能获得的更光滑的表面。焊接以更高的速度进行，并具有一商业上可接受的表面粗糙度，以便在大多数场合不需后续的机械加工。
根据本发明，现已发现：由于当焊接速度增加时，在摩擦搅动焊接期间焊具和被焊工件表面接触所产生的过多热量所引起的焊接表面粗糙度增大的原因，对不可挤压材料，其焊接速度受到限制。使材料软化以构成焊缝所需的热量一定，余热引起被软化的材料粘附到摩擦搅动焊接焊具的旋转焊杆和台肩上。焊具反抗这些粘附力的旋转和水平运动导致不规则的焊接表面。因而，本发明提供一种摩擦搅动焊接的方法，它包括在焊接加工期间同步冷却的步骤，以除去余热。此方法允许焊接速度大大地增加，优选的是至少增加约20％，更优选的是至少增加约100％，同时还保持一可接受的焊缝粗糙度。而且，本发明还提供一种用冷却剂冷却的摩擦搅动的焊接装置。
在一实例中，冷却剂在焊具体内循环以去除余热。在这个实例中，本发明的摩擦搅动焊接焊具有一焊具体，在焊具体的末端有一可旋转的、通常不熔化的焊杆和台肩，它们用来将工件搅动焊接到一起。焊具体有一与焊接焊具的焊杆以及最好也与焊接焊具台肩热传导联系的内部空间。此内部空间用来流通冷却剂，以从焊具上去除余热，包括从台肩和焊杆上传来的热量。
在另一实例中，热量通过围绕焊具体末端的外套从摩擦搅动焊接焊具上去除。此外套具有与冷却剂源相通的进口和为排出热的冷却剂的出口。因而，当焊具在使用时，冷却剂流过外套以从焊具上带走热量，以便从旋转的焊杆和台肩上带走余热。
在又一实例中，在焊接期间，通过将冷却剂(例如冷空气或液体冷却剂，如水)喷射到焊具上和被焊表面周围而完成热量的去除。更可取的是，被冷却的焊具部分装备有翅片，以便于热量去除。
根据本发明，即使对不可挤压的铝合金的摩擦搅动焊接也能以商业上可用的速度来获得，它们具有商业上可用的较低的表面粗糙度的组织。
通过参照下述详细说明以及附图，本发明的上述方面和附带的优点将变得更易于理解。其中
图1A是现有技术摩擦搅动焊接焊具的示意图；
图1B是显示现有技术的摩擦搅动焊接焊具在使用时的示意性侧视图；
图2显示了本发明的摩擦搅动焊接装置，其包括一提供冷却剂的喷嘴；
图3是本发明内部冷却焊接焊具的一个实施例的横剖示意图；
图4是显示本发明焊具带外套实施例部分横剖示意性侧视图；
图5是本发明焊具的带有散热片的实施例的空气冷却示意性侧视图；
图6A是显示用现有技术的摩擦搅动焊接焊具得到的焊缝表面细节的光学显微图；
图6B是按照本发明得到的焊缝表面的光学显微图。
根据本发明，从一摩擦搅动焊接焊具(FSW)上去除余热，以减小焊具和被软化的诸如不可挤压铝合金那样的难以焊接材料之间的粘附程度，以便以较快的速度产生一具有较光滑表面的焊缝。这样具有光滑表面的焊缝有很多潜在的优点，不仅在美学上，而且在降低疲劳裂纹和腐蚀产生的危险上。而且，这种焊缝的产生消除或减少了对焊缝进行进一步昂贵的机械加工以获得光滑表面的需要。本发明也由于允许FSW焊具有较高的旋转速度而提高了焊接速度。
根据本发明的方法，当摩擦搅动焊缝形成时，从摩擦搅动焊接焊具上去除余热。因而，去除热量与焊接操作是同步进行的。本发明的方法和装置适用于能经受摩擦搅动焊接的各种材料，尤其可用于难以实施摩擦搅动焊接的材料，诸如不可挤压的铝合金，如2024，7075，2014和2090合金。在现有技术中，为了得到沿工件延伸的不需后续的机械加工就具有商业上可接受的表面粗糙度的焊缝，这些合金一般以比可挤压铝合金低得多的速度被焊接。