JP2013184205A - Resistance welding method for cylindrical member made of plated steel sheet - Google Patents
Resistance welding method for cylindrical member made of plated steel sheet Download PDFInfo
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- JP2013184205A JP2013184205A JP2012052403A JP2012052403A JP2013184205A JP 2013184205 A JP2013184205 A JP 2013184205A JP 2012052403 A JP2012052403 A JP 2012052403A JP 2012052403 A JP2012052403 A JP 2012052403A JP 2013184205 A JP2013184205 A JP 2013184205A
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- 229910001335 Galvanized steel Inorganic materials 0.000 description 3
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- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
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- HXFVOUUOTHJFPX-UHFFFAOYSA-N alumane;zinc Chemical compound [AlH3].[Zn] HXFVOUUOTHJFPX-UHFFFAOYSA-N 0.000 description 2
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- 239000010953 base metal Substances 0.000 description 1
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- WUUZKBJEUBFVMV-UHFFFAOYSA-N copper molybdenum Chemical compound [Cu].[Mo] WUUZKBJEUBFVMV-UHFFFAOYSA-N 0.000 description 1
- SBYXRAKIOMOBFF-UHFFFAOYSA-N copper tungsten Chemical compound [Cu].[W] SBYXRAKIOMOBFF-UHFFFAOYSA-N 0.000 description 1
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Abstract
Description
本発明は、めっき鋼板を素材とした円筒状部材を抵抗溶接する際に、抵抗溶接電極の損耗を抑制するとともに優れた接合強度と内表面形状の変形を抑制した抵抗溶接方法に関する。 TECHNICAL FIELD The present invention relates to a resistance welding method that suppresses wear of a resistance welding electrode and suppresses excellent bonding strength and deformation of an inner surface shape when resistance-welding a cylindrical member made of a plated steel plate.
近年、金属部材を接合する方法として、被接合金属部材を一対の電極で部材をはさみ、加圧しながら通電を行ってジュール熱で当該部材を加熱溶融させて接合する抵抗溶接法が一般的に用いられている。（例えば特許文献１参照）
一方、金属部材には耐食性を向上させるためめっき等の表面処理を施す場合が多いが、めっき鋼板を抵抗溶接する場合、電極材質である銅合金とめっき金属に含まれる亜鉛、アルミニウム等が溶接の熱で反応して電極先端に硬質で脆弱な合金層を形成し、これが打点の衝撃により脱落して電極が損耗していくことが知られている。
In recent years, as a method for joining metal members, a resistance welding method is generally used in which a metal member to be joined is sandwiched between a pair of electrodes, energized while being pressurized, and the member is heated and melted with Joule heat to join the members. It has been. (For example, see Patent Document 1)
On the other hand, surface treatment such as plating is often applied to metal members in order to improve corrosion resistance. However, when resistance-welding a plated steel sheet, copper alloy, which is an electrode material, and zinc, aluminum, etc. contained in the plated metal are welded. It is known that a hard and fragile alloy layer is formed at the tip of the electrode by reacting with heat, and this is dropped by impact of the hitting point and the electrode is worn out.
