JP2008055503A - Method for manufacturing structure and such structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for friction stir welding a stainless steel panel to an extruded aluminum alloy shape member. <P>SOLUTION: A side structure 2 of a car body 1 is formed by friction stir welding aluminum alloy extruded hollow shape members 30, 40 from the inner side of the car. On the outer side of the side structure 2, stainless steel panels 10, 20 are welded by the friction stir welding to the butted portion between the hollow shape members 30, 40 from the inner side of the car. After friction stir welding the butted portion between the hollow shape members 30, 40, inner face plates 31, 41 of the hollow shape members 30, 40 are connected via a connecting member 51. According to the present method, because of the stainless steel panels 10, 20 arranged on the outer side of the car, scratches on the surface of the car body can be reduced. Except parts of the stainless steel panels 10, 20, the structure is made of aluminum alloy and can be manufactured in light weight and at low cost. Also, between the stainless steel panels and between the hollow shape members, friction stir welding is performed by abutting or overlapping them on each other. A heat insulation member can be arranged between the stainless steel panels and the hollow shape members. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method of friction stir welding a stainless steel plate to an extruded shape made of an aluminum alloy, and a structure manufactured thereby.

  Here, the structure means a structure in which a vehicle body or a stainless steel plate and an extruded shape made of aluminum alloy are joined.

  The vehicle body refers to a rail vehicle body or a rail vehicle body of a monorail car. The vehicle body may be only a part of the side structure.

  As in [Patent Document 1], an extruded hollow profile made of aluminum alloy is friction stir joined to produce a vehicle body, and a lightweight, inexpensive, and highly rigid vehicle body can be obtained and is widely used. However, the extruded shape made of aluminum alloy is relatively soft and the outside of the vehicle is easily damaged. Also, in tunnels, discoloration easily occurs due to water leakage, and painting is necessary.

  [Patent Document 2] discloses that a railway vehicle body is manufactured by welding a stainless steel plate.

  [Patent Document 3] discloses that the body of a railway vehicle is manufactured by friction stir welding using a stainless steel plate. According to this, although damage can be suppressed, there exists a subject in weight reduction and low price property. Also, stainless steel friction stir welding is not as easy as aluminum alloys. In addition, at present, stainless steel sheets cannot be formed into extruded shapes, in particular, hollow shapes, and stainless steel sheets cannot be reduced in weight and cost.

  FIG. 6d of [Non-Patent Document 1] shows that a plurality of metal plates are stacked and the overlapping portions are friction stir welded.

  [Patent Document 4] discloses that the side structure and the roof structure are joined and the side structure and the base frame are joined by a fastener such as a bolt.

Patent No. 3014564 (EP00797043) Japanese Unexamined Patent Publication No. 04-1000076 JP 2004-276724 A JP 55-31694 A Dawes, “An Introduction to Friction Stir Welding and Its Development”, in Welding & Metal Fabrication (Jan. 1995) pp13, 14 and 16.

  As described above, the extruded shape made of aluminum alloy is lightweight and can be easily manufactured, but there is a problem with scratches.

  Stainless steel plates are resistant to scratches, but cannot be manufactured at low cost.

  An object of the present invention is to provide a method for manufacturing a structure by friction stir welding a stainless steel plate to an extruded shape made of an aluminum alloy.

The present invention
The stainless steel plate is overlaid with the first aluminum alloy extruded shape and the second aluminum alloy extruded shape,
Friction stir welding of the butted portion of the first aluminum alloy extruded shape and the second aluminum alloy extruded shape or the overlapped portion to the stainless steel plate,
Friction stir welding the friction stir welded part to the butted part of the stainless steel plate or the overlapped part,
It is in.

  According to this, the stainless steel plate can be formed by friction stir welding like an extruded shape made of aluminum alloy. Since the stainless steel plate is on the outer surface of the structure (visible part), the visible part is hardly damaged. Since an extruded shape is used, it can be manufactured at low cost.

An embodiment of the present invention will be described below with reference to FIGS. 3 is the same as that of FIG.
III is a cross-sectional view, which should be elongated vertically, but is elongated horizontally to show the manufacturing method. The same applies to FIGS. 4, 5, 7, 9, 13, and 14.

As is well known, the vehicle body 1 in FIG. 1 has a space at the end in the longitudinal direction of the base frame 4, the side structure 2, the roof structure 3, and the base frame 4 on which the side structure 2, the roof structure 3, and the side structure 2 are placed. It consists of a wife structure 5 to be closed. The side structure 2 joins a plurality of extruded aluminum alloy hollow members 30 and 40. The same applies to the other roof structures 3 and underframes 4.

There are stainless steel plates 10 and 20 on the outer surface of the side structure 2. The side structure 2 includes the stainless steel plates 10 and 20 and a plurality of aluminum alloy extruded hollow members 30 and 40 inside the vehicle.

The plurality of hollow members 30, 40 are integrated by friction stir welding. Friction stir welding is
This is a known technique. The stainless steel plates 10 and 20 are friction stir welded at their butted portions to the butted portions of the hollow members 30 and 40.

The side structure 2 may be composed of two hollow shapes 30 and 40. However, since such a large hollow shape cannot be produced, a plurality of the hollow shapes 30 and 40 are arranged side by side, and a butt portion at the end portion thereof. Further, the side structure 2 is configured by arranging a plurality of stainless plates 10 and 20 and joining the butted portions at the ends thereof by friction stir welding.