因而，对于四分之一英寸厚的可挤压铝合金，象合金6061，为了获得光滑的焊缝，摩擦搅动焊接焊具可以1600rpm的转速、每分钟15英寸的速度来焊接；而对于不可挤压的合金，就必须以较低的焊具旋转速度和较慢的焊接速度来焊接。一般地，在现有技术中，八分之一英寸厚的不可挤压合金，如合金2024，可以约500rpm的焊具转速、每分钟3.5英寸的焊接速度被焊接。这样可得到遍及整个工件的不需后续的机械加工就具有可接受的表面粗糙度的焊缝。根据本发明，同样的八分之一英寸厚的2024合金工件可以至少约800rpm的焊具转速，每分钟8英寸的速度被焊接，就能得到沿工件延伸的有着商业上可接受的光滑表面的焊缝。类似地，一7075铝合金八分之一英寸厚的工件(不可挤压合金)以1100rpm的焊具转速、每分钟13英寸的焊接速度被焊接，就能得到沿工件延伸的不需后续的机械加工就具有可接受的表面粗糙度的焊缝。在现有技术中，不使用本发明的焊具和方法，相同的7075合金工件以600rpm的焊具转速被焊接，仅以每分钟7英寸的速度才能获得一焊缝。
从上述内容可清楚地看出：本发明在允许摩擦搅动焊接焊具转速显著增加的同时，焊接速度以每分钟增加几英寸这样惊人的速度增加。更可取的是：本发明允许焊接速度增加至少约20％，更优选的是：至少约100％，同时保持焊接表面粗糙度达到通常商业上可接受的水平，而不需要后续的机械加工，尽管为某些特定用途可选择性地实施这样的机械加工。
本发明提供了各种去除余热的装置，为了便于说明，在附图中图示出了这些装置的优选实施例。很明显，完成去除余热这个相同任务以便以较快速度得到较光滑焊接表面的其它装置也在本发明的范围内。
参照图2，即根据本发明装置的优选实施例的示意性侧视图，一大体呈圆柱形的焊接焊具体30有一为转动焊具而与驱动电机工作连接的一近端34和其上装设有台肩38和从台肩的中心向下轴向延伸的大体呈圆柱形的焊杆40的远端36。如图所示，焊杆40有一尖端42和一具有螺旋槽的外表面。台肩38从它的圆周至焊杆40的中心通常以约10°的角度向上被修尖。
根据本发明，当一工件20在垫板24上被施焊时，一喷嘴50在焊接焊具体30尤其是在其远端36附近延伸。旋转圆柱焊杆在其远端有一尖端42，它通过工件20延伸至一定深度，以在它和垫板24之间提供一最小间隙。因而，此焊杆大致延伸通过工件20的整个厚度，从而贯穿整个工件产生一连续焊缝26。喷嘴与一冷却剂源流体相连，冷却剂可以是液体或空气等，冷却剂在加压状态下被供应至喷嘴，以便冷却剂以喷雾方式离开喷嘴，喷雾直接射到焊具的远端36和工件20的周围。因此，冷却剂从在焊接期间位于工件20上面的台肩38的被暴露部分、工件20本身和形成的焊缝26移去余热。通过传导热量从热的旋转焊杆40和台肩38转移至它们周围环境，即工件20和焊缝26，冷却剂从这里移走了热量。结果，旋转台肩38和工件的表面温度大大低于没有提供冷却剂的情况。如上所述，通过去除余热而使表面温度降低提供了以较快的焊接速度获得的较光滑焊接表面。冷却剂的量应被控制至避免移去太多热量而影响焊接操作的进行。通常每分钟约0.01加仑的冷却剂速度是合适的，根据特定应用可很容易地选择优选速度。
