CN109794670B - Dissimilar metal material resistance rivet welding system of light alloy and steel and welding method thereof - Google Patents
Dissimilar metal material resistance rivet welding system of light alloy and steel and welding method thereof Download PDFInfo
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- CN109794670B CN109794670B CN201910245821.4A CN201910245821A CN109794670B CN 109794670 B CN109794670 B CN 109794670B CN 201910245821 A CN201910245821 A CN 201910245821A CN 109794670 B CN109794670 B CN 109794670B
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Abstract
A dissimilar metal material resistance rivet welding system of light alloy and steel and its welding method, utilize the semi-hollow steel nail that the composition can be made to make the direct welding of dissimilar material under the situation that does not need to punch a hole in advance, make light alloy plate, semi-hollow steel nail and steel plate to be connected melt and form the aluminium-steel mixture and weld the nuclear in the local, obtain dissimilar material joint; the rivet is of a semi-hollow structure so as to accommodate a part of the light alloy plates to be connected, and a smaller rivet design can be adopted; the steel nail with a cone angle is adopted to directly pierce the light alloy plate to be connected, so that the existing hole making link is eliminated; the light alloy plate to be connected, the semi-hollow steel nail and the steel plate to be connected are locally melted to form a high-strength aluminum-steel mixture weld core, so that the performance of the joint is improved; the joint performance is improved by regulating and controlling the proportion of each element of the weld nugget through the crushing length of the nail legs and the alloy elements in the rivet cavity. The invention simplifies the production process, improves the production efficiency, reduces the cost and improves the performance of the joint.
Description
Technical Field
The invention relates to a technology in the field of dissimilar metal material connection, in particular to a light alloy and steel dissimilar metal material resistance rivet welding system and a welding method thereof.
Background
The light weight of the automobile body is an effective means for energy conservation and emission reduction in the modern automobile industry, and with the importance of various automobile enterprises, light alloy and ultrahigh-strength steel are widely applied to automobile body manufacturing. Resistance spot welding is used as a traditional spot connection method for vehicle body assembly, and is applied to traditional steel vehicle body welding by virtue of the advantages of high joint strength, low energy consumption and fast takt. However, the application of light alloy materials such as aluminum and magnesium alloy presents a great challenge to the traditional point connection technology, and hard and brittle intermetallic compounds are inevitably formed during fusion welding due to the large difference of thermal physical properties between the light alloy and the steel, so that the effective connection of dissimilar metal materials is difficult to realize by the traditional resistance spot welding process. The above problems make self-piercing riveting based on the cold forming principle the most dominant joining technique for current hybrid material bodies. However, due to the limitation of the rivet hardness and the tonnage of the riveting equipment, when connecting high-strength and high-hardness materials such as advanced high-strength steel or ultrahigh-strength steel, the rivet leg can be severely upset in the self-piercing riveting process, and effective mechanical interlocking cannot be obtained. The existing resistance unit welding technology combines the characteristics of riveting and spot welding, converts the problem of dissimilar metal connection into the problem of welding of the same metal, and can realize reliable connection of light metal and ultrahigh-strength steel. However, the method needs to add an additional blanking process, which is complicated, and thus, the process cost is increased and the production efficiency is reduced. And difficult when the welding accurately place the nail in the blanking hole, the quality controllability is poor.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides a light alloy and steel dissimilar metal material resistance rivet welding system and a welding method thereof, which directly weld dissimilar materials by using a semi-hollow steel nail with customizable components without pre-punching, so that a light alloy plate to be connected, the semi-hollow steel nail and a steel plate to be connected are melted in an open cavity to form a metal mixture weld core, and a high-strength dissimilar material connecting joint is obtained.
The invention is realized by the following technical scheme:
the invention relates to a dissimilar metal material resistance rivet welding system of light alloy and steel, which comprises the following components from top to bottom: the device comprises an upper electrode, a semi-hollow steel nail, a light alloy plate to be connected, a steel plate to be connected and a lower electrode.
The light alloy plates to be connected are at least one layer, and when a plurality of layers of light alloy plates to be connected are adopted, the light alloy plates to be connected are adjacently arranged.