電極が損耗し、先端径が拡大していくと溶接時の電流密度の低下を招き、その結果として溶接強度が低下する。このため、めっき鋼板を連続的に抵抗溶接する際には定期的に電極の研磨、交換が必要である。交換までの打点数は電極寿命と呼ばれるが、電極寿命はめっき種や付着量により異なり、一般的な亜鉛めっき鋼板より耐食性が高いため適用が拡大しているアルミニウムを含有する亜鉛‐アルミニウム合金めっき鋼板やアルミニウムとマグネシウムを含有する亜鉛−アルミニウム−マグネシウム合金めっき鋼板や耐食性・耐熱性に優れるアルミニウムめっき鋼板では電極寿命の低下が著しいという問題がある。
また、電極とめっき層の反応は製品の外観上の問題も引き起こす。電極の合金化、合金層の剥離や脱落により電極先端に不規則な凹凸が生じ、この形状が部材に転写されて溶接後の表面品質を低下させる。これらの問題により部材へのめっき鋼板、特にアルミニウムを含有するめっき鋼板の適用ができないケースがある。
When the electrode is worn and the tip diameter is enlarged, the current density during welding is lowered, and as a result, the welding strength is lowered. For this reason, it is necessary to periodically polish and replace the electrode when continuously welding the plated steel sheet. The number of hit points until replacement is called the electrode life, but the electrode life varies depending on the plating type and the amount of adhesion, and the zinc-aluminum alloy-plated steel sheet containing aluminum, which has expanded its application due to its higher corrosion resistance than ordinary galvanized steel sheets In addition, zinc-aluminum-magnesium alloy-plated steel sheets containing aluminum and magnesium and aluminum-plated steel sheets excellent in corrosion resistance and heat resistance have a problem that the electrode life is significantly reduced.
In addition, the reaction between the electrode and the plating layer also causes problems in the appearance of the product. Irregular unevenness is generated at the electrode tip due to alloying of the electrode, peeling or dropping of the alloy layer, and this shape is transferred to the member, which deteriorates the surface quality after welding. Due to these problems, there are cases where a plated steel sheet, particularly a plated steel sheet containing aluminum cannot be applied to the member.
ところで、溶接を行う部品には円筒状の部材にブラケットを取り付ける場合がある。このような場合、例えば図１に示すように円筒状部材の内部に電極を挿入し、この電極と外部から押し当てる電極の間に通電するスポット溶接や、図２に示すように部材に突起を設けて電流を集中させるプロジェクション溶接で取り付けることが一般的である。
しかしながら、このような抵抗溶接により接合しようとすると、スペースの問題から内部電極を十分に冷却することができないために、接合部位の温度が高くなる。このため、被接合部材としてめっき鋼材を用いた場合、電極とめっき層の合金化が著しくなる傾向がある。その結果、電極の損耗が激しくなるばかりでなく円筒部材の内表面に凹凸が発生し易くなる。
By the way, there is a case where a bracket is attached to a cylindrical member for a part to be welded. In such a case, for example, an electrode is inserted into the cylindrical member as shown in FIG. 1, and spot welding is performed between the electrode and the electrode pressed from the outside, or a protrusion is formed on the member as shown in FIG. It is common to install by projection welding to provide and concentrate the current.
However, when joining by such resistance welding, the internal electrode cannot be sufficiently cooled due to the space problem, and the temperature of the joining portion becomes high. For this reason, when a plated steel material is used as the member to be joined, alloying of the electrode and the plating layer tends to be remarkable. As a result, the wear of the electrode is not only severe, but irregularities are easily generated on the inner surface of the cylindrical member.
円筒状の部材は内部に部品を挿入して使われる場合が多いため、その内表面での凹凸発生が著しいと部品が挿入できず、製品化できなくなる。また、電極を頻繁に研磨、交換することは、電極に関する費用の増大、電極研磨・交換にかかわる生産性の低下を招くことになる。
電極への合金化を抑制する手段としては、前記図２に示すようにブラケットに突起を設け、電流を突起部分に集中させて短時間で接合するプロジェクション溶接が有効である。この場合、図１に示すスポット溶接に比べ電極と鋼板の間の温度上昇を抑制することができることからスポット溶接に比べて電極の損耗は少なく、電極交換頻度を少なくすることはできるものの、円筒部材内面の表面品質低下を大幅に改善することはできない。
Since a cylindrical member is often used with a part inserted therein, if the unevenness on the inner surface is significant, the part cannot be inserted and cannot be commercialized. In addition, frequent polishing and replacement of electrodes leads to an increase in costs related to the electrodes and a decrease in productivity related to electrode polishing and replacement.
