DE102018200049A1 - Composite of different metal sheets produced by welding - Google Patents

Abstract

A composite material comprising at least a first material volume (11) of at least one first material having a first material surface (12), at least one second material volume (14) of at least one second material having a second material surface (15), wherein the first and second material volumes (11) 11, 14) are arranged so that the first and second material surfaces (12, 15) are at least partially arranged with each other, wherein the mutually arranged first and second material surfaces (12, 15) form a separating layer (16) having a median plane (M ), wherein the composite material has at least a first region with a third material volume (17) of a third material and a third material surface (18), wherein the third material volume (17) intersects the median plane (M) of the separation layer (16) and within of the first material volume (11) and within the second material volume (14) is arranged.

Description

The invention relates to a component made of a composite material of at least two different materials. Between the two materials, an additional phase is created, which is suitable for the connection of both materials.

In the DE 196 27 913 B4 discloses a component which has been laser welded from two identical materials. In this case, a plurality of laser welds are introduced, which have an equal distance from each other. As a result, the non-welded areas act as defined folds that absorb energy when exposed to too much stress.

In the DE 102 61 422 B4 a laser optics with a defocused and a focused laser beam is disclosed. The defocusing causes heating, so that gases present in the material are expelled. Subsequently, welding takes place by means of a focused laser beam. This allows degassing of a zinc layer applied to steel, so that it is not destroyed during welding and the corrosion protection is maintained.

In the DE 10 2014 017 563 A1 discloses the manufacture of a component by welding an aluminum sheet to a steel sheet. For this purpose, the laser beam is passed within a pipe and the pipe end used to compress the two sheets. The laser beam is introduced vertically. The disadvantage is that it leads to the formation of intermetallic phases between aluminum and steel, which are brittle. This results in a brittle fracture of the connection between aluminum and steel or the tearing of the intermetallic phase when the component is loaded. For swinging components such as bodies of vehicles, both are not acceptable.

In the DE 103 04 954 A1 the production of a component by a combination of welding and brazing an aluminum sheet with a steel sheet is disclosed. Here, the temperature is chosen so that the aluminum sheet is heated to the melt, but the steel sheet does not merge into the melt. This is a welding of aluminum sheets with each other possible. With respect to the steel sheet, only a wetting with molten aluminum, so that a solder joint between the aluminum sheet and the steel sheet takes place. This largely avoids the formation of brittle intermetallic phases between aluminum and steel.

The disadvantage is that a solder joint with vibrating components in the long run is not as strong as a welded joint. At higher load, a breakage of the solder joint can take place, which is unacceptable.

Furthermore, the materials can only be used in a fixed order, since first the material with the lower melting point must be melted without melting the material with the higher melting point.

The object of the invention is to overcome the problems of the prior art and to produce an advantageous material composite made of different metal sheets by means of welding processes.

Here, a connection between aluminum and steel firmly adhering to vibrating components is sought, which overcomes the disadvantages of brittle intermetallic phases.

The object is achieved by a composite material with the features of claim 1, wherein further features are listed in the subclaims.

1. a) mindestens ein erstes Materialvolumen aus mindestens einem ersten Material mit einer ersten Materialoberfläche
2. b) mindestens ein zweites Materialvolumen aus mindestens einem zweiten Material mit einer zweiten Materialoberfläche
3. c) wobei das erste und zweite Materialvolumen so angeordnet sind, dass die erste und zweite Materialoberfläche zumindest teilweise zueinander angeordnet sind,
4. d) wobei die zueinander angeordnete erste und zweite Materialoberfläche eine Trennschicht bilden, die eine Mittelebene aufweist,
5. e) wobei der Materialverbund mindestens einen ersten Bereich mit einem dritten Materialvolumen aus einem dritten Material und einer dritten Materialoberfläche aufweist,
6. f) wobei das dritte Materialvolumen die Mittelebene der Trennschicht schneidet und innerhalb des ersten Materialvolumens und innerhalb des zweiten Materialvolumens angeordnet ist, wobei
7. g) die dritte Materialoberfläche innerhalb des zweiten Materialvolumens zur Mittelebene der Trennschicht in mindestens einem Bereich einen Winkel zwischen 100° und 170° aufweist, oder
8. h) das dritte Materialvolumen innerhalb des zweiten Materialvolumens eine Rotationsachse aufweist, wobei diese Rotationsachse zur Mittelebene der Trennschicht in mindestens einem Bereich einen Winkel zwischen 100° und 170° aufweist, oder
9. i) das dritte Materialvolumen innerhalb des zweiten Materialvolumens eine Mittelebene aufweist, wobei diese Mittelebene des zweiten Materialvolumens zur Mittelebene der Trennschicht in mindestens einem Bereich einen Winkel zwischen 100° und 170° aufweist, oder
10. j) das dritte Materialvolumen innerhalb des zweiten Materialvolumens einen Kegelstumpf aufweist, wobei die Neigung der Kegelwand zur Mittelebene der Trennschicht in mindestens einem Bereich einen Winkel zwischen 10° und 80° aufweist.

