CN1618563A - 摩擦焊接方法 - Google Patents

摩擦焊接方法 Download PDF

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CN1618563A
CN1618563A CNA2004100949164A CN200410094916A CN1618563A CN 1618563 A CN1618563 A CN 1618563A CN A2004100949164 A CNA2004100949164 A CN A2004100949164A CN 200410094916 A CN200410094916 A CN 200410094916A CN 1618563 A CN1618563 A CN 1618563A
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CN1310732C (zh
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青田欣也
竹中刚
石丸靖男
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Hitachi Ltd
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    • 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
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    • 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
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    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
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    • B23K33/00—Specially-profiled edge portions of workpieces for making soldering or welding connections; Filling the seams formed thereby
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
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Abstract

本发明提出一种接头结构，在对两个外装结构(镶板)进行头尾相接的摩擦焊接时，使用该接头结构可以减小接头区域的变形量，从而获得满意的焊接接头。各个镶板(31，32)具有两块相互平行的板件(33，34)以及与这两个板件(33，34)相接的第三构件(35)。某一镶板(32)之板件(33，34)的端部由摩擦焊接方法焊接在另一镶板(31)之板件(33，34)的端部。至少一个镶板的端部设有用来连接板件(33)和(34)的板件(36)，该镶板的刚度足以承受摩擦焊接过程中所产生的压力。

Description

摩擦焊接方法
本申请是申请人于1997年3月18日提出的申请号为97103497.4的申请的分案申请。
技术领域
本发明涉及一种摩擦焊接方法，该方法适用于铝合金有轨机动车及房屋等场合所用镶板的焊接。
背景技术
日本公开专利说明书246863/1990公开了一种采用中空构件的有轨机动车用双表面结构板(镶板)，而日本公开专利说明书106661/1994则公开了一种采用蜂窝型镶板一类层状镶板的方案。
摩擦焊接是通过旋转某一插入接头区域中的圆杆而实现的，圆杆的旋转可以加热接头区域并使之塑化，从而达到焊接的目的。这种焊接方法适用于对接接头及搭接接头。该工艺在WO93/10935(同于WO0615480B1，也同于外国PCT专利申请指定日本而公开的专利文献No.505090/1995号)和期刊(Welding & Metal Fabrication，January1995，pp.13-16)中已有介绍。
在摩擦焊接中，直接从焊接工具(圆杆)之下挤出的塑化金属会在焊接过程中冲击焊接表面，因而有一下驱力作用在接头区域上。这样，在将该焊接方法运用于双表面结构板(镶板)时，该下驱力将使接头区域的焊接材料向下流动并使接头区域变形。如此便不可能获得满意的焊接质量。