图3显示了根据本发明一内冷却FSW焊具横剖示意图。如图所示，大体呈圆柱形的焊具体60有一为旋转焊具而与电机配合的近端62和有螺纹的远端64。一带有圆形台肩底面65和内螺纹轴环67的帽形台肩66以螺纹连接的方式被接合到FSW的远端64上，以在焊具体60的底面63和台肩的底面65之间形成一内圆柱形空间74。一最好带有外螺纹的焊杆从台肩底面的中心向下延伸。焊具包括一内部空间，最好为螺旋的或盘旋的内部空间，它同冷却剂源及一容纳热的冷却剂的池子相连通。在图示的实施例中，内部空间由垂直间隔开的水平孔组成。因而，大致水平的进口孔70贯穿大约至圆柱形焊具体60远端64的中心。一垂直中心孔72从水平孔70的最远处向下延伸至焊具体60远端64的底面63上的出口，以便它与空间74流体连通。一与中心孔72同轴的环形空间76围绕着中心孔72，并从焊具体60的底面63延伸至进口孔70的下面。因而，中心孔72通过焊具体60的最远端63处的内部空间74与环形空间流体连通。一出口孔78从环形空间76的上端延伸。进入进口孔70的冷却剂流体向下流过中心孔72，到达内部圆柱形空间74，环形空间76，最后从出口孔78排出。
为了引导冷却剂，一与焊具体60同轴并与其之间有间隙的圆柱形冷却剂轴环80围绕进口孔70和出口孔78。在进口孔70之上，用上O形密封环82在轴环80和焊具体60之间进行密封，在出口孔78的下面，用下O形密封环84在焊具体和轴环80之间密封。另外，用第三O形密封环86放置在进口孔70和出口孔78之间使焊具主体60和轴环80之间密封。因而，轴环80构成了一单独的与进口孔70相通的进口腔90和一与出口孔78相通的出口腔96。一冷却剂进口软管92被连接到轴环的进口腔90，而一冷却剂出口软管98被连接到轴环80的出口腔96。为了避免过度冷却焊具而影响焊接加工，控制冷却剂的流量是很重要的。大约每分钟0.1加仑的冷却剂速度是合适的。
使用一外冷却套的另一实施例在图4中被示意性图解说明。在这个实施例中，圆柱形焊接焊具体100有一为旋转焊具而与一装置配合的近端102和一装设有被台肩108包围并沿中心向下延伸的焊杆106的远端104。焊具体100的大致呈圆柱形的远端104装设有一为散热而设计的外部结构，本例中为一系列周向延伸的翅片120。这个结构增加了远端的表面积，因而允许移去更多的热量，以提供更有效的冷却。一大致呈圆柱形的外套110围绕焊具100的带翅片远端104，用一上O形环112和一下O形环114将焊具体100与外套110之间密封。因而外套110围绕翅片120，并与翅片间有间隙，以提供一与外套的进口116和出口118流体连通的环形区122。在使用时，冷却剂流体进入进口116，流进环形空间和翅片120的周围，然后从出口118排出，从焊具100的表面移去热量，余热的移去能通过控制进入冷却剂的温度及其流速来控制，这使得即使当如铝2024或7075那样的高强度铝合金被焊接时，也能在较快的速度下得到大体均匀光滑的焊缝。如前所述，每分钟约0.1加仑的冷却剂供应速度一般是合适的，对特定的应用通过实验很容易选择优选的速度。
在图5中被示意性图解的另一实施例中，用冷空气作为冷却剂来冷却焊接焊具，在这种情况下，如上所述，焊接焊具100在其远端104装备有一系列沿圆周方向延伸的冷却翅片120。然而，代替一环绕外套110的是，至少有一个喷嘴125被定位至向焊接焊具的翅片120上连续喷射冷空气或另一种冷却气体，从而提供冷却。如上所述，余热的去除导致了一较冷的焊接焊具，从而以较快的速度得到一具有均匀、平滑上表面的焊缝。
根据本发明，能获得比现有技术摩擦搅动焊接技术和焊具实现的焊缝光滑得多的焊缝，图6A为放大8倍的铝合金2024搅动焊缝的光学显微图，从中可看出：根据现有技术所获得的焊缝是粗糙的，在其上表面有开裂。这个焊缝是在FSW焊具旋转速度为640rpm，焊接速度为每分钟6.3英寸的情况下获得的。根据本发明所产生的焊缝，例如图6B，其为相同材料在相同放大倍数下的光学显微图，它有一均匀、光滑的表面，而没有表面开裂。这个焊缝由一FSW焊具在640rpm的转速下以每分钟6.3英寸的焊接速度获得的。将一空气/水雾施加于与焊接方向相反侧的焊具台肩和焊接表面的接合处，获得了图6B所示的焊接表面。可预计粗糙度的降低将减少疲劳裂纹产生和表面腐蚀的可能性，从而延长被焊部件的寿命(和可靠性)。而且，可料到能完成长焊接而材料不会聚集到台肩上。