One embodiment relates to a composite material comprising

1. a) at least a first material volume of at least a first material having a first material surface
2. b) at least a second material volume of at least one second material having a second material surface
3. c) wherein the first and second material volumes are arranged such that the first and second material surfaces are arranged at least partially relative to one another,
4. d) wherein the mutually arranged first and second material surfaces form a separating layer which has a median plane,
5. e) wherein the composite material has at least a first region with a third material volume of a third material and a third material surface,
6. f) wherein the third material volume intersects the median plane of the separation layer and is disposed within the first material volume and within the second material volume, wherein
7. g) the third material surface within the second material volume to the center plane of the separation layer in at least one Range has an angle between 100 ° and 170 °, or
8. h) the third material volume has an axis of rotation within the second material volume, this axis of rotation having an angle between 100 ° and 170 ° to the center plane of the separating layer in at least one region, or
9. i) the third material volume has a center plane within the second material volume, wherein this center plane of the second material volume has an angle between 100 ° and 170 ° to the center plane of the separation layer in at least one area, or
10. j) the third material volume within the second material volume has a truncated cone, wherein the inclination of the conical wall to the center plane of the separating layer in at least one region has an angle between 10 ° and 80 °.

This advantageously produces a composite material which has at least one first region with a third material volume and a third material surface, wherein the third material volume intersects the median plane of the separation layer and is disposed within the first material volume and within the second material volume, the second material volume in a second material volume Area, which lies below the separating layer, a layer sequence starting from the separating layer: second material, then third material, then second material.

A further advantageous embodiment relates to a material composite which has at least one additional region with the third material volume with the third material surface within the second material volume, wherein in the additional region, the third material surface within the second material volume to the center plane of the separation layer in at least one area an angle between 80 ° and 170 °.

A further advantageous embodiment relates to a composite material in which the at least two regions with the third volume of material have a distance to one another in the center plane of the separating layer, wherein the distance has a constant, variable or a combination of alternately constant and variable value.

A further advantageous embodiment relates to a composite material, wherein the first material comprises steel, steel alloys, aluminum or aluminum alloys, the second material aluminum, aluminum alloys, steel or steel alloys and the third material comprises a phase with variable proportions of steel or steel alloys with aluminum or aluminum alloys.

A further advantageous embodiment relates to a composite material, wherein the first and second material volumes include a prism, cuboid, sheet metal, strips or combinations of the previous.

A further advantageous embodiment relates to a composite material, wherein the third material volume comprises an irregular shape, a truncated cone, a prism, a cylinder or combinations of the previous ones.

A further advantageous embodiment relates to the above composite material, wherein the second material volume in one area has a layer sequence with different materials, this area being adjacent to the third volume of material of the separation layer, the area starting from the separation layer in the direction of the second material a layer sequence: second material , third material, second material.

A further advantageous embodiment relates to the above composite material, wherein the point of the third material is determined in the second material having the greatest distance from the center plane of the separation layer, this point forms a first extrapolation point, the region of the third material which intersects the median plane of the separation layer two, points of intersection forms, half the distance of these intersections forms a second extrapolation point, wherein the angle of a straight line passing through the first and second extrapolation point, and the straight line passing through the two intersections and thus along the median plane of the separating layer, in a range between 100 ° and 170 °, preferably 115 ° to 155 °, particularly preferably from 130 ° to 150 °.

According to a further advantageous embodiment, it is provided that the material composite has at least one additional region with the third material volume of a third material with the third material surface within the second material volume, wherein the additional region the third material surface within the second material volume to the center plane of the separation layer in at least a range between 80 ° and 170 °.

It is possible that, according to an advantageous development, the at least two regions with the third volume of material have a distance to one another in the center plane of the separating layer, the distance having a constant, variable or a combination of alternately constant and variable values.

According to a particular embodiment of the composite material, it is possible that the first material steel, steel alloys, aluminum or aluminum alloys, the second material aluminum, aluminum alloys, steel or steel alloys and the third material comprises a phase with variable proportions of steel or steel alloys with aluminum or aluminum alloys ,

This offers the possibility to design particularly interesting designs of the composite material. According to a particularly preferred embodiment, it is also possible to form the first volume of material from two materials, which are preferably different steels, for example a layer of ferrite and a layer of austenite. It is also possible to form the second material volume from different materials, for example from a layer of aluminum and a layer of aluminum alloy.

A further advantageous embodiment relates to an apparatus for producing a composite material, wherein at least one electromagnetic radiation is arranged so that it acts at an angle of 10 ° to 80 ° on the opposite material surface to the first material surface of the first material volume.

A further advantageous embodiment relates to a device for producing a composite material, wherein the electromagnetic radiation is reflected by a mirror, so that the electromagnetic radiation acts at an angle of 10 ° to 80 ° on the opposite material surface to the first material surface of the first material volume.

A further advantageous embodiment relates to a device for producing a composite material, wherein the electromagnetic radiation is reflected with a rotating mirror, so that the electromagnetic radiation acts at an angle of 10 ° to 80 ° on the opposite material surface to the first material surface of the first material volume.

A further advantageous embodiment relates to a device for producing a composite material, wherein an additional electromagnetic radiation is arranged so that it acts at an angle of 10 ° to 100 ° on the opposite material surface to the first material surface of the first volume of material.

A further advantageous embodiment relates to an apparatus for producing a composite material, wherein the electromagnetic radiation comprises a wave range of infrared light, visual light, ultraviolet light, X-ray radiation and particle radiation, as well as an electron beam or ion beam.

