EP2780127A1 - Goujon de soudage graduel et procédé de préparation - Google Patents

Goujon de soudage graduel et procédé de préparation

Info

Publication number
EP2780127A1
EP2780127A1 EP12849649.4A EP12849649A EP2780127A1 EP 2780127 A1 EP2780127 A1 EP 2780127A1 EP 12849649 A EP12849649 A EP 12849649A EP 2780127 A1 EP2780127 A1 EP 2780127A1
Authority
EP
European Patent Office
Prior art keywords
substrate
weldable
weld stud
weld
sintering
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP12849649.4A
Other languages
German (de)
English (en)
Other versions
EP2780127A4 (fr
Inventor
Erik Karlsson
Mohamed Radwan
Anders BREMMER
Katarina Flodström
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Diamorph AB
Original Assignee
Diamorph AB
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Diamorph AB filed Critical Diamorph AB
Publication of EP2780127A1 publication Critical patent/EP2780127A1/fr
Publication of EP2780127A4 publication Critical patent/EP2780127A4/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • 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
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
    • B23K35/0288—Welding studs
    • 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
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053—Fe as the principal constituent
    • B23K35/3093—Fe as the principal constituent with other elements as next major constituents
    • 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
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/32—Selection of soldering or welding materials proper with the principal constituent melting at more than 1550 degrees C
    • B23K35/322—Selection of soldering or welding materials proper with the principal constituent melting at more than 1550 degrees C a Pt-group metal as principal constituent
    • 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
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/32—Selection of soldering or welding materials proper with the principal constituent melting at more than 1550 degrees C
    • B23K35/325—Ti as the principal constituent
    • 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
    • B23K9/20—Stud welding
    • 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
    • B23K9/20—Stud welding
    • B23K9/207—Features related to studs
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/64—Burning or sintering processes
    • C04B35/645—Pressure sintering
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B37/00—Joining burned ceramic articles with other burned ceramic articles or other articles by heating
    • C04B37/02—Joining burned ceramic articles with other burned ceramic articles or other articles by heating with metallic articles
    • C04B37/021—Joining burned ceramic articles with other burned ceramic articles or other articles by heating with metallic articles in a direct manner, e.g. direct copper bonding [DCB]
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B37/00—Joining burned ceramic articles with other burned ceramic articles or other articles by heating
    • C04B37/02—Joining burned ceramic articles with other burned ceramic articles or other articles by heating with metallic articles
    • C04B37/023—Joining burned ceramic articles with other burned ceramic articles or other articles by heating with metallic articles characterised by the interlayer used
    • C04B37/026—Joining burned ceramic articles with other burned ceramic articles or other articles by heating with metallic articles characterised by the interlayer used consisting of metals or metal salts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • 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
    • B23K2103/05—Stainless steel
    • 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
    • B23K2103/08—Non-ferrous metals or alloys
    • 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
    • B23K2103/08—Non-ferrous metals or alloys
    • B23K2103/10—Aluminium or alloys thereof
    • 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
    • B23K2103/08—Non-ferrous metals or alloys
    • B23K2103/14—Titanium or alloys thereof
    • 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
    • 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
    • B23K2103/26—Alloys of Nickel and Cobalt and Chromium
    • 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
    • B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
    • B23K2103/52—Ceramics
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
    • C04B2235/6562—Heating rate
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    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/66—Specific sintering techniques, e.g. centrifugal sintering
    • C04B2235/666—Applying a current during sintering, e.g. plasma sintering [SPS], electrical resistance heating or pulse electric current sintering [PECS]
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    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/02—Aspects relating to interlayers, e.g. used to join ceramic articles with other articles by heating
    • C04B2237/12—Metallic interlayers
    • C04B2237/123—Metallic interlayers based on iron group metals, e.g. steel
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    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32—Ceramic
    • C04B2237/34—Oxidic
    • C04B2237/343—Alumina or aluminates
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    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32—Ceramic
    • C04B2237/34—Oxidic
    • C04B2237/345—Refractory metal oxides
    • C04B2237/348—Zirconia, hafnia, zirconates or hafnates
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    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/40—Metallic
    • C04B2237/401—Cermets
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    • C04B2237/40—Metallic
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    • C04B2237/406—Iron, e.g. steel
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    • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
    • C04B2237/58—Forming a gradient in composition or in properties across the laminate or the joined articles
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    • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
    • C04B2237/76—Forming laminates or joined articles comprising at least one member in the form other than a sheet or disc, e.g. two tubes or a tube and a sheet or disc
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    • C04B2237/80—Joining the largest surface of one substrate with a smaller surface of the other substrate, e.g. butt joining or forming a T-joint

Definitions

  • the present invention relates generally to a weldable component with a gradient structure going from one material which is weldable to a substrate, to a second material which is not weldable to the same substrate, and a method of preparation of such as a shape by sintering, preferably by spark plasma sintering (SPS).