双表面结构板(镶板)包含由挤压铝合金制成的中空构件以及蜂窝型镶板。这类镶板的连接可以由MIG焊接法及TIG焊接法实现。而用摩擦焊接进行这类连接则可能使接头区域向下弯曲，或者使接头区域内的材料因焊接过程中产生的下驱力而被迫向下流动。
本发明人通过大量试验发现了上述问题。
发明内容
本发明的第一个目标是：在进行两个表面的摩擦焊接时，通过减小接头区域的变形量而获得满意的焊接接头。
本发明的第二个目标是在进行单个表面的摩擦焊接时获得满意的焊缝。
本发明的第三个目标是：使两个表面的摩擦焊接在较短的时间内以较小的变形量同时完成。
第一个目标的实现方式是：将某一连接件置于接头区域，该连接件可以将构成两个表面的两个板件连接起来。
第二个目标的实现方式是：在构件的接头区域处设置凸出部分，该凸出部分伸向摩擦焊接工具一侧。
第三个目标的实现方式是：在焊接对象的两侧同时设置摩擦焊接用的旋转工具，使某一旋转工具的旋转中心轴线位于另一旋转工具之旋转中心轴线的延长线上，两侧的摩擦焊接同时进行。
本发明的一种摩擦焊接方法，它包括以下步骤：准备两个各具有一个凸出部分的构件，其中，凸出部分位于构件宽度方向的一端并沿厚度方向从某一侧伸出；使二者的凸出部分彼此靠住；以及从凸出部分一侧对构件进行摩擦焊接。
本发明的一种摩擦焊接方法，它包括以下步骤：针对两个构件的接头区域设置两套摩擦焊接旋转工具，将一旋转工具置于构件的上表面一侧，将另一旋转工具置于构件的下表面一侧；使一旋转工具的旋转中心轴线位于另一旋转工具之旋转中心轴线的延长线上；以及使旋转工具同时旋转并移动。
附图说明
图1是本发明某一实施例的垂直截面。
图2是图1在摩擦焊之后的垂直截面。
图3是本发明另一实施例的垂直截面。
图4是图3在摩擦焊之后的垂直截面。
图5是本发明又一实施例的垂直截面。
图6是图5在摩擦焊之后的垂直截面。
图7是本发明再一实施例的垂直截面。
图8是图7在摩擦焊之后的垂直截面。
图9是表示如本发明又一实施例所述摩擦焊过程的垂直截面。
图10是本发明又一实施例的垂直截面。
图11是本发明又一实施例的垂直截面。
图12是本发明又一实施例的垂直截面。
图13是本发明又一实施例的垂直截面。
图14是本发明又一实施例的垂直截面。
图15是有轨机动车的车身透视图。
具体实施方式
在图1所示实施例中，作为镶板的中空构件31，32之间具有对接式的接头结构。中空构件31，32宽度方向的端部设有垂直板36，36。垂直板36，36在焊接之前被直接置于旋转工具50的下方。垂直板36，36彼此面对面接触。即便彼此分离，二者间的距离也很小并大约为1mm。凸部52的中心轴线位于二垂直板36，36之间界面的延伸面上。垂直板36，36的刚度足以承受前面提及的下驱力。垂直板36垂直于另外两块板件33，34。中空构件31，32由铝合金挤压成形。中空构件31的上表面和下表面与中空构件32上对应的上表面及下表面齐平。亦即中空构件31和32具有相等的厚度。下文所述的实施例也是如此。在摩擦焊接中，旋转(焊接)工具50大径部分51与小径凸部52之间的边缘53位于中空构件31，32上表面的上方。标号35表示用来连接两块板件33，34并以桁架结构形式设置的若干个构件。两个中空构件31，32都具有两边对称的端部。中空构件31，32被装在某一底架(图中未加表示)上并被固死。底架也位于垂直板36，36下方。
摩擦焊接的实施方式是：使旋转工具50旋转，将凸部52插入中空构件31，32的接头区域并使凸部52沿接头区域移动。凸部52的转动中心轴线位于两个垂直板36，36之间。
图2表示两个经过摩擦焊接之后的镶板。标号45表示焊接后形成的焊道。焊道45的宽度中心位于垂直板36，36接合线的延长线上。焊道45位于垂直板36，36厚度范围内的某一区域内。焊道45深度取决于旋转工具50底端凸部52插入接头区域中的高度。
在这种结构中，垂直于板件33，34的垂直板36，36支承着摩擦焊接过程中产生的垂向力，所以接头区域不会发生弯曲，由此可获得图2所示的令人满意的接头。制做垂直板36时应使之尽可能地垂直于板33，34。
垂直板36上可以打孔，以减轻重量，下文所述实施例也是如此。
焊接中空构件底侧时可将其上下翻转。