• Bereitstellung eines ersten Materialvolumens aus einem ersten Material mit einer ersten Materialoberfläche,
• Bereitstellung eines zweiten Materialvolumens aus einem zweiten Material mit einer zweiten Materialoberfläche, wobei die zweite Materialoberfläche zur ersten Materialoberfläche zueinander positioniert wird
• Bereitstellung einer Trennschicht mit einer Mittelebene, gebildet durch die erste Materialoberfläche und die zweite Materialoberfläche,
• Beaufschlagen des ersten Materialvolumens mit elektromagnetischer Strahlung, wobei die elektromagnetische Strahlung in einem Winkel von 10° bis 80° auf die entgegengesetzte Materialoberfläche zur ersten Materialoberfläche des ersten Materialvolumens einwirkt, Erzeugung eines dritten Materialvolumens mittels der einwirkenden elektromagnetischen Strahlung.

A further advantageous embodiment relates to a method for producing the abovementioned composite material or for using the abovementioned device, the method comprising the following steps:

• Providing a first material volume of a first material having a first material surface,
• Providing a second material volume of a second material having a second material surface, wherein the second material surface is positioned to the first material surface to each other
• Providing a release layer having a median plane formed by the first material surface and the second material surface,
• Applying the first volume of material to electromagnetic radiation, wherein the electromagnetic radiation acts at an angle of 10 ° to 80 ° on the opposite material surface to the first material surface of the first volume of material, generating a third volume of material by means of the applied electromagnetic radiation.

A further advantageous embodiment relates to a composite material produced by the method listed above.

A further advantageous embodiment relates to a component made of a composite material, which is produced by the method mentioned above.

A further advantageous embodiment relates to a use of the composite material in vehicle construction.

A further advantageous embodiment relates to a use of the above-mentioned device for producing the composite material in vehicle construction.

A composite material is made by placing a first material over a second material and welding it by means of a tilted laser.

The first material includes aluminum, aluminum alloys, steel or steel alloys.

The second material includes steel, steel alloys, aluminum or aluminum alloys.

Preferably, the material combination of the first material: aluminum and second material: steel is used. It is also possible to use the material combination of the first material: steel and second material: aluminum.

Preferably, a combination of materials is used which has different melting points.

The first and second material volumes include a prism, cuboid, or combinations of the previous ones. The third volume of material includes a truncated cone, a prism, a cylinder, an irregular shape or combinations of the previous ones.

A sheet has a cuboid shape, the height being smaller than the width and the width being smaller than the length. The cuboid shape may have rounded edges or rounded corners. Due to rolling processes or cutting processes twisting of the cuboid may occur. Furthermore, cut edges may vary in orientation, ranging from a length perpendicular orientation to a diagonal lengthwise orientation. A sheet can be cut into strips while maintaining the length in width. The first and second material can each be used as a sheet or strip.

With the superposition of both materials, one material surface per material is oriented to one another. Preferably, the material surface is selected with the largest surface area and superimposed. Also, a material surface having the largest area of the one material with a material surface having the smallest area of the other material can be selected and superimposed. Intermediate combinations of the superposition of material surfaces, e.g. Material surfaces with the second largest, third largest, ... surface contents are possible.

The material surfaces can add additional substances from previous process steps, e.g. Oils, foils, oxide layers, silicate layers, dust, metal particles, air or similar.

The superposition of the first material surface of the first material and the second material surface of the second material causes the formation of a release layer. This has a sequence of layers: first material surface, additional substances, second material surface.

In addition, different material thicknesses have an effect on the material surfaces, so that they do not lie exactly plane to each other. The half-distances between the first and the second material surface, viewed over the width and length of the sheet, form a plane which is called in the following center plane of the separating layer. This plane may have bends or deviations from the planarity, which are in the range of 0 ° to about ± 4 ° and are allowed in the tolerance range of the process accuracy.

The first material surface is opposed to an opposite material surface within the first material.

Electromagnetic radiation acts on this opposite material surface. This causes a structural change within the first and second material, e.g. by heat or ionization.

The electromagnetic radiation in this case comprises a wavelength range (1 .mu.m to 100 .mu.m), which ranges from infrared light via visual light via ultraviolet light to X-ray radiation and additionally contains particle radiation as an electron beam or ion beam.

Preferably, an infrared laser is used. It is also an electron beam or ion beam used.

However, the electromagnetic radiation is not used perpendicular to the opposite material surface and thus perpendicular to the median plane of the separation layer, but at a different angle different from 90 °.

The electromagnetic radiation is placed in a device at an angle to the opposite material surface of the first material in the range of 10 ° to 80 °, preferably 25 ° to 65 °, more preferably 40 ° to 50 °.

The electromagnetic radiation causes an oblique melting of the first material volume at this first point of action. This also creates material vapors which are permeable to electromagnetic radiation and thus cause a greater penetration depth.

The electromagnetic radiation can thus penetrate the separation layer and causes an oblique melting in the second material.

The fusions of both materials mix to different proportions and form at least one intermetallic phase, which represents a third material.
This intermetallic phase thus has variable proportions of steel and aluminum. This third material is brittle. The material volume is dependent on the direction of irradiation of the electromagnetic radiation, for example, as an infrared laser and has a third material surface.

The inclination of the third material causes it to form an undercut in the second material. Thus, the undercut causes a portion of the second material to be placed in fixed position with the first material.

