CN1507380A - 合金法激光焊接 - Google Patents

合金法激光焊接 Download PDF

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CN1507380A
CN1507380A CNA018232310A CN01823231A CN1507380A CN 1507380 A CN1507380 A CN 1507380A CN A018232310 A CNA018232310 A CN A018232310A CN 01823231 A CN01823231 A CN 01823231A CN 1507380 A CN1507380 A CN 1507380A
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pair
overlap joint
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�ǵ١����ڵ�
乔蒂·马宗德
阿希什·达斯古普塔
迈克尔·本贝埃克
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University of Michigan
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Abstract

公开一种方法，用于激光搭接焊接一对金属元件到一起。至少一对金属元件之一具有一个保护金属层。金属元件中的每一个具有的熔点高于保护金属层的熔点。此方法包括放置一对金属元件之一的一端与一对金属元件的另一端呈一种搭接的关系，以形成一个搭接段。本方法还包括插入一个金属合金添加剂在搭接段的一对金属元件之间以形成它们之间的一个间隙。一个激光束焊机使用于接合此一对金属元件和合金添加剂到一起，从而使保护金属层和合金添加剂熔化以形成一种合金层位于一对金属元件之间。

Description

合金法激光焊接
                   本发明的领域
本发明总体上涉及一种激光焊接接头和方法，以及尤其是涉及一种激光焊接接头和方法，特别地适用于熔化焊接搭接的镀锌金属板。
                   本发明的背景
镀锌钢板大量地使用于汽车工业，这是因为它的低价格，适用性和耐腐蚀性能。它是汽车车身制造的优选的材料，它通常用熔化焊接接合。然而，镀锌钢板的熔化焊接对制造工程师们提出一个挑战，这是因为锌的低熔点(907℃)和钢的高熔点(1530℃)。在镀锌钢板的搭接焊接中，锌层在焊接界面处强烈地蒸发，导致在焊接接头中不希望的高疏松。
一种现有技术的解决方案是使用搭接钢板之间的一个恒定的间隙。间隙设计为允许激增的锌蒸气通过在可接受的焊接接头内形成的间隙排出。然而，在商业制造环境中保持这样一个恒定的间隙是困难的。因此，使用恒定的间隙在熔化焊接的镀锌钢板组件上没有发现在商业上是可行的。另一个解决方案是使用一个延长的激光束以保持熔化池加热至较长的时期，从而使锌蒸气获得足够的时间以便由焊接区逃逸。然而，这种方法包含附加的麻烦和受到价格的限制。
因此，这里需要一种激光焊接接头和方法，它接合镀锌钢板的搭接层，而又限制锌蒸气的激增行为，减少焊接接头的疏松和产生一个牢固的、无缺陷的和可重复的焊接接头。
                   本发明的概述
本发明力求克服上述的缺点，借助在一个方面提供一种方法，用于一对搭接的镀锌钢板的激光焊接。至少一对搭接金属板之一具有一个保护金属层。该方法包括：夹置一个箔元件和/或涂覆适当的材料，它将与锌合金化以避免在一对搭接的金属板之间的强烈的蒸发；焊接一对搭接的金属板；以及熔化金属层和箔元件以形成一种合金，它设置在搭接的金属板之间。
按照本发明的另一方面，一个焊接接头是用一个激光束焊机形成的。此接头包括一对搭接的金属板。至少一对搭接的金属板之一具有一个锌保护层。此外，一个金属填料元件设置在一对搭接的金属板之间。金属填料元件，锌保护层和一对搭接的金属板是被激光束焊机加热的。激光束焊机蒸发锌保护层，熔化金属填料元件和焊接一对搭接的金属板到一起。蒸发的锌层实质上被捕获和吸收在熔化的金属填料元件内，以形成一种合金。合金设置在一对搭接的金属板之间。
本发明的一个目的是提供一种焊接接头和方法，它焊接一对搭接的镀锌金属板到一起以及提供一种金属填料元件，它设置一个间隙在一对镀锌的金属板之间，以及当加热至熔化以捕获和吸收蒸发的锌时，它形成一种合金和设置在一对镀锌的金属板之间。金属填料可以使用各种形式的，比如箔材，涂料，釉浆或丝材，这里指出几种。
本发明的另一目的是提供一种焊接接头和方法，它搭接焊接一对镀锌金属板到一起以及提供一种金属填料，当被激光焊机加热至熔化时捕获和吸收蒸发的锌，以便减少焊接接头内的疏松。
本发明的各种目的可通过阅读说明书、附图和权利要求书而更明确地理解。
                   附图的简要说明
图1是一对搭接的镀锌金属板的部分横剖面图，带有一个金属隔片位于一个喷口下面，通过它激光束和惰性气体投射在金属板和隔片上；
图2a是图1中圆圈2内部分横剖面图的一个放大图，这时金属涂层被蒸发和金属隔片处于其熔点以下；