在图3所示实施例中，某一中空构件31的端部设有垂直板36，而另一中空构件32的对应端部却没有。在中空构件31的垂直板36上，其垂直方向上的角部被做出切口，由此可嵌接中空构件32上突出体38，38的端部。该切口部分沿中空构件31的厚度方向及厚度的垂直方向(朝向中空构件32一侧)张开。当突出体38被放置(嵌套)于切口部分中时，二者之间留有一定的间隙，尽管在图中看来是彼此相接触的。这些构件的前端之间(即突出体38，38与角边33a，34a之间)也留有间隙。两个中空构件31，32及垂直板36上表面一侧的对接接头部分直接位于旋转工具50中心轴线的下方。旋转工具50凸部52的旋转中心轴线位于垂直板36厚度中心线的延长线上。也就是说，板件33(34)和板件34(33)的接头区域位于垂直板36厚度中心线的延长线上。从板件33，34延伸至切口部分的角边33b，34b位于垂直板36厚度中心线的延长线上。考虑到角边33b，34b与突出体38之间的间隙，角边33b，34b位置应稍稍偏向垂直板36厚度中心线延长线的左侧。垂直板36的刚度应足以承受下驱力。突出体38前端与中空构件31之间的水平间隙同于图1所示情形。焊接工具50凸部52的高度与突出体38的厚度大致相等。塑性流动区域在突出体38下侧扩展，逐渐形成大于凸部52直径的区域，由此完成两个中空构件31，32的摩擦焊接。对于突出体38下侧与垂直板36间的接触区域来说，其下侧也必须分布着按上述方式形成的摩擦焊缝。
图4表示焊接后的接头状况。焊道45的成形特点在于：其宽度中心位于垂直板36，36厚度中心线的延长线上。
为了能承受垂向力，必须使旋转工具50的旋转中心轴线位于垂直板36，36厚度中心线的延长线上。为使左右中空构件31，32的接合量相同，角边33b，34b也必须位于垂直板36，36厚度中心线的延长线上。作为优选方案，旋转工具50的凸部52位于垂直板36厚度延长线的范围内，而垂直板36的厚度又取决于垂向力的大小、凸部52的位置以及垂直板36的强度。因此，垂直板36厚度小于凸部52直径的情况是存在的。鉴于旋转工具50及角边33b，34b可能存在的位置误差，应使角边33b，34b定位于垂直板36厚度延长线的范围内，而且凸部52也应至少有一部分位于该范围内。这种设置可使垂直板36至少承担一部分垂向力，从而基本实现对接头变形的结构性预防。如此便可获得满意的焊接效果。就焊道45来说，即使其尺寸略大于凸部52，上述结论仍然是有效的。对于其它实施例来说也同样如此。
与图1所示的情形相比，这种接头结构即使在突出体38与中空构件31之间间隙较大时，也能够使接头区域的表面凹陷减至最低程度。这一特点可以使该接头获得较好的外观质量，并可减少喷漆时的腻子用量。其原因在于，两个构件之间的间隙终止于与突出体38厚度相等的深度位置上。还需要指出：这种接头结构可以减轻重量。此外，由于两个中空构件彼此嵌接，所以二者在高度方向上的定位也易于实现。
中空构件31的端部具有两边对称的形状。中空构件32也是两边对称的。另外，中空构件31的一端可以是图3所示形状，而其另一端则可做成图3所示中空构件32端部的形状。
在图5所示实施例中，中空构件31上切口部分的角边33b，34b下侧实际上并没有直接设置垂直板36。垂直板36的右端位于角边33b，34b的延伸部分上。旋转工具50的旋转中心轴线对准该延伸部分。中空构件31的端部应具有足以承受垂向力的刚度，为此，可以增厚接头处的下侧突出体37并增大从突出体37的前端部至垂直板36的过渡圆角尺寸。象以上图3所示的实施例一样，另一中空构件32的突出体38可嵌入突出体37的切口部分中。第二个中空构件32的突出体38附近设有用来连接上侧板件33和下侧板件34的垂直板36。对于这种设置来说，即使切口部分的角边正下方没有垂直板36，接头区域中也不会出现缺陷。不过需要指出，焊道45下侧设有板件31的垂直板36。图6表示了焊接之后的状况。
在图5所示实施例中，中空构件32的板件36是可以去除的。
图7表示作为图5所示实施例之改型的另一个实施例，其中，两个中空构件31，32的接头区域设有向外伸出的凸出部分37a，38a。这可以使接头区域增厚。两个凸出部分37a，38a的高度是相等的。除垂直板36和凸部37稍薄以外，该结构的其它部分同于图5所示结构。
对这种结构来说，如果两个凸出部分37a，38a之间在焊接前存在间隙，那么在焊接时就需要用凸出部分37a，38a的材料填充该间隙，由此可改进外观质量并降低腻子用量。
在普通焊缝中，下驱力使材料41向下流动，焊道中的凹陷部分便对应着材料41流失所形成的空隙。在图7所示接头结构中，旋转工具使突出部分37a，38a塑化并迫使其弥补材料41的流失空隙。这样便避免了形成凹陷，从而获得满意的焊接头。图8表示焊接后的焊道45形状。焊接之后如果存在多余部分，可如图所示将其切除。
设置凸出部分37a，38a的做法也适用于图1，3，5及下文所述的各实施例。
图9表示另一实施例，该实施例只允许从一侧对上下表面进行焊接。中空构件31，32底侧的端部设有突出体34a，34a，该突出体与下侧板件34，34齐平并显著地伸向对面的中空构件一侧。两个突出体34a，34a的前端彼此大致相接触。上侧板件33，33的前端比下侧板件34a，34a的前端靠后一些。上侧板件33，33的前端通过垂直板36，36与下侧板件34，34相接。垂直板36，36接在下侧板件34的中部。垂直板36，36的顶部设有可容纳某一连接件60的切口部分39，39。当连接件60被装在切口部分39，39上时，其上表面可与上侧板件33，33的上表面齐平。两个垂直板36，36间的距离应尽可能小，但也应足以保证旋转工具50的插入。垂直板36，36与切口部分39间的关系同于对图5和图7所示实施例的描述。
