CN110312589A - 以热喷涂中间层电阻焊接不可焊金属 - Google Patents
以热喷涂中间层电阻焊接不可焊金属 Download PDFInfo
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- CN110312589A CN110312589A CN201880012634.5A CN201880012634A CN110312589A CN 110312589 A CN110312589 A CN 110312589A CN 201880012634 A CN201880012634 A CN 201880012634A CN 110312589 A CN110312589 A CN 110312589A
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- aluminium
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- 229910052751 metal Inorganic materials 0.000 title claims abstract description 28
- 239000002184 metal Substances 0.000 title claims abstract description 28
- 238000007751 thermal spraying Methods 0.000 title claims description 14
- 239000011229 interlayer Substances 0.000 title description 2
- 238000000034 method Methods 0.000 claims abstract description 58
- 239000000463 material Substances 0.000 claims abstract description 52
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 41
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 40
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 29
- 239000010959 steel Substances 0.000 claims abstract description 29
- 230000008569 process Effects 0.000 claims abstract description 20
- 238000005507 spraying Methods 0.000 claims abstract description 18
- 239000000758 substrate Substances 0.000 claims abstract description 17
- 230000000930 thermomechanical effect Effects 0.000 claims abstract description 6
- 238000010276 construction Methods 0.000 claims abstract 2
- 239000011241 protective layer Substances 0.000 claims abstract 2
- 238000003466 welding Methods 0.000 claims description 68
- 239000004411 aluminium Substances 0.000 claims description 28
- 238000000576 coating method Methods 0.000 claims description 21
- 239000011248 coating agent Substances 0.000 claims description 19
- 239000010410 layer Substances 0.000 claims description 14
- 229910001220 stainless steel Inorganic materials 0.000 claims description 7
- 239000010935 stainless steel Substances 0.000 claims description 7
- 238000005488 sandblasting Methods 0.000 claims description 4
- 230000007704 transition Effects 0.000 claims description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 2
- 229910052799 carbon Inorganic materials 0.000 claims description 2
- 238000004140 cleaning Methods 0.000 claims description 2
- 239000000470 constituent Substances 0.000 claims description 2
- 239000000155 melt Substances 0.000 claims description 2
- 229910000975 Carbon steel Inorganic materials 0.000 claims 3
- 239000010962 carbon steel Substances 0.000 claims 3
- 238000005246 galvanizing Methods 0.000 claims 1
- 229910000679 solder Inorganic materials 0.000 description 10