  • SPS spark plasma sintering
  • a cermet is a composite material composed of ceramic (cer) and metallic (met) materials.
  • Tungsten carbide (WC) often referred to as cemented tungsten carbide or hard metal, for example, is extensively used in the mining and construction industry as heavy wear components.
  • WC tungsten carbide
  • a metallic binder generally cobalt, nickel, iron, or their equivalent that generally makes the carbide a cermet and differentiates it from truly brittle materials, that is, the ceramic family of materials.
  • “cemented” is also used to show that the carbide alloy powder includes an amount of metallic binder. During the sintering process, the tungsten carbide particles are captured in the metallic binder and cemented together by forming a metallurgical bond.
  • Ceramic materials and cermets are not weldable by nature, hence the use of other joining methods such as brazing.
  • Brazing is a relatively slow manufacturing process compared to welding and has limitations in where it can be used. These limitations have in turn limited the scope of using these materials for wear protection and wear parts.
  • Arc welding is a fusion welding process that uses electricity to generate the heat needed to melt the base metals.
  • Stud welding is an industrially mature technology, which is a kind of arc welding. By leading current through a bolt, nut or other specially formed parts, the component is welded onto another metal part by the heat generated through electrical resistance.
  • DA Drawn Arc
  • SC Short Cycle
  • DA studs are typically loaded with an aluminium flux ball on the weld end, which aids in the welding process.
  • the DA studs are used along with a ceramic ring or inert gas to protect the joint from oxidation during the melting phase of the welding process.
  • SC and CD studs differ from DA studs in that the studs do not require flux nor the oxidation protection in form of a ceramic ring or inert gas during welding, due to shorter welding times than for DA.
  • Stud welding is very versatile. Portable stud welding machines are available. Welders can also be automated, with controls for arcing and applying pressure. Typical applications include automobile bodies, electrical panels, shipbuilding and building construction.
  • weld studs made from steel available that are used as weld-on wear protection are used as weld-on wear protection.
  • the weld studs are often tempered.
  • the properties of the tempered steel might be compromised.
  • Previous inventions for joining of different materials in a weld stud are generally based on mechanical anchoring or surface coatings.
  • the German company BETEK produces a weldable stud comprising tungsten carbide, where a solid cemented tungsten carbide core is shrink-fitted to a steel body which in turn fits a stud welding machine.
  • the downside with this product is the more complicated manufacturing process, where the cemented tungsten carbide needs to be sintered, the steel body needs machining and finally the two components are joined by shrink-fitting. Also, if the ceramic core falls out, the wear protection is severely reduced.
  • An object is to provide a weld stud of a functionally graded material (FGM) component prepared by sintering, preferably by spark plasma sintering (SPS), where a weldable material base is combined with an outer surface of a different, non-weldable material.
  • FGM functionally graded material
  • SPS spark plasma sintering
  • Another object is to provide a method of preparation of said weld stud.
  • a weld stud adapted to be welded against a substrate comprises a first, second and third portion.
  • the first portion comprises a first material M1
  • the second portion comprises a second material M2, weldable to the substrate
  • the third portion comprises at least one of: a material being weldable to the substrate, and a flux material adapted to facilitate the welding of the second material M2 to the substrate.
  • the weld stud further comprises a length axis running through said first, second and third portion.
  • the third portion comprises a cross section perpendicular to the length axis having a smaller area than the average cross-section area of the first and second portions perpendicular to the length axis.