以下介绍焊接过程。在图9(A)所示状态下，用旋转工具50焊接下侧板件的前端。此时，包含板件34a，34a之接头区域在内的中空构件31，32被装在底架上。底架的上表面(即焊道背后)为平面。旋转工具50之凸部52的高度小于板件34a，34a的厚度。这种设计可保证底面在焊接后仍然平整。因此，底面一侧无疑可以作为有轨机动车或房屋结构的外表面(该外表面是指未装装饰板的表面)。通常，摩擦焊接区的上表面(在边缘部分51)是不易于平整的。
此后，如图9(B)所示，将连接件60装在两个中空构件31，32之间。连接件60具有T形垂直截面。当连接件60的两端被装在切口部分39，39上时，垂直部分61的底端与下侧板件上的焊道之间将形成一定的间隙。垂直部分61可被省去。
接着，如图9(C)所示，用旋转工具50对连接件60与中空构件31之间的接头部分进行摩擦焊接。旋转工具50无需与图9(A)中所用的工具相同。
然后，如图9(D)所示，用旋转工具50对连接件60与中空构件32之间的接头部分进行摩擦焊接。
上述方法允许从一侧进行焊接，因而除去了翻转操作。除去翻转操作的优点在于省去了翻转及定位操作所需的工时，并省去了翻转装置，而且装配精度也进而得以改善。
图10表示另一实施例，其中采用了对中空构件51，52的上下两侧同时进行摩擦焊接的方法。用于下侧的旋转工具50a在上侧所用焊接工具50的垂直下方布置。第二个焊接工具50a的凸部52朝向上方。两个彼此相向的焊接工具50，50a在进行摩擦焊接时以相同的速度运动。标号70，70表示底架(台面)。工具50和50a的旋转中心轴线位于同一条直线上，中空构件31，32的接头区域也在该直线上。
采用这种布置可以使第二工具50a的旋转中心轴线定位于第一工具50旋转中心轴线的延长线上，二者间的力学平衡有助于在较短的时间内以较小的变形完成接头的焊接。此外，由于无需翻转中空构件31，32，焊接过程将在短时间内完成，而且接头的变形也比较小。
该实施例也适用于其它实施例。
上述各实施例以中空构件为待焊接的镶板。下文的实施例将介绍适用于蜂窝型镶板的摩擦焊接方法。如图11所示，蜂窝型镶板80a，80b包括以下部分：两块表面板件81，82；具有蜂窝状内腔的芯骨构件83；以及沿表面板件81，82边缘布置的边缘构件84，其中，芯骨构件83和边缘构件84被钎焊在表面板件81，82上，从而形成一个整体结构。表面板件81，82，芯骨构件83及边缘构件84均由铝合金制成。边缘构件84为挤压成形件并具有矩形截面。该矩形截面上每一条边的厚度都大于表面板件81，82的厚度。类似于图1所示情形，对于相互接触的两个边缘构件84，84来说，二者垂直边的厚度是相等的。两个蜂窝型镶板80a，80b具有相等的厚度。
图11所示实施例对应于图1所示实施例。旋转工具50凸部52的高度大于表面板件81，82的厚度。这样便于对表面板件81，82和边缘构件84，84进行焊接。加在镶板80a，80b上的载荷主要通过边缘构件84传递。对已完工的镶板80a，80b可进行装配及摩擦焊接。
图12所示实施例对应于图3所示实施例。蜂窝型镶板80a的边缘构件84具有大致为矩形的截面，且角边处设有切口。而蜂窝型镶板80b的边缘构件84则象一个开口朝向蜂窝型镶板80a的管道。边缘构件84的开口端被接在蜂窝型镶板80a之边缘构件84的切口部分上。
对应于图5的蜂窝型镶板可按同样方法制造。
图13表示对应于图7的又一个实施例。在装配好两个蜂窝型镶板80a，80b之后，将板件86放在表面板件81，81上并临时性地将其焊在表面板件81，81上。板件86可对塑化并流出的材料加以补偿。图12所示蜂窝型镶板80a之边缘构件的垂直部分被去掉了，垂向力被边缘构件84的水平部分及其周围其它部分承受。
图14表示本发明的另一个实施例。在图13及其之前的各实施例中，镶板具有两个表面(表面板件)，而图14所示实施例中的镶板91，92实际上只有一个表面(表面板件94，94)。摩擦焊接在镶板91，92毗连端的两个位置上进行，即具有表面板件94的外侧以及没有表面板件的内侧。因此，内侧的接头部分设有较窄的表面板件(表面板件93，93)。较窄的表面板件93，93由垂直板96，96支承。在该例中，垂直板96也大体垂直于表面板件93，94。与图7所示情形类似，表面板件93，94上也设有凸出部分37a，38a。表面板件94，94具有若干个以一定间距分布的加强肋(板件)95，95。这些加强肋95的截面为T形。加强肋95的顶面与接头部分的表面板件93的顶面齐平。可在顶面焊上加固构件(如支柱)，也可将顶面作为物体的安装座。此外，顶面93，93也可以充当控制焊接工具50高度的基准座。工具50的移动载体可以沿着表面板件93，93运动。由于表面板件93和94的存在，可以说镶板91，92也是一个双表面结构。镶板91，92是挤压成形构件。