Reference numeral 9 denotes a line indicating the location of the friction stir welding of the hollow shape members 30 and 40 and the stainless steel plates 10 and 20. In general, the joint line 9 crosses the window W in the lateral direction (horizontal direction). Line 9 is inside the car.

The butted portions of the stainless steel plates 10 and 20 are friction stir welded to the butted portions of the hollow shape members 30 and 40.

A window W and an entrance / exit 90 are provided on the side surface (side structure 2 side) of the vehicle body 1. The entrance / exit 90 has a frame 55 for reinforcing the entrance / exit. The frame 55 extends from the vehicle inner side to the vehicle outer side. The outer side of the frame 55 is friction stir welded to the hollow members 30 and 40 and the stainless plates 10 and 20.

The stainless steel plates 10 and 20 are attached only to the outer side of the side structure 2 of the vehicle body, and it is difficult to touch with the hand, and the roof structure 3 and the wife structure 5 that are difficult to see, and the underside of the underframe 4 on which these are placed. Not provided.

In general, the side structure 2 is connected to the roof structure 3, the end structure 5, and the underframe 4 by welding. However, in the above embodiment, the stainless plates 10 and 20 are provided on the outer surfaces of the hollow members 30 and 40 of the side structure 2. Yes, because the extruded structure made of aluminum alloy and the stainless steel plate are welded to the adjacent aluminum structure of the roof structure 3, the end structure 5, and the underframe 4, the welding is difficult, and the side structure 2 and the roof structure 3, The joint between the wife structure 5 and the underframe 4 is fastened by a rivet, bolt or hack bolt (Huckbolt trade name) fastener (not shown). Details will be described with reference to FIGS. 10, 11 and 12. FIG.

FIG. 2 is a longitudinal sectional view of the general part of the side structure 2. Since the aluminum alloy extruded hollow members 30, 40 are hollow members, the width of the hollow member is restricted by the ability of the press to extrude the aluminum alloy, and the side structure 2 has seven hollow members 30. , 40 are joined and arranged side by side. Since the stainless plates 10 and 20 are not limited in width, they can be configured by two plates.

Here, the aluminum alloy extruded hollow members 30, 40 are extruded hollow members made of an aluminum alloy.

Hereinafter, the aluminum alloy extruded hollow members 30 and 40 of the side structure 2 and the joining procedure between them and the stainless steel plates 10 and 20 will be described below.

In the side structure 2, seven extruded aluminum alloy hollow members 30, 40 are arranged in parallel along the longitudinal direction of the vehicle body 1, and are joined together by friction stir welding. Friction stir welding is performed using the hollow profile 30
, 40 end portions in the width direction are continuously friction stir welded. by this,
The hollow members 30, 40 also serve as the outer surface of the vehicle body and prevent water from entering. Further, the hollow members 30, 40
Is also a bone member.

In FIG. 3, the abutting portion of the hollow shape members 30 and 40 is shown, and the abutting portion is at the end portion in the width direction of the hollow shape members 30 and 40. On the vehicle exterior side of the hollow members 30 and 40, there are stainless plates 10 and 20 substantially parallel to the hollow members 30 and 40.
The end in the width direction is butted against the end in the width direction of the other stainless steel plate 20. This butt portion is friction stir welded to the butt portion of the hollow shape members 30 and 40.

In the friction stir welding, the rotary tool 200 for friction stir welding is inserted into the abutting portion of the hollow shape members 30 and 40 and the abutting portion of the stainless steel plates 10 and 20, and while rotating the rotary tool 200, the hollow shape material 30, 40 and the stainless steel plates 10 and 20 are moved. Alternatively, the hollow members 30, 40 and the stainless plates 10, 20 may be moved without moving the rotary tool 200. That is, the hollow shape members 30 and 40 and the stainless steel plates 10 and 20 may be moved relative to the rotary tool 200.

A procedure for joining the hollow members 30, 40 and the stainless plates 10, 20 will be described. First, the stainless steel plates 10 and 20 are placed on the gantry 100, and the ends of the both 10 and 20 are abutted. The hollow shape members 30 and 40 are overlapped on this from above, and the end portions in the width direction are butted together. Stainless steel plate 10,
The 20 butted portions and the butted portions of the hollow profile members 30 and 40 are substantially at the same position when viewed from above. That is, the butted portions of the hollow shape members 30 and 40 overlap the butted portions of the stainless steel plates 10 and 20.

The hollow shape members 30 and 40 are composed of face plates 31 and 41 on the inside of the vehicle, face plates 32 and 42 on the outside of the vehicle that are substantially parallel to the plate, and ribs 33 and 43 that connect the two in a truss shape. Hollow profile 30,
Forty vehicle-side face plates 32 and 42 have end portions in the width direction protruding beyond the end portions of face-plates 31 and 41 on the inside of the car. The upper side of FIG. 3 is the vehicle inner side, and the lower side is the vehicle outer side.

Next, friction stir welding is performed from above the abutting portion (on the side surfaces of the vehicle side plates 31, 41). There is a space in which a rotary tool 200 for friction stirring can be inserted between one vehicle interior side plate 31 and the other vehicle interior side plate 41 adjacent thereto. By this friction stir welding, the butted portions of the vehicle outer side plates 32 and 42 are friction stir welded. Moreover, the stainless steel plates 10 and 20 are friction stir welded at the butting portion.