As a means for suppressing alloying to the electrodes, projection welding is effective in which protrusions are provided on the bracket as shown in FIG. 2 and current is concentrated on the protrusions to join them in a short time. In this case, since the temperature rise between the electrode and the steel plate can be suppressed compared to the spot welding shown in FIG. 1, the electrode wear is less than the spot welding and the electrode replacement frequency can be reduced. The deterioration of the surface quality of the inner surface cannot be significantly improved.
本発明は、このような問題点を解消するために案出されたものであり、めっき鋼板を素材とした円筒状部材に他の部材を抵抗溶接法で接合する際に、抵抗溶接電極の損耗を抑制するとともに優れた接合強度と内表面形状の変形を抑制した抵抗溶接方法を提供することを目的とする。 The present invention has been devised to solve such problems, and wear of resistance welding electrodes when joining other members to a cylindrical member made of a plated steel plate by resistance welding. It is an object of the present invention to provide a resistance welding method that suppresses deformation and suppresses excellent bonding strength and deformation of the inner surface shape.
本発明のめっき鋼板製円筒状部材の抵抗溶接方法は、その目的を達成するため、めっき鋼板を素材とした円筒状部材に他の部材を抵抗溶接する際に、一対の電極の内の一方の電極を前記他の部材の接合面とは反対側の表面に、また他方の電極を前記円筒状部材の外表面に当接させ、かつ前記円筒状部材の内部に前記円筒状部材よりも電気抵抗の大きな材質からなる円柱形の溶接治具を挿入した状態で前記一対の電極間に通電することを特徴とする。
この際、溶接治具の材質は導電性が無いことおよび高温強度が高いことが求められることからセラミックスが好ましい。
また、円筒状部材の内部に挿入する前記溶接治具は円筒状部材の内径の80〜97％の外径とするものとすることが好ましい。
さらに、他の部材に突起部を設けたプロジェクション溶接法を採用することが好ましい。
In order to achieve the object of the resistance welding method for a cylindrical member made of a plated steel sheet according to the present invention, when another member is resistance welded to a cylindrical member made of a plated steel sheet, one of a pair of electrodes is used. The electrode is brought into contact with the surface opposite to the joining surface of the other member, the other electrode is brought into contact with the outer surface of the cylindrical member, and the electric resistance in the cylindrical member is higher than that of the cylindrical member. A current is passed between the pair of electrodes in a state where a cylindrical welding jig made of a large material is inserted.
At this time, the material of the welding jig is preferably ceramics because it is required to have no electrical conductivity and to have high temperature strength.
Moreover, it is preferable that the said welding jig inserted in the inside of a cylindrical member shall be 80 to 97% of an internal diameter of a cylindrical member.
Furthermore, it is preferable to employ a projection welding method in which protrusions are provided on other members.
本発明方法により、めっき鋼板を素材とした円筒状部材に他の部材を抵抗溶接法で接合する際であっても、抵抗溶接電極の損耗を抑制することができるばかりでなく、優れた接合強度を得ることができ、さらにめっき鋼板を素材とした円筒状部材の内表面形状の変形を抑制することが可能なため、例えばめっき鋼板を素材とした円筒状部材にブラケットを溶接接合した部材を、高精度かつ低コストで効率よく製造することが可能となる。 According to the method of the present invention, even when other members are joined to a cylindrical member made of a plated steel plate by resistance welding, not only can the wear of the resistance welding electrode be suppressed, but also excellent joint strength can be achieved. In addition, since it is possible to suppress deformation of the inner surface shape of the cylindrical member made of a plated steel plate, for example, a member obtained by welding a bracket to a cylindrical member made of a plated steel plate, It becomes possible to manufacture efficiently with high accuracy and low cost.