- 238000005275 alloying Methods 0.000 description 7
- 230000008878 coupling Effects 0.000 description 6
- 238000010168 coupling process Methods 0.000 description 6
- 238000005859 coupling reaction Methods 0.000 description 6
- 238000005260 corrosion Methods 0.000 description 5
- 230000007797 corrosion Effects 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 238000005476 soldering Methods 0.000 description 5
- 229910002056 binary alloy Inorganic materials 0.000 description 3
- 238000010891 electric arc Methods 0.000 description 3
- 230000005611 electricity Effects 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 230000006698 induction Effects 0.000 description 3
- 229910021328 Fe2Al5 Inorganic materials 0.000 description 2
- 229910015392 FeAl3 Inorganic materials 0.000 description 2
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000001962 electrophoresis Methods 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229910052749 magnesium Inorganic materials 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- 229910001105 martensitic stainless steel Inorganic materials 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 230000003746 surface roughness Effects 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 229910000760 Hardened steel Inorganic materials 0.000 description 1
- 229910000635 Spelter Inorganic materials 0.000 description 1
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- KMWBBMXGHHLDKL-UHFFFAOYSA-N [AlH3].[Si] Chemical compound [AlH3].[Si] KMWBBMXGHHLDKL-UHFFFAOYSA-N 0.000 description 1
- -1 acieral Substances 0.000 description 1
- 238000004220 aggregation Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 229910000423 chromium oxide Inorganic materials 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 239000010431 corundum Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000005238 degreasing Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 238000010285 flame spraying Methods 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000005272 metallurgy Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- QMQXDJATSGGYDR-UHFFFAOYSA-N methylidyneiron Chemical compound [C].[Fe] QMQXDJATSGGYDR-UHFFFAOYSA-N 0.000 description 1
- 238000003032 molecular docking Methods 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 238000002161 passivation Methods 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 238000004826 seaming Methods 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Classifications
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- 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
- B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
- B23K3/04—Heating appliances