This creates a kind of anchor by the third material, which positions the second material to the first material and connects the first and second material. Furthermore, the third material absorb forces, so that yields only at much higher loads of the undercut.

The connection of the first and second material is thus effected by the undercut and not by adhesion of the third material within the first material or within the second material. The undercut can thus absorb higher forces, so that higher loads can be absorbed by the vibrating component.

Starting from the separating layer or the center plane of the separating layer, a layer sequence is formed in the second material in the area of the undercut: second material, third material, second material. The area of the undercut is bounded on one side by a continuous third material and on the opposite side by a continuous second material.

From the separating layer in the direction of the second material, it is not absolutely necessary for the second material to be present. It is also possible that, starting from the separating layer, third material, then second material, then third material and subsequently second material follows. In this case, the course of the separation layer may be interrupted by the third material. In this case, the separating layer of adjacent parts is extrapolated by means of a straight line. Thus, the previously existing separating layer and its center plane can be determined in the third material.

Due to the inclination of the electromagnetic radiation source, the third material surface in the second material has a region in which the angle between the center plane of the separation layer and the third material surface is in a range between 100 ° and 170 °, preferably 115 ° to 155 °, particularly preferably 130 ° up to 150 °.

For an irregular third material surface, the angle is determined by extrapolation. Here, the point of the third material in the second material is determined, which has the greatest distance from the median plane of the separation layer. This is the first extrapolation point. The region of the third material that intersects the release layer has two intersections with the midplane of the release layer. Half the distance between these two intersection points serves as a second extrapolation point. Subsequently, the angle between the straight line connecting the first and second extrapolation point and the straight line between the intersections of the third material with the midplane of the separating layer is determined. This angle is in a range between 100 ° and 170 °, preferably 115 ° to 155 °, particularly preferably from 130 ° to 150 °.

The electromagnetic radiation may be directed to a single local area. This creates an area with a third material having an axis of rotation in the second material. This rotation axis and the center plane of the separating layer form an angle which lies in a range between 100 ° and 170 °, preferably 115 ° to 155 °, particularly preferably 130 ° to 150 °.

The electromagnetic radiation may initially be directed to a local area, have a first exposure site and then be continuously displaced, with the electromagnetic radiation also acting on the opposite material surface of the first material during the displacement so that the exposure site is widened in one direction. This results in an area with a third material having a prism-like shape with a median plane in the second material. This median plane of the third material and the median plane of the separating layer form an angle that lies in a range between 100 ° and 170 °, preferably 115 ° to 155 °, particularly preferably 130 ° to 150 °.

The continuous displacement can be limited to a certain length.

Instead of a continuous displacement and a rotation of the electromagnetic radiation is possible. The skew of the electromagnetic radiation with respect to the opposite material surface of the first material may be maintained. The angle of electromagnetic radiation to the opposite material surface need not be kept constant during rotation and may vary. This results in a region having a third material having a truncated cone-like shape with a conical wall in the second material. This conical wall of the third material and the median plane of the separating layer form an angle that lies in a range of 10 ° to 80 °, preferably 25 ° to 65 °, particularly preferably 40 ° to 50 °.

Instead of a continuous displacement or limitation of the continuous displacement, the electromagnetic radiation may act on at least one additional region of the opposite material surface of the first material. The electromagnetic radiation also acts here at an angle to the opposite material surface.

This angle is in a range between 80 ° and 170 °, preferably 115 ° to 155 °, particularly preferably from 130 ° to 150 °. Is preferred this angle of the reflection angle from the electromagnetic radiation to the opposite material surface of the first point of action.

This additional area of action has a certain distance from the first site of action. This distance is adjustable in the plane of the opposite material surface in all directions.

In addition to this second point of action, further points of action can be introduced, the distance and the direction of the distance between the first and second points of action also being maintained at the other points of action. Thus, the distances between the action points are constant, whereby process tolerances can lead to deviations.

Furthermore, the distances between the points of action may also be variable or a combination of alternately constant and variable distances or values.

The directions of the additional contact points may be arranged in one direction, starting from the first point of action. In addition, an alternating direction change is possible, with the alternation sequence being arranged in one direction.

Preferably, a simultaneous use of two electromagnetic radiation, both of which have an inclination at an angle of 10 ° to 80 ° to the opposite material surface and the second electromagnetic radiation opposite to the first electromagnetic radiation, preferably in the reflection angle to the first electromagnetic radiation, is arranged. Both electromagnetic radiation act on a site of action. This causes the formation of a third material, which generates an undercut in the region of the second material in each case in accordance with the direction of irradiation. Thus, when two electromagnetic radiation is used, two mutually oppositely disposed undercuts are produced in the second material. Both have in the region of the undercut in the second material starting from the separating layer, the layer sequence: second material, then third material, then second material.

Both electromagnetic radiation can be moved continuously starting from the first point of action, so that the point of action is widened in one direction. In addition, further areas with third material and thus further points of action can be generated at a constant or variable distance or a combination of constant and variable distances to the first point of action. The further contact points may be arranged in a direction to the first point of action or in different directions. In this case, alternating directions with respect to the first point of action are possible, wherein an alternating sequence is arranged in one direction starting from the first point of action.

The composite material is produced in a device which has at least one electromagnetic radiation source.