图2b是图1中圆圈2内部分横剖面图的一个放大图，这时金属涂层被蒸发和金属隔片处于其熔点以上，以及捕获和吸收来自金属涂层的蒸气；以及
图2c是图1中圆圈2内部分横剖面图的一个放大图，它是一对搭接的金属板被焊接熔化和一种合金形成在金属板之间后。
                优选的实施例的详细说明
如图1，2a，2b和2c所示，按照本发明的焊接接头的图号为100。焊接接头100包括一个激光焊机10，一个第一金属元件20，一个第二金属元件30和一个合金添加剂40。
激光焊机10包括一个激光束2，通过在壳体6内的一个喷口4，由一个激光器(图中未示出)投射出，如本领域普通所知那样。惰性气体12通过一个孔8泵送进入壳体6。激光束2被聚焦入射到一个工件14上，在此处产生一个热影响区。最好，惰性气体12是一种氦(He)和氩(Ar)的混合物。氦是供给进入孔8，仅作为实例，为37标准立方英尺/小时(SCFH)而氩是供给进入孔8，仅作为实例，为15(SCFH)氦作为主要的屏蔽气体使用于产生无缺陷的光泽的焊缝。
第一金属元件20的一端搭接第二金属元件30的一端。第一金属元件20是带有一个保护金属层22的金属板21。最好，金属板21是由钢制成的以及保护金属层22是由锌制成的。在商业中的这种组合通常称为镀锌钢板。
类似地，第二金属元件是带有一个保护金属层32的金属板31。最好，金属板31是由钢制成的以及保护金属层32是由锌制成的。金属板21和31举例来说，仅0.8mm厚，以及保护金属层22和32是由锌形成的，数量为70g/m2。以上所述不是作为本发明的限制，因为其它的厚度和涂层重量也属于本发明的范围内。合金添加剂40是一种金属箔42，它作为一个隔片在第一元件20和第二元件30的搭接端之间设置一个间隙。金属箔42最好是由铜制成和公称厚度为0.004in代替的方案是，铜金属箔42的厚度变化在0.0035至0.0045in之间(这个厚度可以根据以涂层形式存在的锌的数量改变)。选择铜主要是因为它与锌的良好的合金化能力以及它的熔点为1083℃。如下文较详细的说明，铜金属箔42在其熔化状态的作用是捕获和吸收气态锌材料33。铜和锌形成一种合金46，例如，黄铜。其它的合金添加剂，比如镍，它在锌和铁中具有可溶性，也可以工作。类似地，带有不同的涂层和适当的合金添加剂的其它的钢板也可以工作。
当焊接第一和第二金属元件20和30到一起时，激光束2是通过喷口4投射，分别地在第一和第二金属元件20和30内形成一个热影响区。技术熟练人员将会理解，热影响区变成一个焊接区50，它渗透第一金属元件20，第二金属元件30两者，以及合金添加剂40加热它们至它们的相应的熔点。
图2a，2b和2c所示的激光焊机10加热第一金属元件20，第二金属元件30和合金添加剂40至不同的熔点。图2a示出第一和第二金属元件20和30处于907℃，锌的熔点。在此温度锌蒸气33开始形成以及倾向于变成随着温度的升高而激增。图2b示出第一和第二金属元件20和30处于1083℃，铜的熔点。在此温度在第一和第二金属元件20和30之间形成一个金属的熔池44。由于这个温度接近锌的沸点，以及在激光焊接时非常迅速地获得，激增的锌蒸气33被捕获和吸收在熔池44内。这种条件产生一种合金46。这个合金化反应几乎在第一和第二金属元件20和30熔化时完成。图2c示出第一和第二金属元件20和30处于1530℃，钢的熔点。在此时间之前，焊接区50达到此温度以及大部分锌进入与铜的合金化以形成合金金属46。因此，当熔池44形成时，极少量的锌蒸气33仍保持以引起疏松和金属喷溅。大多数的锌以合金金属46的形式保留在焊缝中，带有减少的疏松。
现在参见一个使用实例说明器件的工作。这个实例不应作为本发明的一个限制。使用的激光器是5kWCO2 RF excited Trumpf Laser。激光器具有的束模式为TEM10beammode，聚焦半径为0.268mm和原始束半径为11.456mm。束源和焊接板之间的距离是可调节的，从而使激光束2能够聚焦在焊接区50。直线功率能够在2.5kW至3.5kW之间变化。最好，至激光焊接的直线功率设置在3kW。搭接的第一和第二金属元件20和30前进通过激光束的直线速度为70in/min(IPM)至90IPM，其它的参数，比如紧固和屏蔽气体压力保持为恒定。
作为在铜-钢界面上合金化的结果，在焊接区50形成黄铜的黄色基体。跨过焊缝测量的典型的疏松小于1％以及几乎是恒定的。某些轻度的疏松的形成是由于痕迹量的锌蒸气没有与铜合金化以及仍保留在熔池44内，直到它凝固。
在温度超过1083℃，锌蒸气33企图通过熔池44由焊接区50移出，但被捕获和吸收。当接头凝固时，如果某些锌蒸气仍保留在铜内，某些松孔将在合金金属46内形成。这些松孔形成在焊接区50的外面，不会影响焊缝的强度和质量。
上述的焊接产生一个一致的接合强度，超过120MPa，延伸率在12％或更高，而这种接头的一般安全强度为约83MPa，因此，本发明的焊缝是相当牢固的和能够满足全部安全要求。
上述的实例不应作为本发明范围的一个限制，而仅是本发明的教学的示范。应该理解，在所附权利要求书的范围内本发明可用不同于以上特别地说明的方式进行。