- B23K3/047—Heating appliances electric
- B23K3/0478—Heating appliances electric comprising means for controlling or selecting the temperature or power
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- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/16—Resistance welding; Severing by resistance heating taking account of the properties of the material to be welded
- B23K11/20—Resistance welding; Severing by resistance heating taking account of the properties of the material to be welded of different metals
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- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/06—Resistance welding; Severing by resistance heating using roller electrodes
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- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/10—Spot welding; Stitch welding
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- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/10—Spot welding; Stitch welding
- B23K11/11—Spot welding
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- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/14—Projection welding
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- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/16—Resistance welding; Severing by resistance heating taking account of the properties of the material to be welded
- B23K11/163—Welding of coated materials
-
- 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
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/20—Bonding
- B23K26/32—Bonding taking account of the properties of the material involved
- B23K26/323—Bonding taking account of the properties of the material involved involving parts made of dissimilar metallic material
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- 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
- B23K9/00—Arc welding or cutting
- B23K9/23—Arc welding or cutting taking account of the properties of the materials to be welded
- B23K9/232—Arc welding or cutting taking account of the properties of the materials to be welded of different metals
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
- B32B15/012—Layered products comprising a layer of metal all layers being exclusively metallic one layer being formed of an iron alloy or steel, another layer being formed of aluminium or an aluminium alloy
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
- B32B15/013—Layered products comprising a layer of metal all layers being exclusively metallic one layer being formed of an iron alloy or steel, another layer being formed of a metal other than iron or aluminium
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/08—Metallic material containing only metal elements