A first material is provided. After provision of the second material, the first material surface of the first material volume and the second material surface of the second material volume are positioned relative to each other. Both material surfaces then form a separating layer.

If the device is dimensioned so that both materials and the release layer can be introduced into the device with the at least one electromagnetic radiation source, then both materials are preferably held in position with respect to each other, e.g. by rolling. The device may be dimensioned so that an introduction of the two materials and the release layer in the device is not possible. In this case, the device comprises only a holder of at least one electromagnetic radiation source z. B. welding robot with electromagnetic radiation source. The position stability of the two materials and the release layer is ensured by other means. The device with the electromagnetic radiation source is positioned to the opposite material surface so that the electromagnetic radiation of the radiation source at an angle of 10 ° to 80 °, preferably 25 ° to 65 °, particularly preferably 40 ° to 50 ° to the opposite material surface of the first material can act. Thus, the first material has been exposed to electromagnetic radiation at a first point of action.

The electromagnetic radiation causes the formation of the third material in a third volume of material.

The device may comprise a single angularly variable electromagnetic radiation source.

As a variant, this radiation source can be rotated about an axis which runs perpendicular to the center plane of the separating layer in the direction of the first material. This gives the second material a truncated cone-like third material.

Instead of the rotation of the radiation source, the radiation source is fixedly arranged in a further variant. The electromagnetic radiation acts on the opposite material surface of the first material via a variable-angle, rotating mirror.

The mirror is arranged at an angle of 10 ° to 80 °, preferably 25 ° to 65 °, particularly preferably 40 ° to 50 ° to the opposite material surface, with an axis of rotation which is perpendicular to the center plane of the separating layer in the direction of the first material.

The radiation source is advantageously arranged so that it can guide the electromagnetic radiation onto the mirror in the axis of rotation of the mirror.

The device preferably has two or more electromagnetic radiation sources.

All radiation sources are arranged at an angle of 10 ° to 80 °, preferably 25 ° to 65 °, particularly preferably 40 ° to 50 ° to the opposite material surface.

Two radiation sources are preferably arranged so that the second radiation source is at the angle of reflection to the first radiation source. Both radiation sources are arranged opposite each other. Further pairs of radiation sources may be arranged offset to the first pair of radiation sources.

When using a radiation source pair, both radiation sources are preferably operated at the same time, so that two undercuts are formed by the third material in the second material.

As a variant, it is possible for a radiation source pair to first emit an applied radiation to the first radiation source, then the device generates an offset on the material surface and subsequently the second radiation source emits an acting radiation.

As a further variant, although the radiation source pair is aligned at the reflection angle, the opposite arrangement has a small offset of the second radiation source to the first radiation source. Thus, two offset action points are generated, each forming an opposite undercut in the second material of the third material. The two offset exposure sites are created by the simultaneous action or alternate action of the two radiation sources.

As a further variant, the opposite pair of radiation sources is operated so that the first electromagnetic radiation at an angle of 10 ° to 80 °, preferably 25 ° to 65 °, particularly preferably 40 ° to 50 ° to the opposite material surface acts, the second electromagnetic radiation in one Angle of 10 ° to 100 °, preferably 20 ° to 90 °, preferably 25 ° to 65 °, particularly preferably 40 ° to 50 ° to the opposite material surface acts.

The angle settings allow tolerances of up to ± 3 °.

The device can be moved continuously with simultaneous action of the electromagnetic radiation. This creates an action point which has an extension in the direction of displacement. Furthermore, a continuous displacement is possible, however, the electromagnetic radiation is switched on only in certain time windows, so that distances between the action points arise. These distances may be constant, variable or a combination of constant and variable values.

The composite material produced in this way is used in vehicle construction, preferably body construction. The advantage of the invention is that intermetallic phases can be used for fastening two materials via a welding process. In addition, such a composite material has a higher load capacity even with oscillating loads. This can be dispensed with the riveting of the two materials. This saves material, time and complex assembly structures in hard-to-reach places.

The invention is not limited to the following examples. The schematic drawings are intended to clarify the principle. Therefore, some details have been omitted for simplicity.

• 1 in einer Schnittdarstellung einen erfindungsgemäßen Materialverbund,
• 2a und 2b in schaubildlichen Schnittdarstellungen einen erfindungsgemäßen Materialverbund, jeweils aus unterschiedlichen Materialien,
• 3 bis 6 weitere Ausführungsformen des erfindungsgemäßen Materialverbundes mit einem jeweils unterschiedlichen Einsatz der Laserquelle(n) und
• 7 eine weitere Ausführungsform des erfindungsgemäßen Materialverbundes, der mittels einer Elektronenstrahlquelle verschweißt wird.

Embodiments of the invention are explained below with reference to the drawings in a purely schematic representation. Show it:

• 1 in a sectional view of a composite material according to the invention,
• 2a and 2 B in schematic sectional views of a composite material according to the invention, each made of different materials,
• 3 to 6 further embodiments of the composite material according to the invention with a different use of the laser source (s) and
• 7 a further embodiment of the composite material according to the invention, which is welded by means of an electron beam source.