In FIG. 4, the small diameter portion 201 at the tip of the rotary tool 200 for friction stir welding is inserted into the vehicle outer side plates 32 and 42 and penetrates the vehicle outer side plates 32 and 42. The tip is inserted into the abutting portion of the stainless steel plates 10 and 20 in terms of dimensions, but the insertion amount is very small (the insertion amount of the stainless steel plates 10 and 20 into the abutting portion is about 0.5 mm). Therefore, after joining, the thickness of the butted portion of the stainless steel plates 10 and 20 at the tip of the small-diameter portion 201 is slightly reduced, and it can be said that it is not inserted. This is referred to above as being dimensionally inserted.

Since the small-diameter portion 201 of the rotary tool is inserted into the outer side face plates 32 and 42 of the hollow shape members 30 and 40 and friction stir welding is performed, both are friction stir welded. Further, since the tip of the small diameter portion 201 is inserted up to the stainless steel plates 10 and 20, the stainless steel plates 10 and 20 are friction stir welded to the vehicle outer side plates 32 and 42. This is because the outer side plates 32 and 42 are made of stainless steel plate 10.
, 20 is considered to be joined by being strongly pressed.

The friction stir welding between the vehicle outer side plates 32 and 42 and the stainless steel plates 10 and 20 is a lap friction stir welding.

The friction stir welding of the stainless steel plates 10 and 20 to the vehicle outer side plates 32 and 42 is inserted into the vehicle outer side plates 32 and 42 while rotating the rotary tool 200, moved in the longitudinal direction of the friction stir welding, The amount of insertion of the rotary tool 200 is slightly raised (for example, about 1.0 mm) and moved about 50 mm in that state, and the friction stir welding during the movement of about 50 mm is performed only on the vehicle outer side plates 32 and 42. Is called. Friction stir welding to the stainless steel plates 10 and 20 is not limited. If it is about 50 mm, insert about 1.0 mm and move it. Thus, the friction stir welding of the stainless steel plates 10 and 20 and the vehicle outer side plates 32 and 42 is performed intermittently. This 1.0mm is stainless steel plate 10,
The size is such that insertion into 20 is eliminated.

In the state where the rotary tool 200 is raised, the small-diameter portion 201 of the rotary tool 200 performs friction stir welding of only the vehicle outer side plates 32 and 42. The friction stir welding with the stainless steel plates 10 and 20 does not matter.

The butted portions of the vehicle outer side plates 32, 42 have convex portions 32b, 42b that protrude toward the vehicle inner side at the respective end portions of the vehicle outer side plates. The combined width of the two convex portions 32b and 42b is the rotary tool 200.
It is larger than the diameter of the large diameter portion 202. The rising amount of the rotary tool 200 is such that the connecting portion (referred to as a boundary) between the large-diameter portion 202 of the rotary tool 200 and the small-diameter portion 201 on the tip side thereof is convex portions 32b and 42b.
It is the dimension which does not leave | separate from the upper end of. Since the aluminum alloy flows out from the upper ends of the convex portions 32b and 42b, the friction stir welding is different from the case where the aluminum alloy is not separated (when the vehicle side face plates 32 and 42 are friction stir welded). This is to make them the same.

For example, when the insertion amount of the small diameter portion 201 to the stainless steel plates 10 and 20 is 0.5 mm,
Intermittently raise 0.5 mm or more, then insert 0.5 mm or more.

  The plate thickness of the stainless steel plates 10 and 20 is about 1.0 mm.

According to this, the friction stir welding between the vehicle outer side plates 32 and 42 and the stainless steel plates 10 and 20 does not show the influence of the friction stir welding on the outer surface, and is a good-looking joint.

Since the joining of the vehicle outer side plates 32, 42 and the joining of the stainless steel plates 10, 20 are friction stir welding, the joining temperature is low and the distortion is small.

Next, in FIG. 3 and FIG. 4, the vehicle inner side plate 31 and the adjacent vehicle inner side plate 41 are bonded via a bonding material 51 at the inside of the vehicle where the friction stir welding is performed. As a result, the hollow profile 30,
40 becomes a hollow shape all along the width direction. The outer side plates 32 and 42 are inboard side plates 31,
It protrudes from the end of 41. The joining material 51 is overlapped on the vehicle side plates 31 and 41, and the portions (two places) overlapped from above are subjected to friction stir welding F from above. In order to provide the overlapping portion, the recesses are provided at the end portions of the vehicle interior side plates 31 and 41, but they may not be provided. Moreover, you may join by welding, without using friction stir welding. “F” means FIGS. 3, 4, 5, 6, 8, 9, 12,
Also shown in FIGS.

The friction stir welding F of the bonding material 51 can be performed continuously or intermittently along the longitudinal direction. Friction stir welding of the vehicle outer side plates 32, 42 is continuously performed, and the vehicle inner side plates 32,
The friction stir welding between 42 and the stainless steel plates 10 and 20 may be intermittent.

The “intermittent” will be described. Continuous friction stir welding is used for friction stir welding of the vehicle outer side plates 32, 42, and intermittent friction stirring welding is used for bonding of the vehicle outer side plates 32, 42 and the stainless steel plates 10, 20. This “intermittent” means excluding spot friction stir welding. With spot friction stir welding, a rotating tool is inserted while being rotated, and the rotating tool 200 is raised without moving, and the rotating tool 200 is removed from the materials 30 and 40 to be joined. The friction stir welding is performed by inserting the rotary tool 200 into the plates 32 and 42 to be joined and performing friction stir welding at the unjoined portion. This spot friction stir welding is considered as one of intermittent friction stir welding, but is excluded here.

