JP3761736B2 - Friction stir welding method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a friction stir welding method.
[0002]
[Prior art]
Friction stir welding is a method in which a round bar (referred to as a rotary tool) inserted into a joint is moved along a joining line while rotating, the joint is heated and softened, plastically flowed, and solid-phase joined. A rotary tool consists of a small diameter part inserted in a junction part, and a large diameter part located in the vicinity of the outer surface of a junction part. The small diameter part and the large diameter part are coaxial. The rotary tool is inclined backward with respect to the joining direction. Rotate the large diameter side. The boundary between the small diameter portion and the large diameter portion is slightly inserted into the joint.
[0003]
Further, a convex portion is provided at the abutting portion of the joined portion, and a rotating tool is inserted into the abutting portion including the convex portion to perform friction stir welding, thereby substantially preventing the plate thickness from decreasing. This is applied to the body of a railway vehicle.
[0004]
Moreover, in joining of a hollow shape material, the extension line of the rib which connects two face plates of a hollow shape material is made into the butt | matching part. The insertion force of the rotary tool is supported by ribs on the extension line of the rotary tool, and the deformation of the face plate is prevented.
[0005]
A third member is disposed above the two members to be joined, and the three members are friction stir welded.
[0006]
These are disclosed in JP-T-9-508073 (EP0752926B1) and JP-A-9-309164 (EP0797043A2).
[0007]
[Problems to be solved by the invention]
When performing friction stir welding, a large force is applied to the members to be joined. For this reason, the dimension of the groove | channel of a butt | matching part may become large.
[0008]
When the member to be joined is long like a vehicle body of a railway vehicle, an extruded shape of an aluminum alloy is used as the member to be joined. A plurality of shape members are arranged in parallel with the longitudinal direction of the shape members being directed to the longitudinal direction of the vehicle body, and are fixed to the gantry. Next, the butted portions of the shape members are temporarily fixed and welded at predetermined intervals by MIG welding or the like. This temporary fixing welding is to keep the groove dimension constant during friction stir welding. Thereafter, friction stir welding is performed. Next, the convex part of the abutting part and the convex part of temporary fixing welding are cut to smooth the surface. Next, the surface of the vehicle body is processed with a hairline and finished as a vehicle body.
[0009]
According to this, it can be made unpainted. However, the temporary fixing weld remains in the vehicle body. The temporarily welded portion is discolored and looks bad. This discoloration is caused by the difference between the shape material and the welding rod material.
[0010]
In addition, when the gap between the pair of members to be joined is large, it is conceivable to arrange the third member above the joining portion and perform friction stir welding, but the third member pops out so that good joining cannot be performed. it is conceivable that.
[0011]
An object of the present invention is to enable good bonding even when the gap is large.
[0012]
The above purpose is that each of the pair of long members to be joined has a butt portion that is continuous in the longitudinal direction,
The butted portion of one of the pair of members to be joined and the butted portion of the other of the pair of members to be joined are arranged to face each other within the axial projection range of the rotary tool. And
In the friction stir welding method for inserting into each butted portion of the pair of members to be joined while rotating the rotary tool in the thickness direction of the butted portion and moving in the longitudinal direction of the joined members to perform friction stir welding,
At least one member to be joined of the pair of members to be joined has a projecting portion projecting toward the insertion side of the rotary tool at the butting portion, and another joined member at the end of the joined member. A projecting piece projecting to the butted portion side of the member, and the projecting piece serves as a backing for the other joined member end when the pair of joined members are butted together,
When abutting each butted portion of the pair of members to be joined, a filler is disposed between both butted portions and the protruding piece,
The filler has a height lower than the plate thickness dimension of the protruding portion of one member to be joined,
With the filler and the butted portion of the pair of joined members positioned within the projection range of the rotating tool, the rotating tool is inserted into the protruding portion of the one of the joined members while rotating, Inserting the large diameter part of the rotary tool at a depth within the range of the plate thickness of the protrusion, and performing a first friction stir welding that performs friction stir welding at a predetermined interval in the longitudinal direction,
Next, when the second friction stir welding is performed by inserting the butting portion of the filler and the pair of members to be joined while rotating the rotary tool, the plate thickness of the pair of the members to be joined is determined. This is achieved by inserting the small diameter portion of the rotary tool to a depth that joins the entire range and moving the rotary tool in the longitudinal direction of the member to be joined .