In 1 is shown a composite material, which is a component 10 represents. Here is a sheet as the second volume of material 14 made of steel as a material. This steel sheet has a material surface, which in the following second material surface 15 is called. On this steel sheet is a sheet as the first volume of material 11 made of aluminum as the first material. The aluminum sheet has a material surface, which in the following first material surface 12 is called. The first and second material surfaces are arranged to each other so that the first material surface 12 on the second material surface 15 rests. Both material surfaces form the separating layer 16 , Due to previous processes, residues such as oils, dust, oxidation layers, metal dust from rolls can be present on both material surfaces. This is not a problem, but leads to broadening of the separation layer 16 , Furthermore, the material thicknesses of both sheets may vary. This also leads to broadening of the separation layer 16 , To determine the median plane M the separation layer 16 the distances between the first and second material surface are determined. The middle plane M the separation layer 16 is at half the distance between the first and second material surfaces.

The first volume of material 11 has a material surface opposite the first material surface 13 , This opposite material surface 13 is the work plane for the laser, which is based on the first volume of material 11 acts.

After the aluminum sheet and the steel sheet have been positioned in a holder and briefly pressed, an in 1 Welding robot, not shown, a device with two laser sources without contact over the first volume of material 11 , Both laser sources preferably have a power of over 1 KW. The laser sources are in the 2 shown schematically and laterally offset for reasons of clarity.

The first laser source is at an angle of 60 ° ± 5 ° to the opposite material surface 13 positioned. The second laser source is at an angle of 90 ° ± 5 ° to the opposite material surface 13 positioned. Both laser sources are mounted on a rail so that they face each other.

Both laser sources are activated simultaneously and melt the first volume of material 11 , the separating layer 16 and the second volume of material 14 on. It forms intermetallic phases, which are the third volume of material 17 . 24 produce. The third volume of material 17 . 24 each has a third material surface 18 . 25 that the release layer 16 breaks through and into the second volume of material 14 intervenes. Each laser source is switched off individually after reaching the necessary depth or after a certain time. The first laser source is at the first site of action 26 the third volume of material 17 generated. The second laser source is at the second exposure site 27 the third volume of material 24 generated.

Due to the inclination of the first laser source has the third volume of material 17 an angle 23 between the third material surface 18 and the median plane of the separation layer 16 on. The angle 23 is 130 ° ± 5 °. Furthermore, an undercut is formed 19 of the third volume of material 17 in the second volume of material 14 , Starting from the separation layer 16 This results in an area in which the sequence of layers second material volume 20 , then third volume of material 21 and then second volume of material 22 formed. This area is on the one hand by a continuous second volume of material 14 and on the other side by the third material volume 17 in the separation layer 16 limited.

In the first material volume 11 takes the third volume of material 17 a funnel-shaped training, since the aluminum sheet has a lower melting point than steel.

That in the second site of action 27 generated additional third volume of material 24 with a third material surface 25 causes the position of the first and second material volumes to be fixed relative to one another. This can be the undercut 19 Tensile loads without undercut 19 would lead to the separation of both plates, record and cause a connection of both plates, which can withstand higher loads.

Thus, a component was made of a composite material of aluminum sheet and steel sheet.

In the other figures, the laser sources are shown offset to the point of action for better illustration.

In 2a is a composite material of aluminum sheet on steel sheet shown, with two opposite laser sources, each at an angle of 45 ° ± 5 ° to the opposite material surface 13 of the first material volume 11 Aluminum sheet are arranged. Both laser sources are arranged so that the second laser source in Reflection angle of the first laser source is located. Both laser sources act on an impact site on the opposite material surface 13 of the first material volume 11 on. Both laser sources are started simultaneously.

It form two mutually leading away, opposite undercuts 19 out. This has the advantage that both undercuts 19 Can absorb tensile forces and lateral forces.

Subsequently, the device is moved with the two laser sources 101, which at the same time the welding direction 101 is, with both laser sources remain activated. It creates an impact point with the third volume of material 17 which is stretched in one direction.

In 2 B is a composite material of sheet steel on aluminum sheet shown, with two opposite laser sources, each at an angle of 45 ° ± 5 ° to the opposite material surface 13 of the first material volume 11 Steel sheet are arranged. Both laser sources are arranged so that the second laser source is at the reflection angle of the first laser source. Both laser sources act on an impact site on the opposite material surface 13 of the first material volume 11 on. Both laser sources are started simultaneously.

It form two mutually leading away, opposite undercuts 19 out. This has the advantage that both undercuts 19 Can absorb tensile forces and lateral forces.

Subsequently, the device is moved with the two laser sources 101 what at the same time the welding direction 101 is, with both laser sources remain activated. It creates an impact point with the third volume of material 17 which is stretched in one direction.

In 3 is a composite material of aluminum sheet on steel sheet shown, with two opposite laser sources, each at an angle of 45 ° ± 5 ° to the opposite material surface of the first volume of material 11 Aluminum sheet are arranged. Both laser sources are arranged so that the second laser source is at the reflection angle of the first laser source. Both laser sources act on an impact site on the opposite material surface 13 of the first material volume 11 on. Both laser sources are started simultaneously.

It form two mutually leading away, opposite undercuts 19 out. This has the advantage that both undercuts 19 Can absorb tensile forces and lateral forces.

Subsequently, the device is moved with the two laser sources 101 what at the same time the welding direction 101 is, with both laser sources are activated. This feed can be a short distance. It is also possible to realize no feed.