That is, intermittent refers to friction stir welding in which friction stir welding is continuously performed and then unbonded is continuously performed. The abutting portions of the vehicle outer side plates 32 and 42 and the abutting portions of the stainless steel plates 10 and 20 are “continuously” friction stir welded. In the “missing” section, the rotary tool 200 is shown in FIGS. Raising and friction-stir welding only the butted portions of the vehicle outer side plates 32 and 42 is called “intermittent”.

When the rotary tool is raised for friction stir welding of the vehicle outer side plates 32, 42, the large diameter portion 202 of the rotary tool 200 and the small diameter portion 201 at the tip thereof are raised. When the rotary tool 200 is raised, the small-diameter portion 201 does not come into contact with the stainless steel plates 10 and 20, and the rotary tool 200 performs friction stir welding only on the vehicle outer side plates 32 and 42. Even if the rotary tool 200 is raised, the large diameter portion 202
Is located in the convex portions 32b and 42b, and is a boundary (contact portion) between the large diameter portion 202 and the small diameter portion 201.
Cannot escape upward from the upper ends of the convex portions 32b, 42b.

This is because the boundary between the large diameter portion 202 and the small diameter portion 201 is extracted from the upper ends of the convex portions 32b and 42b, and when the boundary is separated from the upper ends of the convex portions 32b and 42b, the aluminum alloy flows out from the portions,
Unlike the case where the boundary is located within the convex portions 32b and 42b, the friction stir welding where the boundary is located within the convex portion and the friction stir welding where the boundary is removed cannot be made the same.

The definition of “intermittent” is the same in the claims of this specification. However, FIG.
In this embodiment, there is one hollow shape member 40 (30) overlapping the stainless steel plate 10 (20), and there is no butt portion of the hollow shape members 30, 40.

The vehicle exterior side plates 32, 42 in the vicinity of the projections 32b, 42b are thin, and the upper ends of the projections 32b, 42b have the same thickness as the vehicle exterior surface plates 32, 42 below the vehicle interior side plates 31, 41. If the plate | board thickness of the vehicle exterior side surface plates 32 and 42 of the vicinity which should install a part is thick, the convex parts 32b and 42b can be made unnecessary.

However, if there are convex portions 32b and 42b, even if there is a gap in the butted portion, the gap is filled by the convex portion. Further, the vehicle outer side face plate 32 is formed by the lower end of the large diameter portion 202 of the rotary tool 200.
, 42 are cut off and the vehicle outer side plate is locally thinned. However, if the convex portions 32b and 42b are provided, the vehicle outer side plate is not thinned, so that there is no problem in strength.

FIG. 5 shows a case where a plurality of hollow shapes 30 and 40 are stacked on one stainless steel plate 10.
Friction stir welding of the butted portion 9b of the hollow shape members 30, 40 from the side of the vehicle side plate 31, 41,
Thereafter, the bonding material 51 is stacked and friction stir bonded to the vehicle interior side plates 31 and 41.

In FIG. 6, one sheet of hollow material 30 (40) overlaps one sheet of stainless steel plate 10 (20). A stainless steel plate 10 (20) has a convex portion 32c (42c) protruding inward of the vehicle at a desired position corresponding to the abutting portion of the hollow shape members 30, 40, and this is a friction stirrer on the stainless steel plate 10 (20). It is joined. That is, the width of the convex portion 32c (42c) is the same as the width of the two convex portions 32b and 42b of [Example 1]. The convex portion 32c (42c) is friction stir welded as described above. This friction stir welding is performed continuously or intermittently. The friction stir welding between the stainless steel plate 10 (20) and the hollow members 30, 40 is a lap friction stir welding.

There is no face plate 31 (41) inside the vehicle around the convex portion 32c (42c). This portion is a single profile portion of only the vehicle outer side face plate 32 (42). Both sides of the space around the convex portion 32c (42c) are hollow shape portions.

After the convex portion 32c (42c) is friction stir welded, the space around the convex portion 32c (42c) is covered with the bonding material 51, and the bonding material 51 is bonded to the vehicle interior side plates 31, 41 by friction stir welding or welding.

FIG. 6 is an enlarged view of a VI part in FIG. In the case where the size of the stainless steel plate 10 is large, the adhesion between the stainless steel plate and the hollow shape member is deteriorated.

The friction stir welding F location is not the convex portions 32b and 42b but one convex portion 32c (32c). After the friction stir welding F, the bonding material 51 is stacked and bonded. The width of the convex portion 42c (32c) is the same as the combined width of the two convex portions 32b and 42b.

In FIG. 2, when the side structure 2 has seven hollow shape members 30 and 40 friction-stir welded and the stainless plates 10 and 20 are composed of two pieces, the hollow shape members 30 and 40 and the stainless plate are combined. The number 9 of the friction stir welds 10 and 20 can be one. The width of one hollow member 30 (40) can be about 40 cm to about 50 cm.

In this way, the distance from the joining line 9 to the upper and lower ends of the side structure 2 is increased, and the adhesiveness between the hollow members 30 and 40 and the stainless plates 10 and 20 (the stainless plates 10 and 20 are the hollow members 30). , 40) and the appearance is also reduced.

Further, the curved portion of the V portion in FIG. 2 is also considered to have poor adhesion. For this problem, friction stir welding is performed as shown in FIG.