The steel plate to be connected is only one layer and must be arranged on the lower electrode side. In the case of multiple layers, the intermediate layer must be perforated.
The semi-hollow steel nail include: the nail cap, nail leg and the cone angle that connect gradually, wherein: the nail cap and the nail legs form an open cavity, and the height of the open cavity is more than or equal to the thickness of the light alloy plate to be connected.
The top surface of the nail cap is a circular plane, the bottom surface of the nail cap is provided with grooves or inclined angles distributed along the circumferential direction, and the sections of the grooves are circular arcs or rectangles.
Said
The length of the nail leg is 1.2-2.5 times of the total thickness of the light alloy plates to be connected.
The inner side of the open inner cavity can be modified by adding trace alloy elements.
The taper angle can pierce the light alloy plate to be connected and is tightly contacted with the steel plate to be connected under the action of current and electrode pressure.
The invention relates to a resistance rivet welding method of the system, which comprises the following steps:
step 1) a pre-pressing stage: placing the semi-hollow steel nail on the light alloy side of the plate combination to be connected, and applying pre-pressure through the upper electrode and the lower electrode to enable the semi-hollow steel nail, the light alloy plate to be connected and the steel plate to be connected to be in contact with each other and form a conductive path;
step 2) a puncturing stage: applying welding current to soften the light alloy plate to be connected, and piercing the light alloy plate to be connected by the semi-hollow steel nail under the action of electrode pressure and tightly contacting the light alloy plate to be connected with the steel plate to be connected;
step 3) a welding stage: the pressure and the current of the electrode are changed, resistance heat is generated for a certain duration, and the purpose that the light alloy plate materials trapped at the lower end of the steel nail and the cavity to be connected are melted in the open cavity of the steel nail is achieved;
step 4) cooling stage: and applying a protective pressure through the electrode cap, and solidifying the nugget under the action of the water-cooling copper electrode to form the rivet welding joint.
The judgment mode of the steel plate to be connected in close contact with the steel plate to be connected adopts any one or the combination of the following operations to determine:
a) the displacement of the steel nail is 1.0-1.2 times of the thickness of the light alloy plate to be connected;
b) the time of the puncture phase is set empirically.
The starting time of the cooling stage is determined by adopting any one or combination of the following operations:
a) the bottom surface of the nail cap is in contact with the light alloy plate material to be connected;
b) the time of the welding phase is set empirically.
The light alloy plate material trapped in the cavity refers to the light alloy plate material to be connected trapped in the cavity of the semi-hollow steel nail in the puncturing stage.
Technical effects
Compared with the prior art, the rivet adopts a semi-hollow structure, can accommodate part of the light alloy plates to be connected, and can adopt a smaller rivet design; the steel nail with the cone angle is adopted to directly pierce the light alloy plate to be connected, so that the hole making link of the traditional technology is eliminated; the light alloy plate to be connected, the semi-hollow steel nail and the steel plate to be connected are locally melted to form a high-strength aluminum-steel mixture weld core, so that the performance of the joint is improved; meanwhile, the proportion of each element of the weld nugget can be regulated and controlled through the crushing length of the nail legs and the alloy elements in the rivet cavity, so that the performance of the joint is improved. Generally, the invention simplifies the production process, improves the production efficiency, reduces the cost and improves the performance of the joint.
Drawings
FIG. 1 is a schematic structural view of a semi-hollow steel nail according to the present invention;
in the figure: a. b is a structural schematic diagram of the semi-hollow steel nail; c is a sectional view of the semi-hollow steel nail; the nail head 101, the nail leg 102, the taper angle 103, the bottom surface 104 and the cavity 105;
FIG. 2 is a schematic view of a welding process;
in the figure: a is a schematic diagram of a prepressing stage; b. c is a schematic diagram of the middle process of puncture and the end of puncture; d. e is a schematic diagram of a welding stage; f is a schematic diagram of a cooling process; an upper electrode 106, a lower electrode 107, a light alloy plate 108 to be connected, a steel plate 109 to be connected, a semi-hollow steel nail 110, a light alloy plate 111 to be connected and a welding core 112 retained in a cavity;
FIG. 3 is a schematic of electrode pressure and welding current over time for a welding process;
FIG. 4 is a schematic view of a nugget according to embodiment 1;
FIG. 5 is a schematic sectional view of a semi-hollow steel nail according to example 2;
FIG. 6 is a schematic view of a nugget according to embodiment 2;
FIG. 7 is a schematic cross-sectional view of a semi-hollow steel nail according to example 3.