以上虽然只描述了本发明的几个典型实施例，本领域的技术人员将很容易理解到：实质上根据这些典型实施例，不脱离本发明的新颖性和优点，能得到很多变形。相应地，所有这些变形都被包括在如下述权利要求书所限定的本发明的范围之内，在权利要求书中，任何装置加功能的条款确定为涵盖在此被描述的实现所列举功能的结构，其不仅指结构上的同等物，而且指等效的结构。因此，尽管钉子和螺钉不是结构上的同等物，钉子用圆柱面来将木制部件紧固在一起，而螺钉用螺旋面，但在固定木制部件的情况下，钉子和螺钉仍然是等效的结构。

Claims (14)

1.一种摩擦搅动焊接方法，它包括：(a)用一旋转摩擦搅动焊接焊具来焊接由难以用摩擦搅动焊接的材料组成的工件；(b)同步去除摩擦搅动焊接焊具所产生的余热；由此热量的移去就能以较快的速度获得较光滑的焊接表面，而不需机械加工焊接表面。
2.如权利要求1所述的方法，其特征在于，余热的去除包括通过在焊具内部空间流通冷却剂的方式冷却旋转焊具。
3.如权利要求1所述的方法，其特征在于，余热的去除包括在焊接步骤中通过喷射冷却剂雾到焊具上从而冷却焊具。
4.如权利要求1所述的方法，其特征在于，余热的去除是通过围绕焊具的外表面流通冷却剂来实现。
5.如权利要求3所述的方法，其特征在于，冷却剂包括空气。
6.如权利要求3所述的方法，其特征在于，冷却剂包括水。
7.如权利要求1所述的方法，其特征在于，所用的旋转焊具采用比没有移去余热步骤以获得光滑焊缝时所用焊具转速要高的转速。
8.如权利要求1所述的方法，其特征在于，以与不实施同步去除余热步骤焊接而得到一粗糙焊接表面相同的焊接速度焊接，而得到较光滑的焊接表面。
9.如权利要求1所述的方法，其特征在于，焊接速度至少比没有去除余热的焊接约大100％，以获得具有大致相同表面粗糙度的焊缝。
10.如权利要求1所述的方法，其特征在于，焊接速度至少比没有去除余热的焊接约大20％，以获得具有大致相同表面粗糙度的焊缝。
11.如权利要求1所述的方法，其特征在于，工件是由从2014，2024，2090和7075合金中选出的不可挤压铝合金组成。
12.一种摩擦搅动焊接焊具，所述焊具包括在其远端具有一焊杆和一台肩的焊具体，当所述焊杆和台肩与要被焊到一起的工件旋转接触时，它们用于产生摩擦热，所述热引起工件之间形成焊缝，其改进包括：在焊接焊具体内限定有一内部空间，该空间与冷却剂源流体连通，所述空间壁与焊具体的远端热传导连通，由此，在焊接操作期间，当冷却剂流过所述空间时，就会冷却远端。
13.如权利要求12所述的焊具，其特征在于，所述内部空间与围绕焊具体的轴环流体连通，该轴环被划分为进口和出口区，轴环的进口区与所述内部空间的一个进口和冷却剂源流体连通。
14.一摩擦搅动焊接焊具，所述焊具包括在焊具远端有一焊杆和一台肩的焊具体，当该焊杆和台肩与被焊工件旋转接触时，它们用于产生摩擦热，所述热使焊缝成形，其改进包括：一围绕焊具体远端的外套，所述外套具有与冷却剂源流体连通的进口和为排出热的冷却剂的出口，由此，在焊接期间，当冷却剂流过所述外套时，就会从焊具体的远端移去余热。
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