The friction stir welding of the stainless steel plate 10 (20) and the convex portions 32b, 42b, 32c (42c) is performed intermittently. When there are a plurality of friction stir welding lines 9, the “absent” region of the friction stir welding is such that there is a continuous friction stir welding region of a line perpendicular to the longitudinal direction. As a result, it can be said that it is continuously joined as a whole.

In each of the above-described embodiments, the hollow shape member has been described. However, a single shape member having only a face plate outside the vehicle may be used.

In each of the above embodiments, the end portions of the hollow shape members are butted and the butted portions are friction stir welded. However, the end portions may be overlapped and the overlapped portions may be friction stir welded. Moreover, you may provide a convex part in an overlap part. The convex portion may be on one face plate of the overlapping portion.

In the above-described embodiment, the butted portions of the stainless steel plates 10 and 20 are overlapped with the butted portions of the vehicle outer side surface plate. However, since the side structure 2 has a camber, the stainless plates 10 and 20 are butted according to the camber. Is considered difficult. The following examples consider this point. This will be described with reference to FIGS.

First, the camber will be described. In FIG. 7, it is a side view of the vehicle body 1 provided with a camber. The vehicle body 1 is about 20 mm taller due to the camber at the center in the longitudinal direction.
First, the hollow members 30 and 40 are joined with the camber provided. In order to provide the camber, the plurality of hollow members 30, 40 placed on the gantry 100 are pushed from the lateral direction perpendicular to the longitudinal direction to provide the camber, and then the butt portion is friction stir welded.

The plurality of hollow members 30 and 40 are arranged side by side with their extrusion direction (longitudinal direction) facing the longitudinal direction of the vehicle body. A camber can be installed by bending from a horizontal direction perpendicular to the direction of extrusion. Friction stir welding is performed along the camber with the camber installed. The camber is to prevent the center part of the vehicle body 1 from drooping by the occupant.

The stainless plates 10 and 20 are not provided with a camber. It is considered that it is desirable to cut the upper end of the uppermost stainless steel plate in the case of the vehicle body 1 so as to have the same arc as the camber. FIG. 7 illustrates the camber excessively.

In FIG. 8, the end portions of the stainless steel plates 10 and 20 overlap in the vertical direction. Since the camber is about 20 mm, the overlap margin is about 50 mm, which is more than the equivalent.
If it is 50 mm, the abutting portions of the vehicle body side plates 32, 42 can be friction stir welded along the camber, even if misalignment is taken into account. Although the friction stir welding is performed along the camber, since the stainless plates 10 and 20 are stacked, the friction stir welding along the camber can be performed even if the stainless plates 10 and 20 do not have a camber.

When the abutting portions of the vehicle outer side plates 32 and 42 and the overlapped portions of the stainless steel plates 10 and 20 are friction stir welded, a joining material is stacked on the vehicle inner side plates 31 and 41 and joined by friction stir welding or welding.

FIG. 9 is an enlarged cross-sectional view of the friction stir welded portion between the hollow shape members 30 and 40 and the stainless steel plates 10 and 20. The rotary tool 200 for friction stir welding passes through the upper stainless steel plate 20 and is slightly inserted into the lower stainless steel plate 10. For example, this insertion amount is about 0.5 mm.
However, this state is an imaginary state before friction stir welding. After joining, the stainless steel plate 10 at the tip of the small diameter portion 201 is in a state where the thickness is slightly reduced, and it can be said that the stainless steel plate 10 is not inserted into the stainless steel plate 10. Therefore, the influence of the friction stir welding does not appear on the vehicle outer side of the stainless steel plate 10, and the joining portion has a good appearance.

The upper stainless steel plate 20 is overlapped and joined to the vehicle outer side plates 32 and 42 by friction stir welding. The lower stainless plate 10 is overlapped and joined to the upper stainless plate 20 by friction stir welding.

Thus, the amount of insertion of the rotary tool 200 into the stainless steel plate 10 is very small (0.5 mm), and the thickness of the insertion location of the rotary tool 200 into the stainless steel plate 10 is slightly reduced and inserted. It can be said that it is not.

The friction stir welding of the stainless steel plates 10 and 20 to the vehicle outer side surface plates 32 and 42 is performed by intermittently raising the insertion amount of the rotary tool as in the above embodiment.

Next, the connection between the side structure 2 of the rail vehicle formed in this way, the roof structure 3, and the underframe 4 will be described with reference to FIGS. FIG. 11 shows the side structure 2 between FIG. 10 and FIG. This joining is usually performed by welding or friction stir welding, but this joining is considered difficult because there is an aluminum alloy and a stainless steel plate. Here, rivets, bolts and nuts or hacks are used. A bolt (Huckbolt product name) fastener 61 is used.

The coupling | bonding of the side structure 2 and the roof structure 3 of FIG. 10 is shown. The stainless steel plate 10 on the outer surface of the side structure 2 is folded back at the upper end of the side structure 2, and is screwed to the vertical surface on the inner side of the hollow shape member 40 from the lateral direction (the center side in the width direction of the vehicle body 1). It is concluded. Further, the hollow shape member 40 at the upper end of the side structure 2 has a projecting piece 46 protruding toward the roof structure 3, and the end of the roof structure 3 in the width direction is a projecting piece of the hollow shape material 54. 47 overlaps from above. Side structure 2 fixed to underframe 4
On the other hand, if the roof structure 3 is lowered from above, it can be overlapped. The overlapping portion is fastened with a fastener 61 from above. The fastener 61 is a hack bolt (trade name). The hack bolt 61 can also be fastened only from the insertion side. An adhesive is applied to the contact portion between the side structure 2 and the roof structure 3.