Detailed Description
Example 1
As shown in fig. 1, the semi-hollow steel nail 110 applied in the present embodiment includes: the nail head 101, the nail leg 102 and the cone angle 103 are connected in sequence, wherein: the nut 101 and the legs 102 form an open cavity 105.
The nail head 101 is 10mm in diameter and 2mm in height, the inclination angle of the bottom surface 104 is 15 degrees, and the radius of the chamfer is 0.8 mm.
The cavity 105 is shaped as a cylinder with a diameter of 3.4mm and a height of 2.2 mm.
The outer diameter of the nail leg 102 is 5.3mm, and the height is 2.9 mm.
The section of the taper angle 103 is a regular triangle.
The light alloy plate 108 to be connected adopted by the embodiment is an AA6061-T6 aluminum alloy plate with the thickness of 1mm, and the steel plate 109 to be connected is PHS ultrahigh-strength steel with the thickness of 1.55 mm.
As shown in fig. 2, the present embodiment achieves the joining of the light alloy plate to be joined 108 and the steel plate to be joined 109 through the following four stages:
step 1) a pre-pressing stage: placing the semi-hollow steel nail 110 on the light alloy plate 108 to be connected, and applying pre-pressure through the upper electrode 106 and the lower electrode 107 to enable the semi-hollow steel nail 110, the light alloy plate 108 to be connected and the steel plate 109 to be connected to be in contact with each other to form a conductive path;
step 2) a puncturing stage: applying welding current to soften the light alloy plate 108 to be connected, and piercing the light alloy plate 108 to be connected by the semi-hollow steel nail 110 under the action of electrode pressure to closely contact the steel plate 109 to be connected;
step 3) a welding stage: the pressure and the current of the electrode are changed, and resistance heat is generated for a certain duration, so that the light alloy plate materials 111 trapped at the lower ends of the steel plate 109 to be connected and the semi-hollow steel nail 110 and in the cavity are melted in the open cavity 105 of the steel nail;
step 4) cooling stage: by applying a protective pressure to the electrode cap, the nugget 112 is solidified under the action of the water-cooled copper electrode to form a rivet welded joint.
In this example, the pre-pressure was 2kN, the piercing current was 10kA, the time was 30ms, the welding current was 8kA, the time was 200ms, and the welding force was still 2 kN.
In the present embodiment, the close contact between the semi-hollow steel nail 110 and the steel plate 109 to be connected is determined by a manner that the displacement of the semi-hollow steel nail exceeds 1.1 mm.
The start of the cooling phase is determined by the contact of the underside of the nut with the light alloy sheet material to be joined. .
As shown in fig. 4, the aluminum-steel mixture nugget formed in this example. The average tensile-shear strength of the joint was 4094.7kN, and the fracture modes were pull-out fractures.
Example 2
As shown in fig. 5, the semi-hollow steel nail 110 applied in this embodiment is compared with that of embodiment 1: the inclination angle of the bottom surface 104 of the nail head 101 is 5 degrees, the height of the cavity 105 is 2.8mm, the height of the nail leg 102 is 1.8mm, and the section of the taper angle 103 is a right triangle.
The light alloy plate to be joined 108 and the steel plate to be joined 109 used in this embodiment are the same as those of embodiment 1.