  • the first material M1 and second material M2 are bonded with a gradual transition, wherein the first material M1 is not weldable to the substrate, and the second material M2 is weldable to the substrate. Furthermore, the first and second portions comprise a sintered transition region comprising a mix of the first M1 and the second M2 materials. [0016] By providing the FGM weld stud, a non-weldable material can be welded onto a substrate which makes it possible to apply materials with superior properties to substrates by means of welding.
  • the weld stud comprises a rounded (4) or tapered (4a; 4b) portion adapted to initiate contact with the substrate which is crucial for a homogeneous melt of the materials and the best possible result when welding.
  • the rounded or tapered portion may comprise a flux for facilitating and/or improving the weld between the substrate and the weld stud.
  • the non-weldable surface can preferable be of a ceramic material or a cermet.
  • the non-weldable surface preferably has a good wear resistance.
  • Other desirable properties of this surface can be low weight, high corrosion resistance and an insulating nature.
  • the non-weldable surface can have different shapes, such as flat, tapered and spherical.
  • tungsten carbide often referred to as cemented tungsten carbide or hard metal.
  • Suitable materials are ceramic oxides, nitrides, borides or other carbides.
  • aluminium oxide (AI2O3) and zirconium oxide (ZrO 2 ) are suitable for this invention.
  • the non-weldable material can also be a metal or metal alloy which is not weldable to the substrate.
  • the weldable material is preferably a metal or metal alloy, but can also be plastic.
  • weldable metals including their alloys are aluminium, nickel, gold, platinum, titanium, tantalum and zirconium. Further, steel and some stainless steel alloys (300 and 400 series) are weldable.
  • the weldable material is preferably a steel alloy or a stainless steel alloy.
  • the weld stud is a FGM weld stud made of steel/cemented tungsten carbide (steel / WC-Co FGM).
  • the weld stud is a FGM weld stud of stainless steel /cemented tungsten carbide (SS / WC-Co FGM).
  • the weld stud is a FGM weld stud of stainless steel or steel /aluminium oxide (SS / AI2O3 FGM).
  • the weld stud is a FGM weld stud of stainless steel or steel /zirconium oxide (SS / Zr02 FGM).
  • the non-weldable material M1 does not comprise 100% of one material, but also some portion of the weldable material.
  • the shape of the weld stud can be achieved directly through the sintering, or the stud can be machined to proper geometry after the sintering.
  • a cylindrical shape with circular cross section is very common for weld studs, and is one shape possible for the present invention.
  • the shape of the weld stud is however not limited to the circular cross- section, but the cross-section can also be square, rectangular, hexagonal, octagonal or of other similar shapes.
  • a tip or a slightly conical structure of the welding surface is in many cases suitable for the weld studs. This shape can be machined after the sintering or the component can be sintered into this shape. [0037] A hole in the tip of the conical part can be formed for receiving a piece or slug of welding flux which may be aluminium or some other similar material used as flux in welding.
  • the wear resistant material of a gradient weld studs is present throughout the wear surface and the gradient region, because of the gradual compositional change between the two materials. This further improves the wear properties and the lifespan of the components, compared to components with a wear resistant surface coating.
  • a ceramic material's properties such as hardness are not affected by the heat during a welding process, and the properties will not change after the welding.
  • the invention also relates to a method for producing the weld stud. More specifically the invention relates to a method for producing a ceramic or cermet/metal FGM, shaped as a weld stud. The method comprises the following steps:
  • Fig. 1 shows a weld stud according to one embodiment having a functionally graded material structure, where portion I comprises a wear resistant part, portion II comprises a weldable part and portion 5 comprises a gradual transition between the two materials with four intermediate layers i-iv,
  • Fig. 2 shows a weld stud 1 in an embodiment similar to that of fig. 1 , the difference being that there is a third portion III, consisting of two tapered parts 4ab,
  • Fig. 3a, 3b shows a weld stud in an embodiment similar to that of fig. 1 and fig.2, the difference being that the third portion III has a spherical and frustoconical shape, respectively,
  • Fig. 4 shows a weld stud according to an embodiment in which the weld stud comprises a gradient portion 5 being an intermediate region comprising a mix of non-weldable and weldable material,
  • Fig. 5 is a perspective view of a weld stud according to any of the embodiments of figs. 1 - 4 when welded onto a substrate 2,
  • Fig. 6 shows the weld stud in form of a nut having a plurality of weld flux portions
  • Fig. 7 shows a scoop for excavators comprising weld studs according to any of the embodiments herein,
  • Fig. 8 shows a drill bit for a rock drill comprising weld studs according to any of the embodiments herein,
  • Fig. 9 shows a feed roller for example for a forest harvester head comprising weld studs according to any of the embodiments herein.