Subsequently, both laser sources are deactivated. This creates a distance to the first point of action. When a certain distance is reached, both laser sources are activated simultaneously, creating an additional point of contact with the third volume of material 17 , The activated laser sources are shifted in the activated state or remain in place. Subsequently, the laser sources are deactivated. The process of shifting, activating, shifting and deactivating can still be repeated. When the end of the particular welding direction has been reached, the device with the laser sources can be oriented in a different direction and the process is repeated, the direction changing.

In 4 is a composite material of aluminum sheet on steel sheet shown, with two opposite laser sources, each at an angle of 45 ° ± 5 ° to the opposite material surface 13 of the first material volume 11 Aluminum sheet are arranged. Both laser sources are arranged so that the second laser source is at the reflection angle of the first laser source. However, both laser sources are laterally offset, so that both laser sources have two laterally offset, different exposure points on the opposite material surface 13 of the first material volume 11 effect. Preferably, only one laser source, then the other laser source is activated. It is also possible to activate both laser sources simultaneously.

Subsequently, both laser sources are deactivated and the device is moved with the two laser sources 101 what at the same time the welding direction 101 is.

There are two mutually leading away, laterally offset undercuts 19 out. This has the advantage that both undercuts 19 Can absorb tensile forces and lateral forces. Starting from the first point of action, the displacement causes an alternating arrangement of the points of action. Furthermore, an alternation sequence of the action points has a distance by which the device has been displaced with deactivated laser sources.

The process of moving, activating and deactivating can still be repeated. If the end of the particular welding direction is reached, the device can be oriented with the laser sources in a different direction, and the process is further repeated, wherein the welding direction 101 changes.

In 5 a composite material of aluminum sheet is shown on steel sheet, with a laser source at an angle of 45 ° ± 5 ° to the opposite material surface 13 of the first material volume 11 Aluminum sheet are arranged. The laser source is rotated about an axis of rotation. The axis of rotation has an angle of 90 ° ± 5 ° to the central plane of the separating layer and is thus approximately perpendicular to the median plane of the separating layer. The laser source is activated and forms an impact site. Subsequently, the laser source is rotated in the activated state at an angle of 10 ° to 370 °.

The third volume of material 17 thus forms in the second material volume 14 a truncated cone-like shape. This has in cross-section two mutually leading away, opposite undercuts 19 , This has the advantage that the entire undercut area 19 Traction forces and lateral forces can absorb.

Subsequently, the device is moved with the laser source deactivated. It creates an impact point with the third volume of material 17 ,

The rotation is only possible from 10 ° to 190 ° ± 20 °. With a rotation of the laser source by 180 ° ± 5 °, the laser is only in the range of 0 ° to 10 ° and 170 activated up to 180 °.

It form two mutually leading away, opposite undercuts 19 which can absorb tensile forces and lateral forces.

In 6 a composite material of aluminum sheet is shown on steel sheet, with a laser source is fixed. Through a rotating mirror, the electromagnetic radiation is at an angle of 45 ° ± 15 ° to the opposite material surface 13 of the first material volume 11 Deflected aluminum sheet. The mirror moves about an axis of rotation which is oriented at an angle of 90 ° ± 10 ° to the median plane of the separating layer. The rotation is from 0 ° to 360 °. However, the laser is only activated in the range of 350 ° to 360 ° and 0 ° to 10 ° per ± 10 ° and 170 ° to 190 ° per ± 10 °.

It creates an impact point with the third volume of material 17 , It form two mutually leading away, opposite undercuts 19 out. This has the advantage that both undercuts 19 Can absorb tensile forces and lateral forces.

During the deactivation of the laser source and the rotation of the mirror from 190 ° to 350 °, the device with the rotating mirror in the direction 101 be moved, which at the same time the welding direction 101 is.

The act of activating, deactivating and shifting the mirror while rotating can still be repeated. When the end of the particular welding direction is reached, the device need not be reoriented. By changing the rotation angle of the activation and deactivation can be welded in a different direction. Thus, a weld can take place at right angles to the previous welding direction by subsequently deactivating an activation at 80 ° to 100 ° per ± 10 ° and reactivating at 260 ° to 280 ° per ± 10 °. By appropriate activation phases in certain rotation angles of the mirror are the undercuts 19 positionable in certain directions. Thus, this device can easily realize multiple changing welding directions.

In 7 a composite material of aluminum sheet is shown on steel sheet, with an electron beam source is fixed. The rotating mirror off 6 is replaced by deflecting magnetic fields, magnetic deflection coil. The electron beam is preferably at an angle of 45 ° ± 15 ° to the opposite material surface 13 of the first material volume 11 Aluminum sheet deflected, but can also within the first volume of material 11 be deflected by external magnetic fields at an angle of 45 ° ± 15 ° to the center plane of the separation layer.

Depending on the arrangement of the deflection coils, a rotation of the electron beam around 0 ° to 360 ° is possible. The axis of rotation is oriented at 90 ° ± 10 ° to the median plane of the separating layer. However, the electron beam is activated only in the range of 350 ° to 360 ° and 0 ° to 10 ° per ± 10 ° and 170 ° to 190 ° per ± 10 °, eg by focusing. At other angles of rotation, the electron beam is deactivated, eg by defocusing or shielding to the opposite material surface 13 of the first material volume 11 ,

It creates an impact point with the third volume of material 17 , It form two mutually leading away, opposite undercuts 19 out. This has the advantage that both undercuts 19 Can absorb tensile forces and lateral forces.