めっき鋼板を素材とした円筒状部材に他の部材を抵抗溶接法で接合する際に、円筒状部材で特に重要な内面めっき層の品質の劣化は内部に通電のための電極を設けていることによるものと鑑み、通電のための一対の電極を円筒部材の外部に設けることを検討した。
そして、例えば図３ａに示すように、円筒状部材の内部に挿入していた電極を円筒状部材外部に移し、円筒部材の外側から通電することにした。一対の電極を円筒部材の外部に設けると、通電経路は上電極からブラケットを経て円筒部材に流れ、下電極に流れる。この場合、上電極直下の円筒部材内部表面に流れる電流は少ないため、通電及び電極との合金化によるめっき層のダメージは大幅に改善されることになる。
ここで、図３ａでは一方の電極（上電極）をブラケットの外側表面に、他方の電極（下電極）を円筒状部材のブラケットを配置した部位とは反対側の外側表面に当接させているが、他方の電極の当接部位はこれに限定されるものではなく、円筒状部材の外表面であればどこでもよい。例えば、図３ｂ、ｃに示すように、他方の電極を円筒状部材側面の外表面や、一方の電極と同じ面の外表面であっても、本発明の効果を得ることができる。
なお、抵抗溶接する際、めっき層のダメージを極力抑制するために、部材に突起を設けるプロジェクション溶接を採用することが好ましい。
When joining other members to a cylindrical member made of galvanized steel by resistance welding, the deterioration of the quality of the inner plating layer, which is particularly important for cylindrical members, must be equipped with electrodes for energization. In view of the above, it has been considered to provide a pair of electrodes for energization outside the cylindrical member.
Then, for example, as shown in FIG. 3 a, the electrode inserted inside the cylindrical member is moved to the outside of the cylindrical member and energized from the outside of the cylindrical member. When the pair of electrodes are provided outside the cylindrical member, the energization path flows from the upper electrode through the bracket to the cylindrical member and then flows to the lower electrode. In this case, since the current flowing through the inner surface of the cylindrical member directly below the upper electrode is small, damage to the plating layer due to energization and alloying with the electrode is greatly improved.
Here, in FIG. 3a, one electrode (upper electrode) is brought into contact with the outer surface of the bracket, and the other electrode (lower electrode) is brought into contact with the outer surface opposite to the portion where the bracket of the cylindrical member is arranged. However, the contact portion of the other electrode is not limited to this, and may be anywhere as long as it is the outer surface of the cylindrical member. For example, as shown in FIGS. 3b and 3c, the effect of the present invention can be obtained even if the other electrode is the outer surface of the cylindrical member side surface or the outer surface of the same surface as the one electrode.
In addition, when performing resistance welding, in order to suppress damage to the plating layer as much as possible, it is preferable to employ projection welding in which protrusions are provided on the member.
しかしながら中空の円筒状部材を一対の電極で加圧しながら加熱する態様となるため、円筒部材が変形してしまう欠点がある。そこで、変形を防止するため内部に円柱形の溶接治具を挿入することとした。
溶接治具の材質としては溶接時の電極加圧に耐えられる強度は必要であり、特に鋼が溶融するほどの高熱が発生するため高温強度の高い材質が望ましい。また、円筒部材に電流を集中させるため治具には電流が流れ難くすることが必要である。これらの要求を両立させる材質としては強度、耐熱性に優れ、絶縁体であるセラミックスが最適である。
また、セラミックスは熱膨張係数が５×１０−６程度と低いため、溶接の発熱によって熱膨張し溶接治具が抜き取りにくくなることもない。
However, since a hollow cylindrical member is heated while being pressed with a pair of electrodes, there is a drawback that the cylindrical member is deformed. Therefore, in order to prevent deformation, a cylindrical welding jig was inserted inside.
The material of the welding jig needs to be strong enough to withstand the pressure of the electrode during welding. In particular, a material with high high-temperature strength is desirable because high heat is generated to melt the steel. Moreover, in order to concentrate an electric current on a cylindrical member, it is necessary to make an electric current difficult to flow through a jig | tool. As a material that satisfies both of these requirements, ceramic that is excellent in strength and heat resistance and is an insulator is optimal.