  • a functionally graded material is a material design concept which provides a joining solution to incorporate incompatible properties of two dissimilar materials, such as the heat, the wear, and the oxidation resistance of a ceramic or a cermet, such as for example cemented tungsten carbide, with the high
  • a functionally graded material is thus a material bonded with a gradual transition from at least a first to at least a second material.
  • FGMs can be prepared through different techniques such as
  • SPS spark plasma sintering method
  • FAST field assisted sintering technique
  • SPS field assisted sintering technique
  • Other sintering techniques could possibly also be used for preparing FGMs, such as for example direct hot- pressing, hot-pressing or hot isostatic pressing.
  • a flux is to be understood as a chemical cleaning agent, flowing agent, or purifying agent used in welding for preventing oxides from forming on the surface of the molten metal and/or absorbing impurities.
  • the flux could for example comprise a piece of aluminium, however it is also conceivable that the flux is a flux comprising ammonium chloride, hydrochloric acid, zinc chloride or borax.
  • Fig. 1 shows an example of a metal / ceramic FGM with a graded portion 5 consisting of several composite layers, there is a gradual variation of the microstructure with the compositional change.
  • the matrix is replaced gradually from metal to ceramic, and the microstructure profile varies concurrently from II a pure metal , iii-iv a metal-rich region (the ceramic particles are dispersed in metal matrices), i-ii a ceramic-rich region (the metal matrix diminishes and turns into discrete phases or particles in ceramic matrices), to finally (portion I) a pure ceramic.
  • This gradient in the composition-microstructure-properties along the FGM is the key for its stability and performance.
  • Fig. 2 shows a weld stud 1 according to one embodiment.
  • the weld stud 1 is adapted to be welded against a substrate (shown as reference numeral 2 in fig. 5) by means of electric resistance welding.
  • electric resistance welding heat is generated by the electrical resistance of the material to be welded which makes a portion of the material of the weld stud 1 and a portion of the substrate melt and thus forming the weld between the weld stud 1 and the substrate.
  • the first portion I of the weld stud 1 comprises a first material M1 which is a material which is not possible to weld against the substrate.
  • the material M1 could for example be a ceramic, cermet or polymer material.
  • the material M1 could be a wear resistant material adapted to increase the wear resistance of weld stud or a chemically resistant material adapted to increase the chemical resistance of weld stud 1 .
  • the weld stud 1 further comprises a second portion II comprising a second material M2 being a material weldable against the substrate.
  • the second material M2 could for example comprise steel or stainless steel.
  • the first portion I is joined to the second portion II by means of the weld stud having a functionally graded region
  • the weld stud further comprises a third portion III comprising two tapered portions 4a, 4b such that the third portion comprises a cross section perpendicular to the length axis of the weld stud 1 having a smaller area than the average cross-section area of the first and second portions perpendicular to the same length axis.
  • the tapered portions 4a, 4b are needed to initiate the welding process and could furthermore comprise a flux for facilitating the welding of the second material M2 against the substrate.
  • Fig. 3a shows a weld stud 1 according to an embodiment similar to the embodiment of fig.1 , with the difference that the third portion III comprises a rounded portion 4 which, just as the tapered portions of fig. 1 , is needed to initiate the welding, and could also comprise a flux for facilitating the welding of the second material M2 against the substrate.
  • Fig. 3b shows a weld stud 1 according to an embodiment similar to the embodiment of fig.1 , with the difference that the third portion III comprises a frustoconical portion 4 which is used to initiate the welding, and could also comprise a flux for facilitating the welding of the second material M2 against the substrate.
  • Fig. 4 shows an embodiment of the weld stud 1 very similar to the embodiment shown in fig. 2, the difference being that the weld stud of fig. 4 has a transition region 5 which is a substantial part of the weld stud 1 .
  • the transition region 5 comprising a mix of the materials of the first I and second II portions and creates the material joint between the first and second portion.