[0013]
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the present invention will be described with reference to FIGS. The case where it applies to the body of an unpainted railway vehicle is demonstrated. In FIG. 10, the vehicle body of the railway vehicle includes a side structure 50, a roof structure 60, a base frame 70 constituting a floor, and a wife structure 80 at an end portion in the longitudinal direction. 61 is an entrance / exit, and 62 is a window. The side structure 50 and the roof structure 60 are joined by MIG welding.
[0014]
The side structure 50 includes extruded shapes 100 and 110 on the left and right sides of the doorway 61 (or between the doorway 61 and the window 62), extruded shapes 130 and 140 below the window 62, an extruded shape 160 above the window 62, It consists of these extruded shapes 170 above. These joints are friction stir welded.
[0015]
The extruded shape members 100, 110, 130, 140, 160, and 170 are hollow shapes made of an aluminum alloy. The extrusion direction of the shape members 100 and 110 is the vertical direction. The extrusion direction of the shape members 130, 140, 160, and 170 is the longitudinal direction of the vehicle body. For this reason, the shape member 110 and the shape members 130, 140, 160 are orthogonal to each other in the extrusion direction. Further, the extrusion direction of the profile 170 and the profiles 100 and 110 are orthogonal to each other.
[0016]
In FIG. 5, the periphery of the joint part of the shape members 100 and 110 to be joined is shown. The shape of the joint between the shape member 130 and the shape member 140 is also the same. The hollow shape member 100 (110) connects two parallel face plates 101, 102 (111, 112) and face plates, and a plurality of ribs 103 (113) inclined with respect to the face plate, At the end of the hollow shape member 100 (110), the two face plates 101, 102 (111, 112) are connected, and the rib 105 (115) orthogonal to the face plate is formed. The ribs 103 (113) are arranged in a truss shape. Between the rib 105 (115) and the adjacent rib 103 (113), there are face plates 101, 102 (111, 112). One of the two face plates may be inclined with respect to the other.
[0017]
In FIG. 1, the shape of the joint will be described. Here, the shape on the upper surface side of the hollow shape members 100 and 110 in FIG. 5 will be described, but the shape on the lower surface side is the same. The configuration of the upper surface and the configuration of the lower surface are the same in the shapes of other examples described later.
[0018]
The face plate 101 of the hollow shape member 100 protrudes to the end side from the rib 105. The end of the face plate 101 of one hollow shape member 100 is located within the plate thickness range of the rib 115 of the other hollow shape member 110. In order to receive the face plate 101, the face plate 111 side of the end of the hollow shape member 110 is a recess.
[0019]
The end of the hollow shape member 110 has a protruding piece 116 that protrudes to the end side from the rib 115. The protruding piece 116 is located on the back side of the end portion of the face plate 101 and serves as a backing.
[0020]
The outer surface side of the end portion of the face plate 101 (111) of the hollow shape member 100 (110) protrudes into a protruding portion 107 (117).
[0021]
The surface of the end of the protrusion 107 (117) of the face plate 101 (111) is orthogonal to the face plate 101 (111). The surface of the recess on the side of the face plate 111 (the face with which the end of the face plate 101 is abutted) is orthogonal to the face plate 111. The butting surface on the face plate 111 side of the recess is in the range of the plate thickness of the rib 115. The end of the protrusion 107 that enters the recess is orthogonal to the face plate 101 and parallel to the orthogonal surface of the recess.
[0022]
There are often gaps between the butted portions of the two profiles 100 and 110 (the butted portion between the end of the hollow profile 100 and the end of the hollow profile 110) as shown in FIG.
[0023]
The centers of the friction stir welding rotary tools 200 and 220 are located on the extension line of the rib 115, that is, within the range of the extension line of the rib 115. The axial centers of the rotary tools 200 and 220 are located between the two protrusions. For this reason, the rib 115 supports most of the insertion force of the rotary tools 200 and 220. Within the axial projection range of the rotary tools 200, 220, the ends of the two profiles 100, 110 of the joint are located. In FIGS. 1 to 4, the end portions are the protruding portions 107 and 117, while in FIGS. 6 to 9, one shape member 130 (140) is a face plate 131 (141).