The nearby roof structure 3 with the fasteners 61 is recessed. The recess 32 is water-cracked.
The central part in the width direction of the vehicle is above. There is a connecting pipe (not shown) that guides the water of the raft 32 downward at the longitudinal end of the vehicle. The connecting pipe opens on the lower surface of the flange 32. The wife structure 5 covers the roof structure 3 and the eaves 32. The central portion of the roof structure 3 in the width direction protrudes upward.

The upper end of the fastener 61 is substantially flush with the upper surface of the protruding piece 57 of the hollow profile 54. The lower end is substantially flush with the lower surface of the projecting piece 46 of the hollow profile 40.

FIG. 12 shows the coupling between the side structure 2 and the underframe 4. It is called a hollow shape member 35 below the side structure 2, and the plate shape of the hollow shape member 35 is thick and strong. The lower end of the stainless steel plate 20 is folded back to the lower side of the vehicle interior (the vehicle interior in this case means the central portion side in the width direction of the vehicle body 1 and does not have to be in the vehicle). The shape 45 is fixed to the vertical surface of the vehicle inner surface with screws 63.

The hollow member 35 has a protrusion 46 that protrudes toward the hollow member 45 of the frame 4, and this protrusion 46 overlaps the upper surface of the hollow member 45 of the frame 4. The overlapping portion is fastened with a fastener 64 from above.

Further, there are a vertical surface of the hollow frame 35 on the side of the frame 4 and a protruding piece 47 protruding downward from the hollow frame 45 of the frame 4, and the protruding piece 47 is formed on the vertical surface of the hollow frame 35 on the inside of the vehicle. Fastened with a fastener 65 from the lateral direction. The hole on the vertical surface into which the fastener 65 is inserted is opened at a required position in consideration of the camber. A spacer is disposed between the projecting piece 46 and the hollow shape member 45.

  The fasteners 64 and 65 are the same as the fastener 61.

In the above-described embodiment, the protruding piece 56 is provided integrally with the hollow shape member 35 of the side structure 2, but a protruding piece is provided from the hollow shape 45 along the vertical surface on the inner surface side of the hollow shape member of the side structure 2. Also good. According to this, a spacer can be made unnecessary.

The upper end of the fastener 64 fastened from above is lower than the upper surface of the floor board 68 of the cabin and does not protrude upward. A floor plate 68 is covered above the fastener 64.

The stainless steel plates 10 and 20 are bent so as to surround the hollow members 40 and 35 at the upper and lower ends of the side structure 2. You may bend | fold before joining to the hollow shape members 40 and 35. FIG. Between the upper and lower ends of the hollow shape members 40 and 35 and the upper and lower ends of the stainless steel plates 10 and 20, there are gaps of about 50 mm corresponding to the camber amount.

The gap between the upper end of the hollow shape member 40 at the upper end of the side structure 2 and the upper end of the stainless steel plate 10 is small. As the occupant rides and the camber of the vehicle body 1 is reduced, the gap is increased. For this reason,
There may be no gap at the upper end.

The gap between the lower end of the hollow shape member 35 at the lower end of the side structure 2 and the lower end of the stainless steel plate 20 is large. As the occupant gets on and the camber of the vehicle body becomes smaller, the gap becomes smaller.

For this reason, the stainless plates 10 and 20 have long holes (not shown) that allow the screws 62 and 63 to move.

Since the stainless steel plates 10 and 20 are fixed to the hollow shape members 55 and 45 with screws 62 and 63,
Both will not leave.

The gap between the stainless steel plates 10 and 20 and the upper and lower ends of the hollow profiles 55 and 45 is arranged by placing the stainless plates 10 and 20 in which the stainless steel plate is folded in advance and friction stir welding to the hollow profiles 30 and 40. Good. Alternatively, after the friction stir welding, the upper and lower end portions of the stainless plates 10 and 20 are pressed by a roller and bent. Thereafter, it is fixed with screws 62 and 63.

Fastening by the fastener 63 from above the hollow member 35 of the side structure 2 and the hollow member 45 of the frame 4 is performed by inserting the fastener 64 into the hollow part 45b of the hollow member 45 of the frame 4. Therefore, there is no need to provide a space for fastening.

As described above, before the fastening of the frame 4, the side structure 2, and the roof structure 3 by the fasteners 61, 63, the floor covering, the seat, the toilet, the electric wires under the floor, and the air piping on the upper surface of the frame 4 are provided. Installed. Further, the side structure 2 is provided with a heat insulating material 66 and an interior material 67. Further, on the ceiling surface of the roof structure 3, an illuminator, a load shelf, an air conditioning duct, a heat insulating material 66, and an interior board 67 are installed. Further, a control device (not shown) is installed in the wife structure 5. After installing the outfit in this way, the underframe 4, the side structure 2, the roof structure 3, and the wife structure 5 are fixed to form the vehicle body 1.

The side structure 2 and the roof structure 3 can be fastened to the side structure 2 and the roof structure 3 on the side surface of the vehicle body 1 instead of the location of FIG. 10. The tool becomes visible, its covering is required and expensive. In this embodiment, it can be fastened.