In addition, since ceramic has a low thermal expansion coefficient of about 5 × 10 −6, it does not become difficult to remove the welding jig due to thermal expansion due to heat generated by welding.
治具全体をセラミックスで製造することも可能であるが、図４に示すように外表面にコーティングする（図４ａ）、圧入等によりはめ込むような形態（図４ｂ）も可能であり、図４ｃに示すように金属製の治具を２分割しその間にセラミックスを挟み込む形式でも有効である。
セラミックス以外の材質であっても、鉄よりも電気抵抗の大きな材質であれば治具への電流の分流が抑制され、効率よく溶接することが可能である。
It is possible to manufacture the entire jig with ceramics, but it is possible to coat the outer surface as shown in FIG. 4 (FIG. 4a), or to fit by press-fitting or the like (FIG. 4b). As shown, it is also effective to divide a metal jig into two parts and sandwich ceramics between them.
Even if it is a material other than ceramics, if the material has a larger electrical resistance than iron, the shunting of the current to the jig is suppressed, and efficient welding can be achieved.
なお、この溶接治具は円筒部材の内径の80〜97％の外径とすることで安定した溶接と円筒部材の変形抑制を両立することが可能である。外径が大きすぎると挿入が困難であったり、溶接後に取り外せない問題が生じる。また、小さすぎると、図５ｃに見られるように治具の挿入効果がなくなり円筒部材の変形が残ってしまう。両者を勘案したときの溶接治具の最適な外径は、円筒部材の内径の前記した80〜97％である。 This welding jig can achieve both stable welding and suppression of deformation of the cylindrical member by setting the outer diameter to 80 to 97% of the inner diameter of the cylindrical member. If the outer diameter is too large, there is a problem that the insertion is difficult or cannot be removed after welding. On the other hand, if it is too small, the effect of inserting the jig is lost as shown in FIG. The optimum outer diameter of the welding jig when considering both is 80 to 97% of the inner diameter of the cylindrical member.
ところで、部材に電流を通電させるための電極については、めっき層との反応による合金化が抑制できる材質が望ましい。本発明方法が好適に適用される鋼材としては亜鉛系のめっき鋼板及び亜鉛アルミニウム系の合金めっき鋼板であることから、亜鉛と合金化し難い材質が適しており、さらに溶接時の熱で変形、圧潰しにくいことが求められる。
種々の材質を検討した結果、タングステン、モリブデンが最も有効である。これらの材質は特開２００６‐１５３４９号公報でスポット溶接用電極として公知であるが、本発明方法にも好適に用いられる。
By the way, about the electrode for supplying an electric current to a member, the material which can suppress alloying by reaction with a plating layer is desirable. Steel materials to which the method of the present invention is suitably applied are zinc-based plated steel sheets and zinc-aluminum-based alloy plated steel sheets, and therefore, materials that are difficult to be alloyed with zinc are suitable. Furthermore, deformation and crushing are caused by heat during welding. It is required to be difficult to do.
As a result of examining various materials, tungsten and molybdenum are the most effective. These materials are known as spot welding electrodes in Japanese Patent Application Laid-Open No. 2006-15349, but are also suitably used in the method of the present invention.
更に詳しく説明すると、電極材質としては純タングステン又は純モリブデン、あるいはこれらの複合材料が最も効果が高い。しかしながらこれらの金属は高価であるためその一部を銅に置き換えた銅比率10〜50％の銅‐タングステン材、銅‐モリブデン材も十分使用できる。
本方式の溶接方法では電極の加熱も抑制されることから、一般的なクロム‐銅電極を用い、研磨、交換頻度を上げて生産することも可能である。
More specifically, as the electrode material, pure tungsten, pure molybdenum, or a composite material thereof is most effective. However, since these metals are expensive, copper-tungsten materials and copper-molybdenum materials having a copper ratio of 10 to 50%, in which some of them are replaced with copper, can be used sufficiently.