As shown in fig. 2, the present embodiment achieves the joining of the light alloy plate to be joined 108 and the steel plate to be joined 109 through the following four stages:
step 1) a pre-pressing stage: placing the semi-hollow steel nail 110 on the light alloy plate 108 to be connected, and applying pre-pressure through the upper electrode 106 and the lower electrode 107 to enable the semi-hollow steel nail 110, the light alloy plate 108 to be connected and the steel plate 109 to be connected to be in contact with each other to form a conductive path;
step 2) a puncturing stage: applying welding current to soften the light alloy plate 108 to be connected, and piercing the light alloy plate 108 to be connected by the semi-hollow steel nail 110 under the action of electrode pressure to closely contact the steel plate 109 to be connected;
step 3) a welding stage: the pressure and the current of the electrode are changed, and resistance heat is generated for a certain duration, so that the light alloy plate materials 111 trapped at the lower ends of the steel plate 109 to be connected and the semi-hollow steel nail 110 and in the cavity are melted in the open cavity 105 of the steel nail;
step 4) cooling stage: by applying a protective pressure to the electrode cap, the nugget 112 is solidified under the action of the water-cooled copper electrode to form a rivet welded joint. In this example, the pre-pressure was 3kN, the piercing current was 10kA, the time was 30ms, the welding current was 8kA, the time was 300ms, and the welding force was 2 kN.
In the present embodiment, the close contact between the semi-hollow steel nail 110 and the steel plate 109 to be connected is determined by a manner that the displacement of the semi-hollow steel nail exceeds 1.1 mm.
The start of the cooling phase is determined by the contact of the underside of the nut with the light alloy sheet material to be joined.
As shown in FIG. 6, the average tensile strength and shear strength of the joint of the aluminum-steel mixture nugget formed by the embodiment is 3090.4kN, and the fracture modes are pull fracture.
Example 3
As shown in fig. 7, the semi-hollow steel nail 110 applied in the present embodiment includes: the nail head 101, the nail leg 102 and the cone angle 103 are connected in sequence, wherein: the nut 101 and the legs 102 form an open cavity 105.
The diameter of the upper surface of the nail head 101 is 7.8mm, the diameter of the lower surface is 10.8mm, the height is 2mm, and the radius of the arc-shaped groove on the bottom surface 104 of the nail head 101 is 0.8 mm.
The cavity 105 is in the shape of a circular truncated cone, the inclination angle of the cross section of the circular truncated cone is 69 degrees, the diameter of the lower end of the circular truncated cone is 5mm, and the height of the circular truncated cone is 2.2 mm.
The section of the taper angle 103 is an isosceles triangle with the vertex at 140 degrees.
In the present embodiment, the time of the piercing step is set to 30ms empirically in the manner of determining the close contact between the semi-hollow steel nail 110 and the steel plate 109 to be connected.
The welding stage is determined to be completed by empirically setting the time of the welding stage to 200 ms.
Other embodiments of this example are the same as example 1.
The average tensile-shear strength of the aluminum-steel mixture weld nugget formed by the method is 4758.9kN, and the fracture modes are pull fracture.
Compared with the prior art, the invention has the advantages that: the bottom surface of the nail cap is designed into a groove or an inclination angle structure, so that extruded molten metal can be contained in the nail cap during welding, and the welded joint is ensured to be attractive; the steel nail leg part is designed into a semi-hollow structure with a certain wall thickness, so that redundant light metal at the lower end of the leg part can be accommodated to prevent molten metal from splashing, the deformation of the joint is reduced, meanwhile, the proportion of each element of the weld nugget can be regulated and controlled by the length of the nail leg and the size and shape of the inner cavity to improve the performance of the joint, and the flexibility of the process is improved; the light alloy plates to be connected are penetrated by adopting a direct welding mode, a link of hole making is omitted by adopting a simple welding process, and the process time is shorter than 1 s; the tensile-shear strength can reach 4758.9kN, and is improved by about 48 percent compared with the tensile-shear strength of a resistance unit welding head 3200.6kN under the same condition.