Similarly, the side structure 2 and the frame 4 may be fastened to the side surface of the side structure 2 above the frame 4. However, in the present embodiment, since it is fastened and fastened to the underframe 4 from above, it can be fastened at a lower cost than the side face.

There is a heat insulating material 66 inside the side structure 2 and the roof structure 3. Insulation 66 is 30, 40,
54 or the interior board 67 with an adhesive or the like. The interior plate 67 is fixed to rails 57 and 58 installed on the hollow members 30, 40 and 54 of the side structure 2 or the roof structure 3. Rail 57
, 58 are extruded integrally with the hollow members 30 and 40 of the side structure 2 along the longitudinal direction of the vehicle body, and a concave portion (hereinafter referred to as a groove) is formed on the inner end surface of the vehicle. The end of the interior plate 67 is bent and inserted into the groove. If there is a space between the two interior plates 67, 67 inserted into the groove, the interior plate 67 will come out, so a press-fitting material 67b is inserted between the two interior plates 67, 67 and fixed. . The press-fitting material 67b is, for example, a rubber material, but may be anything.

  According to this, a screw (screw) is not required as a fixing means for the interior plate, and the cost can be reduced.

The end portions of the two interior plates 67 are in one groove, but when there is only one interior plate 67 as in the lower part of the window W, the end portions of the one interior plate 67 enter, and the press-fitting material 67 b is press-fitted between the interior plate 67 and the rails 57 and 58.

In addition, the “circumferential direction” in the claims (claim 84) is the circumferential direction of the vehicle body 1. If only the side structure is considered, it is the vertical direction, but if the roof structure is put in this, it cannot be said that it is vertical, but it is called the circumferential direction.

In FIG. 13, the abutting portions of the vehicle outer side plates 32 and 42 are recessed about the plate thickness (1 mm) of the stainless steel plate 20 on the vehicle inner side. The width of the dent (the width in the horizontal direction in FIG. 13) is wider than the overlap margin of the stainless steel plates 10 and 20.

Moreover, in FIG. 13, when the stainless steel plates 10 and 20 are lap-joined, in order to reduce the weight of the aluminum alloy extruded shape members 30 and 40, portions other than the vicinity of the joint portion are also recessed.

In FIG. 14, the outer side plates 32 and 42 and the stainless plate 10 other than the friction stir welded portion,
Insulating material 80 is arranged between the two. The hollow members 30 and 40 having the heat insulating material 80 are placed on the stainless steel plates 10 and 20, and friction stir welding is performed. By this friction stir welding, the hollow shape members 30, 40 and the stainless steel plates 10, 20 are also joined. Any heat insulating material 80 may be used, but it is desirable that the vacuum heat insulating material can be made thin in order to make it thin. The heat insulating material 80 is bonded to the hollow shape members 30 and 40 in advance with an adhesive. Since the temperature rising by the friction stir welding is lower than the temperature rising by welding, the influence on the heat insulating material 80 is small.

Moreover, the heat insulating material 80 is not provided between the vehicle outer side plates 32, 42 and the stainless steel plates 10, 20,
It is good also as only an air layer.

Next, the joining with the frame of the doorway 90 will be described with reference to FIG. The frame 70 is formed by bending an extruded hollow shape member for a frame into a U-shape and welding a U-shaped lower end to the base frame 4.

The frame 70 is abutted against the vehicle outer side plates 32, 42 of the hollow members 30, 40, and the vehicle outer side plate 32,
The abutting portion with 42 is friction stir welded, and then the vehicle interior side plates 31 and 42 and the vehicle inner side of the frame 70 are welded or friction stir welded.

Further, the protruding piece 79 on the doorway 90 side of the frame 70, the hollow shape member 30 (40), and the stainless steel plate 10.
(20) and friction stir welding from above. This friction stir welding is performed intermittently or continuously. Since the protrusion 79 has a thin plate thickness, it can be easily friction stir welded.

In this way, after various devices (fittings) are installed on the side structure 2, the roof structure 3, the frame 4, and the wife structure 5, the side structure 3, the roof structure 3, and the wife structure 5 are installed on the frame 4. .

In the above-described embodiment, the stainless plates 10 and 20 are installed on the vehicle outer surfaces of the hollow members 30 and 40 of the side structure 2.
Can be configured. The main purpose of this is to construct the car body after installing the fittings.

FIG. 16 shows bonding around the opening of the window W. The end portion on the window W side of the vehicle exterior side plate 32 (42) of the hollow profile 30 (40) and the stainless steel plate 10 (20) are friction stir welded.

In the embodiment of FIG. 2, the side structure is configured by friction stir welding the stainless plates 10, 20 to the plurality of hollow shapes 30, 40. The stainless plates 10 and 20 in parallel with the hollow members 30 and 40 swell with respect to the hollow members 30 and 40. This is considered to be caused by the fact that the shrinkage amount at the two friction stir welding locations of the hollow shape members 30 and 40 is larger than the shrinkage amount of the stainless steel plate due to heating by friction stir welding.

In order to prevent this, friction stir welding is performed in a state where the stainless plates 10 and 20 are heated to a high temperature (for example, 100 ° C.) and the stainless plates 10 and 20 are extended. Heated stand 100
The stainless steel plates 10 and 20 placed on the surface may be heated to heat the entire surface, or the heated stainless steel plates 10 and 20 may be placed on the gantry 100. The heating temperature is preferably about 150 ° C. in consideration of room temperature. The temperature of the stainless steel plates 10 and 20 is related to the heat yield and the distance between the two friction stir welds.