Since the welding of this method also suppresses heating of the electrode, it is possible to produce by using a general chromium-copper electrode and increasing the frequency of polishing and replacement.
板厚1ｍｍの合金化溶融亜鉛めっき鋼板（GA）およびZn‐6%Al‐2.9%Mg合金めっき鋼板（ZAM）を素材とする外径30mm長さ40ｍｍの円筒形部材に板厚1.2mmのブラケットを取り付ける溶接を図３ａの態様で行った。めっき付着量はいずれも片面45g／ｍ2のものを用いた。溶接機は定格容量35kVAの単相交流式スポット溶接機を用い、加圧力30kN、通電時間10サイクルとし、溶接電流についてはそれぞれの施工条件で母材破断となり、かつチリが発生しない電流値を抽出した。また、連続打点試験では設定した条件で連続的に溶接を行い、50個ごとにサンプリングしたサンプルで評価を行った。 Bracket with 1.2mm thickness on cylindrical member with outer diameter of 30mm and length of 40mm made of alloyed hot-dip galvanized steel sheet (GA) and Zn-6% Al-2.9% Mg alloy-plated steel sheet (ZAM) Welding was performed in the manner of FIG. 3a. The plating adhesion amount was 45 g / m 2 on one side. The welding machine is a single-phase AC spot welder with a rated capacity of 35 kVA, with a pressure of 30 kN and energization time of 10 cycles. For the welding current, a current value that causes fracture of the base metal under each construction condition and does not generate dust is extracted. did. In the continuous spot test, welding was continuously performed under the set conditions, and evaluation was performed on samples sampled every 50 pieces.
連続打点試験においては引張試験においてシャー破断が発生するまでの溶接数を計測した。
また、円筒部材内面の凹凸については溶接サンプルの形状を形状測定器で計測し凹凸が0.3mmを超えるものを不良とし、シャー破断あるいは内面の凹凸過大のどちらかが発生するまでの溶接数をもって電極寿命とした。
そして、溶接時の加圧による円筒部材の変形については変形量が0.3mm未満となる場合を良とした。
電極材質としては一般的な１％クロム銅電極およびタングステンとし、内部治具はアルミナセラミックスを用い治具全体をセラミックス製としたものと（図４ｂ）に示す形態のものを用いて実験を行った。
In the continuous spot test, the number of welds until shear fracture occurred in the tensile test was measured.
In addition, for the irregularities on the inner surface of the cylindrical member, the shape of the weld sample is measured with a shape measuring instrument, and the irregularities exceeding 0.3 mm are regarded as defective, and the number of welds until either shear fracture or excessive irregularities on the inner surface occurs The life is assumed.
As for the deformation of the cylindrical member due to the pressurization at the time of welding, the case where the deformation amount was less than 0.3 mm was determined as good.
The electrode material was a general 1% chromium copper electrode and tungsten, and the internal jig was made of alumina ceramics and the whole jig was made of ceramic, and the experiment shown in FIG. .
内部治具の直径については表１に示すように種々変化をさせた。
比較例としては図１、２に示す施工法についても実験を行った。結果を表1に示す。
以上の結果に示されるように本発明の方法によると電極の損耗による溶接強度の低下、円筒部材の内表面の品質低下による電極寿命の低下が抑制され、安定した溶接結果、製品品質が得られることが明らかとなった。
The diameter of the internal jig was changed variously as shown in Table 1.
As a comparative example, the construction method shown in FIGS. The results are shown in Table 1.
As shown in the above results, according to the method of the present invention, a decrease in welding strength due to electrode wear and a decrease in electrode life due to a decrease in quality of the inner surface of the cylindrical member are suppressed, and stable welding results and product quality can be obtained. It became clear.
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| KR20200086000A (en) * | 2019-01-08 | 2020-07-16 | 주식회사조흥기계 | Method For Manufacturing Mold For Ice Bar |
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