图14表示了彼此相对的两个镶板91及92在其接头部分处的垂直板96，96，其结构类似于图1，不过对此也可以采取图3，5及7所示的方式，亦即将垂直板彼此装配起来。
图15表示该实施例在有轨机动车车身结构上的应用实例。该车身结构具有侧部车身101，车顶结构102，底板结构103以及处于纵向端部的角形结构104。侧部车身101和车顶结构102使用了长边指向车辆纵向的镶板31，32，80a，80b，91，92。侧部车身101与车顶结构102之间以及侧部车身101与底板结构103之间的接合由MIG焊接法实现。车顶结构102及侧部车身101一般做成弧形截面。当用镶板91，92做侧部车身101时，具有垂直板96和加强肋96的一侧朝向车辆内侧，而且支柱由加固构件构成。
图9所示镶板31和32可以以镜像布置方式配合使用。将各镶板之伸出板件34a的端部置于另一镶板上板件33的切口部分39处。这样将无需使用连接件60，而且可以对上下两侧的接头区域同时进行摩擦焊接。如图7所示，镶板33，34a上可设置凸出部分。

Claims (1)

1.一种摩擦焊接方法，它包括以下步骤：
针对两个构件的接头区域设置两套摩擦焊接旋转工具，将一旋转工具置于构件的上表面一侧，将另一旋转工具置于构件的下表面一侧；
使一旋转工具的旋转中心轴线位于另一旋转工具之旋转中心轴线的延长线上；以及
使旋转工具同时旋转并移动。
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CN011118040A Expired - Fee Related CN1216713C (zh) 1996-03-19 2001-03-16 摩擦焊接方法
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CNB011118075A Expired - Fee Related CN1199756C (zh) 1996-03-19 2001-03-16 用于摩擦焊接的构件
CNB011118024A Expired - Fee Related CN1203957C (zh) 1996-03-19 2001-03-16 摩擦焊接方法及使用摩擦焊接方法的结构体
CNB011114991A Expired - Fee Related CN1192848C (zh) 1996-03-19 2001-03-16 摩擦焊接方法、结构体以及制造该结构体的方法
CNB011114967A Expired - Fee Related CN1192847C (zh) 1996-03-19 2001-03-16 摩擦焊接方法和结构体

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US7032804B2 (en) 2006-04-25
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EP1222994A3 (en) 2002-07-24
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DE69732260D1 (de) 2005-02-17
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DE69734368T2 (de) 2006-07-27
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EP1190806B1 (en) 2005-03-02
CN1410220A (zh) 2003-04-16
JP2000205216A (ja) 2000-07-25
DE69739569D1 (de) 2009-10-15
KR100426023B1 (ko) 2004-04-03
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CN1165403C (zh) 2004-09-08
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JP2000205218A (ja) 2000-07-25
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DE69735144D1 (de) 2006-04-13