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
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- C—CHEMISTRY; METALLURGY
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/18—After-treatment
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- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/02—Iron or ferrous alloys
- B23K2103/04—Steel or steel alloys
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- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/18—Dissimilar materials
- B23K2103/20—Ferrous alloys and aluminium or alloys thereof
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- Plasma & Fusion (AREA)
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- Chemical Kinetics & Catalysis (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Optics & Photonics (AREA)
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Abstract
本发明是关于一种利用热结合过程以搭接构造结合至少两种彼此不可直接焊接的材料的方法，其中使用由第一步骤及第二步骤所组成的两步骤顺序，第一步骤是将热机械或机械表面保护层施加于(不锈)钢基板(1)的表面上，及在第二步骤中，使用热结合过程来焊接喷涂层(2)与外加铝片材(3)，且于整个材料构造中不具有脆性金属间相。
Description
本发明是关于通过在(不锈)钢的表面上施加具有明确厚度、表面粗糙度及过渡电阻的铝热喷涂层，而使不可焊的金属组合如铝对(不锈)钢变得可电阻焊接。随后在第二步骤中，接着进行电阻(点)焊接过程。所使用的焊接参数必需以仅铝对铝接触面积熔融，且在铝层与(不锈)钢之间不具有脆性金属间相的方式来选择。
电阻焊接是金属制造工业中的其中一种最常用的焊接程序。可例如通过点焊(spotwelding)、辊缝焊接(rollerseamwelding)、突点焊接(Projectionwelding)或点焊黏结(weldbonding)来进行电阻焊接，以获得经焊接的白色家电、燃料槽、汽车、铁路或卡车的车体构造。但有许多材料(诸如热成形马氏体不锈钢或二及三接点材料组合)不具有用于电阻焊接过程的可焊接性。针对这种材料，存在若干于材料上产生机械焊料或硬焊沉积物的概念。然而，这种机械焊料或硬焊沉积物需要变形及/或切割材料以在材料与机械焊料或硬焊沉积物之间获得良好黏结或形成闭合。当材料进一步通过传统电阻焊接过程处理时，焊接点通常最终具有冷裂脆性断裂行为及因此这具有低强度水平以及低电力传递。整个汽车车体工程工业希望以多材料设计利用不同接头使用不同金属如(不锈)钢及铝。当前最新技术没有可利用的热焊接方法，而仅可使用黏结及机械结合。利用已知的焊接方法，会在铝与(不锈)钢之间产生脆性金属间相。通过本发明，可使用廉价且循环时间快速的电阻点焊。此外，(接触)抗腐蚀性会提高。通过本发明，可针对不同组合达成如类似铝接头的结合力。
EP专利申请案2679328A1是关于一种通过电阻焊接来结合第一结合伴体与第二结合伴体的方法，及在两结合伴体之间的程序新型永久连接。目标是要提供一种使用结合辅助件及焊接过程结合第一结合伴体与第二结合伴体的替代方式，具体而言提供一种添加待结合的不同部件，具体而言不同结合伴体(其中之一包含氧化物层)的方式。
DE专利申请案102016106756是关于一种用于腐蚀保护的热喷涂，例如铝热喷涂。在一实施方式中，提供一种抗腐蚀组件，其包括：与第二金属组件组装的第一金属部件，介于第一与第二组件之间的接头，及覆盖至少一部分接头的腐蚀保护层，其中该腐蚀保护层是铝或锌。
DE专利申请案102014011599是关于一种用来结合至少两组件的方法，其中可以过程及制造技术简单的方式实现两组件的可靠连接。焊块自结合辅助组件与第二组件(钢)的内部之间居中形成。这容许减小偏心材料锁定连接、以及不良透镜形成、结合辅助组件倾斜、孔隙及空隙形成及各向同性强度性质的缺点。在材料增厚上方的圆顶的直径可小于组件头部直径且仅将尺寸定得够大使得仍获得两组件间的可容许间隙。
EP专利申请案1582283是关于一种用于点焊两个最终于电泳浴中底涂或涂漆的硬钢片材部件的过程，其包括将优选为诸如低碳铁的易焊金属的小片状物设置于片材间的焊接点处。用于点焊由高强度钢制成的两片状金属部件的方法随后通过电泳浴涂漆或待涂漆。
DE专利申请案10251414是关于一种通过电阻或感应加热组件(具体而言由金属性材料制成的片状金属部件)的点焊或焊接方法，以及一种用来实施结合辅助构件的特定方法。使用电阻或感应加热进行点焊或焊接的过程包括确定通过电流强度的受控变化引入的热及取决于插入于待焊接或软焊的组件间的接头辅助组件的选定横截面轮廓的结合力。
DE专利申请案102004025493及102004025492是关于一种用来结合组件的方法、一种结合组件及一种用于结合组件的组件。使两个或更多个结合部件(具体而言金属片材及/或塑料片材)通过结合组件结合在一起。当结合组件时，其可充作铆钉或螺钉。待结合的组件具有开口，具体而言具有结合组件可插入其中的钻孔。将部件彼此定位然后通过焊接结合组件来结合。有利地可使用已知的焊枪作为已知的焊接，但软焊(soldering)所需的热输入显著地低于焊接。