This heating is performed by installing a heater on the gantry 100 and heating the entire surface of the stainless steel panels 10 and 20.
Or only the main part is heated.

According to this, since friction stir welding is performed in a state where the stainless steel plates 10 and 20 are at a high temperature, the shrinkage of the hollow shape members 30 and 40 can be absorbed if cooled to room temperature.

Further, the bulge can be absorbed also when the longitudinal ends of the hollow shape members 30 and 40 are friction stir welded.

Further, the entire surface of the hollow shape members 30 and 40 or the friction stir welding portion is cooled, and the shrunk stainless steel plates 10 and 20 are friction stir welded to prevent a temperature rise due to the friction stir welding. Friction stir welding is performed on both ends of the hollow members 30 and 40 in the width direction.

Instead of heating the stainless steel plates 10 and 20, the hollow shape members 30 and 40 may be heated (or cooled) for friction stir welding. For cooling, water or a refrigerant is used. Water and refrigerant flow around the friction stir weld. Alternatively, air is passed through the friction stir weld. The cooling may be performed by cooling the entire hollow members 30 and 40 from the side on which the rotary tool is inserted, or by flowing cooling water, refrigerant, and air into the space from the opposite side of the surface on which the rotary tool 200 is inserted.

Instead of heating the stainless steel plate and cooling the hollow profile, it can be carried out as follows. The stainless steel plates 10 and 20 having convex beads protruding to the outside of the vehicle along the longitudinal direction of the hollow profile are friction stir welded between both ends of the stainless steel plates 10 and 20 in the width direction. In addition, when the stainless steel plates 10 and 20 are stacked on the gantry 100, it is not necessary to regulate the position of the bead.

The bead protrudes in an arc shape. The beads protruding in an arc shape and the stainless plates 10 and 20 are connected in an arc shape. This arc is at the connection between the flat stainless steel plate and the convex arc.

According to this, although the stainless steel plate does not shrink, the bulge of the stainless steel plate is collected in the bead portion by the bead, and visual observation of the bulge is suppressed.

Although the above embodiment has been described for a vehicle body, joining a stainless steel plate to an extruded shape made of aluminum alloy is also desired for other applications. The present invention can also be used in that case. For example, a kitchen wall member or a kitchen counter of a kitchen.

The perspective view seen from the outside of the vehicle body of one example of the present invention. Sectional drawing of II-II of FIG. III-III sectional drawing of FIG. The enlarged view of the III section of FIG. The IV section enlarged view of FIG. The enlarged view of the V section of FIG. The VI section enlarged view of FIG. The side view of the vehicle body which shows the friction stir welding location of the hollow shape material and stainless steel plate of one Example of this invention. FIG. 3 is a view corresponding to FIG. 3 of another embodiment of the present invention. FIG. 4 is an enlarged longitudinal sectional view of the friction stir welding portion between the hollow shape member and the stainless steel plate of FIG. 8 (corresponding to FIG. 4 and FIG. 8). The expanded longitudinal cross-sectional view of the junction part of the side structure and roof structure of the upper end part of FIG. It is a longitudinal cross-sectional view of the principal part of the side structure of FIG. 2, and it connects with FIG. 10 and FIG. The expanded longitudinal cross-sectional view of the junction part of the side structure and base frame of the lower end part of FIG. FIG. 8 is a view corresponding to FIG. 8 of another embodiment of the present invention. FIG. 8 is a view corresponding to FIG. 8 of another embodiment of the present invention. IV-IV longitudinal cross-sectional view of FIG. The IVI-IVI longitudinal cross-sectional view of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Vehicle body, 2 ... Side structure, 3 ... Roof structure, 4 ... Underframe, 5 ... Wife structure, 10, 20 ... Stainless steel plate, 30, 35, 40, 45 ... Extruded hollow shape made of aluminum alloy, 31, 41 ... Vehicle side plate, 32, 42 ... Vehicle side plate, 32b, 42b, 32c, 42c ... Projection, 46, 47
57 ... Projection piece, 51 ... Bonding material, 61, 64 ... Fastener, 62, 63 ... Screw, 66, 80 ... Insulation material, 67 ... Interior plate, 67b ... Press-fitting material, 68 ... Floor plate, 90 ... Doorway, 100 ... mount,
200 ... Rotary tool for friction stir welding, 201 ... small diameter portion, 202 ... large diameter portion.

Claims (4)

The stainless steel plate is overlaid with the first aluminum alloy extruded shape and the second aluminum alloy extruded shape,
Friction stir welding of the butted portion of the first aluminum alloy extruded shape and the second aluminum alloy extruded shape or the overlapped portion to the stainless steel plate,
A method of manufacturing a structure characterized by the above. In the manufacturing method of the structure of Claim 1,
The friction stir welding of the butted portion or the overlapped portion and the stainless steel plate is intermittently performed in the longitudinal direction of the friction stir welding,
A method of manufacturing a structure characterized by the above. The stainless steel plate is overlaid with the first aluminum alloy extruded shape and the second aluminum alloy extruded shape,
The first aluminum alloy extruded shape and the second aluminum alloy extruded shape are in contact with each other, or the overlapped portion is friction stir joined to the stainless steel plate;
A structure characterized by The structure according to claim 3.
The friction stir welding of the butted portion or the overlapped portion and the stainless steel plate is intermittently performed in the longitudinal direction of the friction stir welding,
A structure characterized by

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