  • the weld stud has a length axis LA running through said first I, second II and third III portion.
  • the third portion III comprises a cross section B - B perpendicular to the length axis LA having a smaller area a 2 than the average cross-section area a 1 of the first and second portions perpendicular to the length axis LA, in figure 4 shown with the cross-section A - A, as the weld stud of fig. 4 is cylindrical and thus has an equal cross-section over the entire length of the weld stud 1 .
  • the sintered graded region comprises a mix of the first M1 and the second M2 materials which could be a mix creating a gradual variation in composition, smoothly or stepwisely, throughout the transition region 5.
  • the material M1 could in one example be tungsten carbide and the material M2 could be steel and the gradient change throughout the third portion could be 20vol% (i.e. 80/20, 60/40, 40/60, 20/80 vol%).
  • the first I and second II portion may comprise the first M1 and second M2 material in its pure form, respectively, or it may comprise a mix of the materials M1 and M2, with the percentage of M2 being higher in the second portion II than in the first portion, and the percentage of M1 being higher in the first portion I than in the second portion II.
  • Fig. 5 shows the weld stud 1 according to any of the embodiments herein when welded to a substrate 2 such that a weld 3 is formed between the substrate 2 and the weld stud 1 , fixating the weld stud 1 to the substrate 2.
  • Fig. 6 shows an embodiment of the weld stud 10 in which the weld stud 10 has the shape of a nut comprising internal threads 15 enabling the fixation of an object having external threads to the nut 10.
  • the weld nut 10 comprises a first portion I comprising a first material M1 , alone or in combination with at least a second material M2, the material of the first portion I is not weldable to the substrate but chosen for the reason of a particular material property, which may be a mechanical property, such as good wear resistance, or a chemical property, such as good chemical resistance.
  • the weld nut further comprises a second portion II comprising a material weldable against the substrate.
  • the weld nut 10 further comprises a third portion III comprising a plurality of rounded portions needed to initiate the welding process.
  • the rounded portions 14 could be tapered or otherwise shaped such that they have a cross section area being smaller than the average cross-section area of the weld nut for initiating the welding process.
  • the plurality of rounded portions 14 may comprise a flux for facilitating and/or improving the weld between the weld nut 10 and the substrate 2.
  • the weld nut is to be seen as an example showing that there is no limitation to the shape in which the weld stud may be produced as long as the basic principle of a first non-weldable material integrated with a weldable material applies.
  • Fig. 7 shows a scoop 20 for an excavator comprising a substrate 22 adapted to form the scoop 20.
  • the substrate 22 is for example steel or a steel based alloy such as stainless steel.
  • the scoop 20 furthermore comprises weld studs 21 , according to any of the embodiments herein, welded to the substrate 22 for improving the wear resistance of the scoop 20.
  • the weld studs 21 are shown welded to the side of the scoop 20, however it is equally conceivable that the weld studs 21 are welded to the front 23 of the scoop, the inside 24 of the scoop 20, or the teeth 25 of the scoop 20.
  • the scoop 20 shown in fig. 7 is to be seen as an example of an application area of the weld studs 21 according to any of the embodiments disclosed under reference to figs. 2 - 6.
  • Fig. 8 shows a drill bit 30 for a rock drill.
  • the drill bit 30 comprises a substrate 32 adapted to be rotated for exerting a drilling force on a target material, such as a rock wall or a sediment layer.
  • the drill bit 30 furthermore comprises weld studs 31 a, 31 b, according to any of the embodiments herein, welded to the top surface of the substrate 32 (the weld stud 31 a) and along the periphery or lateral surface of the substrate 32 (the weld stud 31 b).
  • weld studs 31 a, 31 b for example comprises a ceramic or cermet material they substantially improve the wear resistance of the drill bit 30 at the same time as they are easy to apply or replace as they can be welded directly on to the substrate 32 by means of resistance welding.
  • the drill bit 30 shown in fig. 8 is to be seen as an example of an application area of the weld studs 31 a, 31 b according to any of the
  • Fig. 9 shows a roller 40 for feeding, for example for use in a forest harvester head.
  • the roller 40 comprises weld studs 41 according to any of the embodiments disclosed herein.
  • the roller 40 comprises a substrate 42 having a substantially circular periphery adapted to rotate for feeding for example logs when harvesting.