DE专利申请案102012013325是关于较容易制造的三个或更多个组件的复合物，具体而言透过在最终制造整个复合组件之前将两个或更多个组件简单地预固定至部分复合物。一种组装不同材料的组件的方法。一种以第一组件用来实现第二组件及第三组件的经改良的复合组件，提供辅助黏结构件，通过结合辅助件制造两组件中之一的部分复合物，其中：通过结合助件穿透其中两个组件，并于该两个组件与结合工具之间产生正面及/或非正面连接，及通过压力焊接将穿透结合辅助件的部分复合物结合至剩余的一个组件。
DE专利申请案102012013589是关于用于电阻器组件焊接以结合多于两个由扁平材料所形成的组件的自冲孔紧固组件。所述类型的自刺穿紧固组件适用于结合多于两个组件，其中这种组件中的至少一个也可由非塑性可变形材料形成。
WO专利申请案2010022709是关于一种如此提供的至少在由钢(具体而言热成形高强度钢)与至少一个来自铝材料的片状金属组件之间产生接头连接的方法，其中首先通过电弧或激光过程沉积焊料以确保固定对其中一个金属组件的安全输送，然后通过在接头区域中施加电流及施加金属组件压力或通过感应加热来加热而安置于经设置的焊料沉积物上的片状金属部件与金属组件之间，以致在由钢制成的片状金属部件与焊料之间沉积焊料并在来自铝材料的片状金属组件与焊料沉积物之间形成焊接或软焊。
US专利申请案5273204涉及一种方法，其中使用对接构造来将焊接缝热喷涂成v形对接。热喷涂材料同时位在焊接缝上。
US专利申请案20100089977A1描述一种摩擦搅拌焊接过程，其中将粉末松散地施加于两金属之间以产生特殊的冶金学并(例如)硬化铝合金。
当前最新技术不存在任何用来结合不同金属组合(如铝对(不锈)钢)的焊接方法，而仅可利用黏结或机械结合(两者皆具有较低的电力传递)。在已知的(电阻)焊接中，焊接接触面积在高于350℃的温度范围中熔融，从而产生FeAl3及Fe2Al5的脆性金属间相。
在提高车体工程的多材料设计过程中，制造工业同时使用铝及(不锈)钢。电阻点焊是于车体工程中主要使用的结合方法。
本发明的概念是要通过在(不锈)钢的表面上施加具有明确厚度、表面粗糙度及过渡电阻的铝热喷涂层来使不可焊的金属组合如铝对(不锈)钢或一般的不可焊材料如热成形马氏体不锈钢变得可电阻焊接。随后在第二步骤中，接着进行电阻(点)焊接过程。所使用的焊接参数必需以仅铝对铝接触面积熔融，且在铝层与(不锈)钢之间不具有脆性金属间相的方式来选择。
用于相成长的公式可以拋物线成长曲线来表示：Xm 2＝k·t，其中
Xm＝平均穿透深度＝金属间相厚度，
k＝成长是数，文献值：8.46·10-15m2/s(于873K下)
t＝焊接时间。
拋物线成长曲线公式提供关于典型点焊的层厚度的信息，其表示强度与铝基础材料相比减小超过50％。
点焊的典型层厚度是大于或等于15μm。其表示与铝基础材料(280N/mm2)相比强度减小超过50％。因此，本发明必需避免在焊接期间的任何金属间相成长。
关于本发明的热机械涂布方法可由火焰喷涂、电弧喷涂、电浆喷涂、激光喷涂、冷气体喷涂、爆震喷涂、高速氧燃料喷涂或熔池喷涂组成。
在喷涂过程中，材料或喷涂消耗物是作为线、杆、棒、索、粉末或作为熔池供应。
在没有本发明方法所使用的热喷涂层的情况下不可直接焊在一起的材料可为例如钢如未合金化、低合金化或不锈钢、铝、铝基合金、镁或镁基合金。
热喷涂层是根据本发明通过电弧、激光束、电子束、嵌柱或电浆焊接，优选利用电阻焊接过程如电阻点焊、点焊黏结、电阻辊缝焊接或突点焊接，进行与外加片材的焊接。自然地，可于根据本发明的焊接过程中使用其他焊接方法。
热喷涂层厚度对由点焊所达成的直径的比是小于/低于或等于0.25mm。
包括基板、热喷涂层、外加片材的总片材厚度是介于1.5mm至6.0mm之间，同时介于热喷涂层与基础材料间的过渡区是在350℃以下。于运输应用中用于薄座椅结构部件之一典型的厚度组合可以是：
T[mm]＝t基础+t喷涂层+t外加片材＝0.5mm+0.25mm+0.75mm＝1.5mm
可针对客车的碰撞相关结构部件(如电动车的b-柱或电池壳的连接性)制作厚度设计的另一实例：
T[mm]＝t基础+t喷涂层+t外加片材＝1.7mm+1.5mm+2.8mm＝6.0mm
其中T是t基础+t喷涂层+t外加片材加总的总片材厚度[mm]，t基础是基础材料(在以上实例中为(不锈)钢)的片材厚度[mm]，t喷涂层是热喷涂层(在以上实例中利用电弧喷涂过程制造，其中使用AlMg3的线)的厚度[mm]。至少t外加片材是施加在热机械涂布层上的片材的厚度[mm]，其在以上实例中是ENAW-6081合金的铝片材。
待热喷涂的基板可由钢材料，优选具有热浸及电解镀锌表面涂层的未合金化或低合金化钢所组成。更佳地，其是具有氧化铬钝化层的不锈钢。另外，适用于本发明方法中的材料也可以是具有包括铝-硅或锌涂层的对比面(scaledsurface)或表面保护层的热成形或模压淬火钢(press-hardenedsteel)。
该方法尤其适用于脆性材料如具有超过800MPa的抗拉强度的高强度钢。此外，待热喷涂的基板可以是具有高于0.65％的碳当量(CEV)的未合金化或低合金化钢，其中CEV是使用下式来计算(元素含量以重量％计)CEV＝C+Mn/6+(Cu+Ni)/15+(Cr+Mo+V)/5。
此外，基板表面可根据本发明来处理，通过清洁或脱脂、及喷砂或珠击来预处理。在该情况中，用于喷砂或珠击的喷砂磨料也可由刚玉、钢线、碳化硅、及硬铸沙砾或玻璃珠组成。
本发明显示不同焊接的高电力传递。断裂行为可集中于外加片材区域。因此，本发明可相对于当前最新技术中的其中一种材料的相似焊接，与相同厚度组合相比实现较高或相等的电力传递。
待用于本发明方法中的优选的电阻焊接过程步骤可通过不同种类的电阻焊接(诸如点焊、辊缝焊接、突点焊接或点焊黏结)来实施。
本发明参照附图更详细地说明于下，其中
图1示出如本发明的现有技术中所述的介于铝与钢之间的相的二元系统Fe/Al金属间成长。
图2示出如本发明的现有技术中所述的金属间层厚度与所得强度值的关系。
图3示出本发明的热喷涂层与(不锈)钢基板的一优选实施方式的示意性侧视图，且其显示喷涂铝层至基础材料/基板的第一步骤。
图4示出本发明的电阻点焊热喷涂铝层与铝扁平片材的另一优选实施方式的示意性侧视图，其中展示具有另一铝扁平片材的焊接热喷涂层/不锈钢。