Claims (20)

1.一种激光焊接方法，用于激光焊接一对金属元件，至少一对金属元件之一具有一个保护金属层，一对金属元件中每一个具有的熔点高于保护金属层的熔点，上述的方法包括：
放置一对金属元件之一的一端与一对金属元件之一的另一端放置成一种搭接关系，以形成一个搭接段；
将一个合金添加剂插入在上述的搭接段之间，以形成在一对金属元件之间的一个间隙；以及
激光焊接一对金属元件以及上述的合金添加剂，从而使保护金属层和上述的合金添加剂熔化到一起，以形成在一对金属元件之间的一个合金层。
2.如权利要求1所述的方法，其特征在于，上述的合金添加剂的厚度在0.0035至0.0045in之间。
3.如权利要求1所述的方法，其特征在于，一对金属元件中的每一个具有一个锌层，以及其中上述的激光焊接步骤熔化上述的锌层和上述的合金添加剂。
4.如权利要求1所述的方法，其特征在于，一对金属元件中的每一个包括一个保护金属层，上述的保护金属层在上述的合金添加剂之前熔化以及上述的合金添加剂至少在一对金属元件之一之前熔化。
5.如权利要求1所述的方法，其特征在于，上述的激光焊接步骤包括一个激光焊机，上述的激光焊机是一个CO2激光器。
6.如权利要求1所述的方法，其特征在于，至少一对金属元件之一包括一个镀锌层，以及上述的合金添加剂是由铜形成的，其中上述的激光焊接步骤包括熔化上述的镀锌层以及上述的铜合金添加剂，上述的镀锌层形成一种蒸气和上述的铜形成一种液体，上述的液体捕获和吸收上述的蒸气以形成一种黄铜。
7.如权利要求1所述的方法，其特征在于，保护金属层在比上述的合金添加剂低的温度熔化。
8.一种激光焊接一对搭接的金属板的方法，至少一对搭接的金属板之一具有一个金属保护层，上述的方法包括：
在一对搭接的金属板之间插入一个箔元件；
将金属保护层和上述的箔元件熔化到一起从而形成一种合金，上述的合金是设置在一对搭接的金属板之间；以及
将一对搭接的金属板焊接到一起。
9.如权利要求8所述的方法，其特征在于，上述的箔元件是用铜制成的。
10.如权利要求8所述的方法，其特征在于，上述的熔化步骤包括加热一对搭接的金属板至温度约1083℃。
11.如权利要求8所述的方法，其特征在于，上述的箔元件在一对搭接的金属板之间形成一种填料，上述的填料具有一个厚度在0.0035至0.0045in之间。
12.如权利要求8所述的方法，其特征在于，上述的焊接步骤是一个激光焊机焊接，上述的激光焊机是一个CO2激光器，具有氦和氩的气体混合物。
13.如权利要求9所述的方法，其特征在于，保护金属层是锌，以及上述的铜箔元件和上述的锌形成一个黄铜层。
14.如权利要求13所述的方法，其特征在于，在上述的熔化步骤中，上述的锌形成蒸气和上述的铜形成一个熔池，上述的熔池捕获和吸收上述的蒸气以形成在一对搭接的金属板之间的一个焊接界面层。
15.一种使用激光束焊机形成的焊接接头，上述的接头包括：
一对搭接的金属板，至少一对上述的搭接的金属板之一具有一个保护金属层；以及
一个金属填料元件设置在一对搭接的金属板之间，上述的金属填料元件，上述的保护金属层和上述的一对搭接的金属板是被激光束焊机加热的，激光束焊机蒸发上述的保护金属层，熔化上述的金属填料元件和焊接上述的一对搭接的金属板到一起，上述的蒸发的保护金属层实质上是被上述的熔化的金属填料元件吸收以形成一种合金，上述的合金是设置在上述的一对搭接的金属板之间的。
16.如权利要求15所述的焊接接头，其特征在于，上述的金属填料元件是用铜形成的。
17.如权利要求15所述的焊接接头，其特征在于，金属填料元件具有一个厚度在0.0035和0.0045in之间。
18.如权利要求16所述的焊接接头，其特征在于，上述的保护金属层是锌以及上述的铜金属填料元件熔化和吸收上述的蒸发的锌层以形成一种黄铜合金。
19.如权利要求16所述的焊接接头，其特征在于，上述的一对搭接的金属板是由一种镀锌钢板制成的。
20.如权利要求16所述的焊接接头，其特征在于，激光束焊机具有一种气体混合物，上述的气体混合物包括氦和氩。
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CA2443224A1 (en) 2002-10-17
WO2002081138A1 (en) 2002-10-17
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US6479168B2 (en) 2002-11-12

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