The foregoing embodiments may be modified in many different ways by those skilled in the art without departing from the spirit and scope of the invention, which is defined by the appended claims and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
Claims (2)
1. A light alloy-steel dissimilar metal material resistance rivet welding method is characterized in that a semi-hollow steel nail with customizable components is utilized to directly weld dissimilar materials without pre-punching, so that a light alloy plate to be connected, the semi-hollow steel nail and a steel plate to be connected are locally melted to form a metal mixture weld core, and a high-strength dissimilar material connecting joint is obtained;
the semi-hollow steel nail include: the nail cap, nail leg and the cone angle that connect gradually, wherein: the nail cap and the nail legs form an open cavity, and the height of the open cavity is more than or equal to the thickness of the light alloy plate to be connected; the length of the nail leg is 1.2-2.5 times of the total thickness of the light alloy plates to be connected;
the rivet welding method is realized by a dissimilar metal material resistance rivet welding system, and the system comprises the following components from top to bottom: the device comprises an upper electrode, a semi-hollow steel nail, a light alloy plate to be connected, a steel plate to be connected and a lower electrode;
the dissimilar material connecting joint is connected in the following mode:
step 1) a pre-pressing stage: placing the semi-hollow steel nail on the light alloy side of the plate combination to be connected, and applying pre-pressure through the upper electrode and the lower electrode to enable the semi-hollow steel nail, the light alloy plate to be connected and the steel plate to be connected to be in contact with each other and form a conductive path;
step 2) a puncturing stage: applying welding current to soften the light alloy plate to be connected, and piercing the light alloy plate to be connected by the semi-hollow steel nail under the action of electrode pressure and tightly contacting the light alloy plate to be connected with the steel plate to be connected;
step 3) a welding stage: the pressure and the current of the electrode are changed, resistance heat is generated for a certain duration, and the purpose that the light alloy plate materials trapped at the lower end of the steel nail and the cavity to be connected are melted in the open cavity of the steel nail is achieved;
step 4) cooling stage: and applying a protective pressure through the electrode cap, and solidifying the nugget under the action of the water-cooling copper electrode to form the rivet welding joint.
2. The method of resistance rivet welding according to claim 1, wherein the contact with the steel plates to be connected is determined by any one or a combination of the following operations to prevent the steel nails from collapsing:
a) the displacement of the steel nail is 1.0-1.2 times of the thickness of the light alloy plate to be connected;
b) empirically setting the time of the piercing phase;
the starting judgment mode of the cooling stage is determined by adopting any one or combination of the following operations to prevent the nail cap from softening and thinning excessively to the light alloy plates to be connected:
a) the bottom surface of the nail cap is in contact with the light alloy plate material to be connected;
b) the time of the welding phase is set empirically.
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111889866A (en) * | 2020-06-19 | 2020-11-06 | 西安石油大学 | Friction hot riveting threaded nail and welding process |
| CN112475573A (en) * | 2020-11-25 | 2021-03-12 | 东风(武汉)实业有限公司 | Rivet welding nail and resistance rivet welding method thereof |
| CN115213535B (en) * | 2021-04-20 | 2024-01-30 | 上海交通大学 | Magnetic-assisted multistage resistance spot welding connection method for light metal and steel |
| CN115464288A (en) * | 2022-10-13 | 2022-12-13 | 长沙学院 | Resistance heat-assisted hybrid welding system based on heterogeneous metal |
| CN115780980B (en) * | 2022-10-14 | 2024-05-17 | 中国科学院上海光学精密机械研究所 | Welding element for welding dissimilar metals by resistance spot welding and welding method thereof |
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| US6836948B2 (en) * | 2003-02-05 | 2005-01-04 | General Motors Corporation | Method of joining a sheet metal part to a metal tube |
| US7267736B2 (en) * | 2003-12-18 | 2007-09-11 | General Motors Corporation | Method of joining dissimilar materials |
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| CN1938120A (en) * | 2004-01-27 | 2007-03-28 | Gm全球科技运作股份有限公司 | Method for joining two or several profiled parts or metal sheets which are mechanically joined and pressure-welded at one or several connection points |
| CN104797372A (en) * | 2012-09-25 | 2015-07-22 | 伯尔霍夫连接技术有限公司 | Welding auxiliary joining part and method for connecting components by way of said welding auxiliary joining part |
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