  • the weld studs 41 are welded to the circular periphery of the substrate 42.
  • the roller 40 shown in fig. 9 is to be seen as an example of an application area of the weld studs 41 according to any of the embodiments disclosed under reference to figs. 2 - 6.
  • the invention also relates to a method for producing weld studs according to any one of the embodiments herein. More specifically the invention relates to a method for producing a ceramic or cermet / metal FGM, shaped as a weld stud. The method comprises the following steps:
  • [0070] 1 Forming a FGM powder structure, wherein the first material surface comprises up to 100% of the first material M1 , the weldable second surface comprises up to 100% of the second material M2, and the intermediate graded region has several or at least one composite interlayers together creating an intermediate graded composite region, essentially consisting of an intermix of the first M1 , second M2 and possible a third material M3, by loading mixtures of all layers in order, layer by layer, into a sintering tool called die, preferably consisting of graphite and of a desirable shape such as cylindrical or rectangular.
  • a sintering tool called die preferably consisting of graphite and of a desirable shape such as cylindrical or rectangular.
  • the starting materials (M1 , M2) may be delivered continuously into a sintering die in which the material is sintered, creating at least one interlayer with gradual variation in composition, smoothly or stepwisely, throughout the FGM shape consisting of different mixtures of the materials.
  • sintering additives may further be added to the first and/or the second material M1 , M2 in order to improve its properties.
  • the gradient region may further comprise at least one more material, with an expansion coefficient intermediate to the two outer materials.
  • each composite interlayer may be automatically or manually weighed and mixed, by dry mixing or wet mixing, until homogeneity, and if necessary dried and sieved.
  • the numbers of graded layers are between two and twenty. However, other numbers of layers are of course also possible.
  • the change in composition profile along the layers can be linear as well as non-linear
  • an electrically insulating layer of an electrically insulating powder or coating can be inserted in the FGM structure.
  • the whole die is according to this example pre-pressed by cold uniaxial pressing prior to sintering.
  • a weldable metal substrate is used as a base in the FGM structure prior to sintering, and the powder layers are joined with the weldable substrate during the sintering.
  • the production costs can be reduced as the amount of powder is reduced.
  • Cutting can preferably be performed with techniques such as laser cutting, water jet cutting, cutting wheel, plasma cutting or wire EDM.
  • the outer surfaces of material M1 and M2 are flat and parallel, shaped during the sintering by the so called pressing punches, which form the sintering tool together with the die, these punches having flat surfaces.
  • At least one of the pressing punches has a non flat surface, giving at least one of the FGM component surfaces a non-flat nature, to reduce the amount of finishing needed.
  • the FGM components are sintered one at a time, in a single sintering tool.
  • one large FGM component is sintered at a time, which is subsequently cut into smaller components.
  • the weldable end of the gradient weld stud and the metal substrate to which it is to be attached are being brought together in a substantially parallel relationship, and thereafter welded.
  • a steel / WC-Co FGM was designed to comprise four composite interlayers between the pure steel and tungsten carbide layers at the two ends.
  • the composites consisted of steel - cemented carbide mixtures with a 20vol% gradient change (i.e. 80/20, 60/40, 40/60, 20/80 vol%).
  • a die for production of 6 cylindrical components was used. The total six layers for each component were loaded in order, layer by layer, in a graphite die and a BN insulating layer was interposed between the punch and the steel layer.
  • the WC had a Co content of 1 1 % and the grain size was approximately 2 pm.
  • the steel had a D50 size of 10 pm.
  • the die was sintered in a SPS unit at 1 100 °C during 6 minutes and at a pressure of 30 MPa.
  • the heating rate was 50 °C/min.
  • the sintering took place in vacuum.
  • the dimension of the sintered FGMs was 012x22 mm.
  • the steel surface of the FGM was turned into a slightly conical shape, a small hole was made in the steel and aluminium was added as flux.
  • the components were welded onto steel substrates through drawn arc stud welding.
  • a FGM component of stainless steel and yttria-stabilized zirconia was sintered with the SPS technology in a single component graphite tool.
  • the dimensions of the sintered component were 020x17 mm.
  • the component was sintered at 1 100 °C during 22 minutes and at a pressure of 75 MPa.
  • the heating rate was 50 °C/min.