一种实例是在不锈钢表面的顶部上产生铝热喷涂层，其使用层的扩散、黏附、机械互锁效应、化学结合，且其中不锈钢上的层是由铝基合金组成，且该组合是通过电阻焊接进行与外加铝片材的焊接以避免金属间脆性相。
图1中说明二元系统的理论背景，其仅适用于无限长的冷却速率，因此电阻点焊具有≈1,500K/s冷却速率与脆性金属间相：FeAl3及Fe2Al5。Fe/Al的二元系统*以温度范围表示。
*来源是来自Guimaraens,E.,university of Bayreuth,2005。
图2中说明相成长的理论背景，其以拋物线成长曲线表示。呈现金属间层厚度与抗拉强度的关系。结果，典型点焊的层厚度是大于或等于15μm。曲线显示与铝基础材料(280N/mm2)相比，强度减小超过50％。由于该现象，因此在本发明中，与此相关的方法必需避免焊接期间的金属间相的任何成长。
图3中示出本发明的优选实施方式的侧视图的示意图。利用热喷涂中间层(2)制造的热机械或机械Al合金化表面涂层位于不可彼此直接焊接的基板材料(1)如不锈钢的顶部。
图4中示出本发明的优选实施方式的侧视图的示意图，其中使用在基板(1)上的热喷涂涂层(2)与外加铝(3)片材之间的已知电阻焊接过程来结合材料组合。在基板(1)、热喷涂中间层(2)与铝片材(3)之间存在点焊区域(4)。在基板(1)与热喷涂涂层间的接触面积中的温度低于摄氏350度。
Claims (15)
1.一种利用热结合过程以搭接构造结合至少两种彼此不可直接焊接的材料的方法，其特征在于使用由第一步骤及第二步骤所组成的两步骤顺序，第一步骤是将热机械或机械表面保护层施加于(不锈)钢基板(1)的表面上，及在第二步骤中，使用热结合过程来焊接喷涂层(2)与外加铝片材(3)，且于整个材料构造中不具有脆性金属间相。
2.如权利要求1所述的方法，其中，仅铝喷涂层(2)对铝片材(3)接触面积熔融，且在铝喷涂层(2)与(不锈)钢基板(1)之间的接触区域中不具有脆性金属间相。
3.如权利要求1或2所述的方法，其中，该表面保护层是通过热机械涂布方法实施。
4.如权利要求1、2或3所述的方法，其中，该表面保护层是通过热喷涂方法实施。
5.如权利要求1或2所述的方法，其中，该焊接构造是设置为搭接。
6.如权利要求1至5中任一项所述的方法，其中，该热喷涂层(2)是铝、铝基合金或铝与碳化物的组合。
7.如权利要求1至6中任一项所述的方法，其中，该热喷涂层(2)是通过电阻焊接方法如点焊黏结、点焊、突点焊接或辊缝焊接而与外加片材(3)焊接。
8.如权利要求1至7中任一项所述的方法，其中，该热喷涂层(2)厚度对所达成的点焊(4)直径的比是低于或等于0.25mm。
9.如权利要求1至8中任一项所述的方法，其中，包括基板(1)、热喷涂层(2)、外加片材(3)的总片材厚度是介于1.5mm至6.0mm之间。
10.如权利要求1至9中任一项所述的方法，其中，该热喷涂层(2)的厚度是自0.25至1.5mm。
11.如权利要求1至10中任一项所述的方法，其中，介于热喷涂层(2)与基础材料之间的过渡区是在350℃以下。
12.如权利要求1至11中任一项所述的方法，其中，待热喷涂的该基板(1)是具有高于0.65％的碳当量(CEV)的碳钢，其中CEV是使用下式来计算(元素含量以重量％计)CEV＝C+Mn/6+(Cu+Ni)/15+(Cr+Mo+V)/5。
13.如权利要求1至12中任一项所述的方法，其中，待热喷涂的该基板(1)是碳钢材料，优选是具有镀锌表面涂层的碳钢。
14.如权利要求1至13中任一项所述的方法，其中，待热喷涂的该基板(1)是不锈钢。
15.如权利要求1至14中任一项所述的方法，其中，该基板(1)表面是通过清洁及喷砂来预处理。
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| SG11201907514XA (en) | 2019-09-27 |
| TWI762588B (zh) | 2022-05-01 |
| SG10202108993YA (en) | 2021-09-29 |
| CN110312589B (zh) | 2022-12-16 |
| KR102436341B1 (ko) | 2022-08-25 |
| RU2019126649A3 (zh) | 2021-04-07 |
| US11548087B2 (en) | 2023-01-10 |
| BR112019017427A2 (pt) | 2020-04-07 |
| CA3053613A1 (en) | 2018-08-30 |
| AU2024201319A1 (en) | 2024-03-21 |
| EP3369516A1 (en) | 2018-09-05 |
| TWI783095B (zh) | 2022-11-11 |
| US20190381592A1 (en) | 2019-12-19 |
| TW201938390A (zh) | 2019-10-01 |
| RU2019126649A (ru) | 2021-03-24 |
| US11524351B2 (en) | 2022-12-13 |
| AU2018223090A1 (en) | 2019-09-05 |
| WO2019149336A1 (en) | 2019-08-08 |
| CN111432971A (zh) | 2020-07-17 |
| KR20190122219A (ko) | 2019-10-29 |
| TW201838493A (zh) | 2018-10-16 |
| US20210069819A1 (en) | 2021-03-11 |
| JP7261167B2 (ja) | 2023-04-19 |
| JP2020508877A (ja) | 2020-03-26 |
| EP3366406A1 (en) | 2018-08-29 |
| EP3369516B1 (en) | 2023-10-18 |
| MX2019010071A (es) | 2019-10-15 |
| WO2018153785A1 (en) | 2018-08-30 |
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