During deactivation and rotation of the electron beam from 190 ° to 350 °, the device can move with the electron beam in the direction 101 be moved, which at the same time the welding direction 101 is.

The process of electron beam activation, deactivation and shift can be repeated. When the end of the particular welding direction is reached, the device need not be reoriented. By changing the rotation angle of the activation and deactivation can be welded in a different direction. Thus, a weld can take place at right angles to the previous welding direction by subsequently deactivating an activation at 80 ° to 100 ° per ± 10 ° and reactivating at 260 ° to 280 ° per ± 10 °. By appropriate activation phases in certain angles of rotation of the electron beam are the undercuts 19 positionable in certain directions. Thus, this device can easily realize multiple changing welding directions.

LIST OF REFERENCE NUMBERS

10

Component as composite material

11

first volume of material

12

first material surface

13

opposite material surface

14

second volume of material

15

second material surface

16

Separating layer with center plane

17

third volume of material

18

third material surface

19

Area of the undercut starting from the separating layer

20

Area of the undercut with second material volume

21

Area of the undercut with third material volume

22

Area of the undercut with second material volume

23

Angle between the median plane of the separation layer and the third material volume

24

additional area with third volume of material

25

additional area with third material surface

26

first site of action

27

second or additional site of action

101

Displacement direction or welding direction

M

midplane

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 19627913 B4 [0002]
• DE 10261422 B4 [0003]
• DE 102014017563 A1 [0004]
• DE 10304954 A1 [0005]

Claims (10)

A composite material comprising at least one first volume of material (11) of at least one first material having a first material surface (12), at least one second material volume (14) of at least one second material with a second material surface (15), wherein the first and second material volumes (11, 14) are arranged such that the first and second material surfaces (12, 15) are at least partially arranged relative to one another, wherein the mutually arranged first and second material surfaces (12, 15) form a separating layer (16). form, which has a median plane (M), wherein the composite material has at least one first region with a third material volume (17) made of a third material and a third material surface (18), wherein the third material volume (17) intersects the median plane (M) of the separation layer (16) and is disposed within the first material volume (11) and within the second material volume (14) a) the third material surface (18) within the second material volume (14) to the median plane (M) of the separating layer (16) in at least one region has an angle between 100 ° and 170 °, or b) the third volume of material (17) within the second material volume (14) has an axis of rotation, said axis of rotation to the median plane (M) of the separating layer (16) in at least one area has an angle between 100 ° and 170 °, or c) the third material volume (17) within the second volume of material (14) has a center plane, said center plane of the second material volume (14) to the center plane (M) of the separation layer (16) in at least one area an angle between 100 ° and 170 ° has, or d) the third material volume (17) within the second material volume (14) has a truncated cone, wherein the inclination of the cone wall to the center plane (M) of the separating layer (16) in at least one region has an angle between 10 ° and 80 °. A composite material after Claim 1 characterized in that the composite material has at least one additional region with the third material volume (17) of a third material with the third material surface (18) within the second material volume (14), the additional region comprising the third material surface (18) within the second material surface (18) second material volume (14) to the center plane (M) of the separating layer (16) in at least one region has an angle between 80 ° and 170 °. A composite material according to one of the preceding claims, characterized in that the at least two regions with the third material volume (17) to each other a distance in the median plane (M) of the separating layer (16), wherein the distance is a constant, variable or a combination of alternately constant and variable value. A composite material according to any one of the preceding claims, characterized in that the first material is steel, steel alloys, aluminum or aluminum alloys, the second material is aluminum, aluminum alloys, steel or steel alloys and the third material is a phase having variable proportions of steel or steel alloys with aluminum or aluminum alloys includes. Device for producing a composite material according to one of Claims 1 to 4 , characterized in that at least one electromagnetic radiation is arranged so that it acts at an angle of 10 to 80 ° on the opposite material surface (13) to the first material surface (12) of the first material volume (11). Device after Claim 5 , characterized in that the electromagnetic radiation is reflected by a mirror, so that the electromagnetic radiation at an angle of 10 ° to 80 ° on the opposite material surface (13) to the first material surface (12) of the first material volume (11) acts. Device according to one of Claims 5 to 6 , characterized in that the electromagnetic radiation is reflected by a rotating mirror, so that the electromagnetic radiation at an angle of 10 ° to 80 ° on the opposite material surface (13) to the first material surface (12) of the first material volume (11) acts. Device after Claim 5 , characterized in that an additional electromagnetic radiation is arranged so that it acts at an angle of 10 ° to 100 ° on the opposite material surface (13) to the first material surface (12) of the first material volume (11). Process for producing a composite material according to one of Claims 1 to 4 or for use with a device according to Claims 5 to 8th characterized in that it comprises the following steps: a) providing a first material volume (11) of a first material having a first material surface (12), b) providing a second material volume (14) of a second material having a second material surface (15 ), the second C) providing a release layer (16) having a median plane (M) formed by the first material surface (12) and the second material surface (15), d) applying the first volume of material (11) with electromagnetic radiation, wherein the electromagnetic radiation at an angle of 10 ° to 80 ° on the opposite material surface (13) to the first material surface (12) of the first material volume (11) acts, e) generating a third material volume (17) from a third material by means of the acting electromagnetic radiation. A composite material produced by a method according to Claim 9 ,

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