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US6966481B2 (en) 2005-11-22
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KR970064806A (ko) 1997-10-13
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CN100475411C (zh) 2009-04-08
EP1222997A1 (en) 2002-07-17
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CN1199756C (zh) 2005-05-04
CN1310732C (zh) 2007-04-18
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US20040069834A1 (en) 2004-04-15
JP2000202650A (ja) 2000-07-25
CN1899746A (zh) 2007-01-24
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US20040068955A1 (en) 2004-04-15
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US20050161491A1 (en) 2005-07-28
DE69735905T2 (de) 2007-01-11
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EP1222996B1 (en) 2005-10-12
DE69732191T2 (de) 2005-12-29
KR100428544B1 (ko) 2004-04-29
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EP1222992A3 (en) 2003-02-05
EP1222998A1 (en) 2002-07-17
EP1222996A1 (en) 2002-07-17
KR100428553B1 (ko) 2004-04-27
CN1410219A (zh) 2003-04-16
KR100426021B1 (ko) 2004-04-03
EP1190805A2 (en) 2002-03-27
EP1222993A2 (en) 2002-07-17
KR100426025B1 (ko) 2004-04-03
DE69736959D1 (de) 2006-12-28
US20040025741A1 (en) 2004-02-12
CN1322241C (zh) 2007-06-20
CN1322603A (zh) 2001-11-21
CN1163813A (zh) 1997-11-05
DE69732669D1 (de) 2005-04-07
EP0797043B1 (en) 2003-06-04
US7520104B2 (en) 2009-04-21
KR100426024B1 (ko) 2004-04-03
KR100428554B1 (ko) 2004-04-27
CN1880002B (zh) 2010-11-03
CN100441935C (zh) 2008-12-10
DE69736958T2 (de) 2007-03-08
DE69734367D1 (de) 2006-02-23
US6978923B2 (en) 2005-12-27
CN1192847C (zh) 2005-03-16
DE69735388T2 (de) 2006-12-07
CN1322604A (zh) 2001-11-21
DE69735964D1 (de) 2006-06-29
EP1676667B1 (en) 2009-09-02
US7032805B2 (en) 2006-04-25
EP1222993B1 (en) 2006-05-17
DE69722493T2 (de) 2004-05-13
EP1222991A3 (en) 2002-07-24
JP2000205217A (ja) 2000-07-25
US20040069833A1 (en) 2004-04-15
US20040025467A1 (en) 2004-02-12
US20040065715A1 (en) 2004-04-08
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