  • the sintering took place in vacuum.
  • the stainless steel part of the component was turned into a slightly conical shape and aluminium was added as flux.
  • a FGM of stainless steel and alumina was prepared, with zirconia as an additive in the intermediate layer.
  • the sample was densified with SPS at 1 100 °C for 30 minutes. The sintering took place in vacuum. The SPS pressure was kept at 75 MPa. A heating rate of 100 °C/ min was applied.
  • the FGM was produced as a cylinder with a diameter of 20 mm and a height of 22 mm.

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Abstract

L'invention concerne un goujon de soudage conçu pour être soudé contre un substrat. Le goujon de soudage (1 ; 10 ; 21 ; 31 ; 41) comprend : des première (I), deuxième (II) et troisième (III) parties. La première partie comprend un premier matériau M1 et la seconde partie comprend un second matériau M2 pouvant être soudé au substrat (2). La troisième partie comprend au moins un élément parmi : un matériau pouvant être soudé au substrat et un matériau de flux conçu pour faciliter le soudage du second matériau M2 au substrat, le goujon de soudage comprenant un axe longitudinal (LA) traversant lesdites première, deuxième et troisième parties et la troisième partie comprenant une section transversale (B-B) perpendiculaire à l'axe longitudinal présentant une zone (a2) inférieure à la zone transversale moyenne (a1) des première et deuxième parties perpendiculaires à l'axe longitudinal. Le premier matériau M1 et le second matériau M2 sont raccordés avec une transition graduelle (5), le premier matériau M1 ne peut pas être soudé au substrat, le second matériau M2 peut être soudé au substrat et les première et seconde parties comprennent une région de transition graduelle frittée comprenant un mélange des premier et second matériaux M1 et M2, respectivement.
EP12849649.4A 2011-11-18 2012-11-14 Goujon de soudage graduel et procédé de préparation Withdrawn EP2780127A4 (fr)

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SE1151094A SE536766C2 (sv) 2011-11-18 2011-11-18 Svetsbult med en gradientstruktur, metod för dess framställning och vals för matning innefattande svetsbult
PCT/SE2012/051250 WO2013074028A1 (fr) 2011-11-18 2012-11-14 Goujon de soudage graduel et procédé de préparation

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US4389462A (en) * 1981-07-08 1983-06-21 Cabot Corporation Process for enclosing a pin shank within an enclosing member and article produced thereby which is substantially devoid of a gap between the enclosing member and the head of the pin
DE8612330U1 (de) * 1986-05-05 1986-06-26 AVT Anti-Verschleiss-Technik GmbH, 5860 Iserlohn Schleißresistenter Noppenbolzen
DE4431563A1 (de) * 1994-09-05 1996-03-07 Kloeckner Humboldt Deutz Ag Verschleißfeste Oberflächenpanzerung für die Walzen von Hochdruck-Walzenpressen zur Druckzerkleinerung körnigen Gutes (Unterlagen zu P 44 44 337.4 gegeben)
JPH09194909A (ja) * 1995-11-07 1997-07-29 Sumitomo Electric Ind Ltd 複合材料およびその製造方法
US6089444A (en) * 1997-09-02 2000-07-18 Mcdonnell Douglas Corporation Process of bonding copper and tungsten
US5988488A (en) * 1997-09-02 1999-11-23 Mcdonnell Douglas Corporation Process of bonding copper and tungsten
US6503575B1 (en) * 2000-05-22 2003-01-07 Praxair S.T. Technology, Inc. Process for producing graded coated articles
US8349396B2 (en) * 2005-04-14 2013-01-08 United Technologies Corporation Method and system for creating functionally graded materials using cold spray
JP2009129637A (ja) * 2007-11-21 2009-06-11 Harison Toshiba Lighting Corp 封着部材、管球
KR100967629B1 (ko) * 2008-02-14 2010-07-07 한양대학교 산학협력단 경사기능재료, 그 제조방법, 그 제조장치 및 이를 이용한이종재료간 경사기능재료 접합방법
SE534696C2 (sv) * 2010-03-26 2011-11-22 Diamorph Ab En funktionell gradientmaterialkomponent och metod för att producera en sådan komponent

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SE1151094A1 (sv) 2013-05-19

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