[0024]
Hereinafter, the joining procedure will be described. First, the two shape members 100 and 110 are placed on a frame and firmly fixed.
[0025]
First, in FIG. 1 to FIG. 3, the upper surfaces of the projecting portions 107 and 117 of the two shape members 100 and 110 are temporarily fixed and joined at predetermined intervals (intermittently). This is performed by friction stir welding with the rotary tool 200.
[0026]
FIG. 1 shows a state in which friction stir welding for temporary fixing is performed. In the temporary joining, the rotary tool 200 is pressed against the protrusions 107 and 117 while rotating, and when it reaches a predetermined position, the rotary tool 200 is held in that state for several seconds. This is because the two projecting portions 107 and 117 are heated and softened for a few seconds to cause plastic flow. As a result, the two protrusions 107 and 117 are joined. If there is a gap in the butted portion, the softened metal is filled in the upper part of the gap. W1 is a joining bead by friction stir welding.
[0027]
Since normal friction stir welding is to join the face plates 101 and 111, the position of the tip of the small diameter portion 201 of the rotary tool 200 needs to reach the protruding piece 116. However, since this is temporary bonding, the length of the small diameter portion 201 may be short. The position of the tip of the small diameter portion 201 (insertion allowance) and the position of the lower end of the large diameter portion 202 (insertion allowance) are between the tops of the protrusions 107 and 117 and the extended lines of the upper surfaces of the face plates 101 and 111. For this reason, there is a gap between the lower end of the large diameter portion 202 and the extended line of the upper surfaces of the face plates 101 and 111. The insertion allowance of the large diameter portion 202 of the rotary tool 200 should not be deeper than the insertion allowance of the large diameter portion 222 of the rotary tool 220 in the subsequent process. It is considered that the diameter of the large diameter portion 202 should not be larger than the diameter of the large diameter portion 222 of the rotary tool 200. The size and insertion allowance of the rotary tool 200 are determined from the viewpoint of temporary joining.
[0028]
In the above, the rotary tool 200 is only inserted into the protrusions 107 and 117, and is not moved along the joining line. However, you may move along a joining line like the rotary tool 220. FIG. In this case, it is desirable that the rotary tool 200 is inclined rearward with respect to the moving direction, like the rotary tool 220. The moving amount of the rotary tool 200 is 30 mm, for example. It is considered that the moving speed of the rotary tool 200 can be higher than the moving speed of the rotary tool 220. This is because the protrusion margin of the small diameter portion 201 is small.
[0029]
In this way, if the temporary joining is performed at predetermined intervals over the entire lengths of the shape members 100 and 110, the full lengths of the two shape members 100 and 110 are joined by the rotary tool 220. In FIG. 4, the rotary tool 220 includes a small diameter portion 221 and a large diameter portion 222. The small diameter portion 221 has a length that reaches the protruding piece 116. The insertion allowance (the position of the lower end) of the large-diameter portion 222 is between the tops of the protruding portions 107 and 117 and the extension lines of the upper surfaces of the face plates 101 and 111. The rotary tool 220 moves along the joining line of the butted portion. The rotary tool 220 is inclined backward with respect to the moving direction. This joining is called main joining.
[0030]
Next, the shape group (100, 110) is inverted, and temporary bonding and main bonding are performed as described above.
[0031]
The structure and joining of the profiles 130 and 140 are the same as described above. The structures of the profiles 160 and 170 are the same as described above.
[0032]
The shape group (100, 110), the shape group (130, 140), and the shape members 160, 170 obtained in this way are placed on a frame, fixed, and subjected to friction stir welding.
[0033]
In FIG. 6, the joining of the shape member 110 of the shape member group (100 , 110 ) and the shape member group (130, 140) will be described. In addition, the shape member 130 and the shape member 140 are joined, and the shape member 140 is located in a direction perpendicular to the paper surface of FIG. Shape of the end portion of the profile group (130, 140) side of the profile 110 is substantially similar to the shape of the end portion of the butted profile 110 to frame member 100 of FIG. 1 (butt portion). The profile 110 has a protruding portion 117b, a protruding piece 116b, and a rib 115b. Since the extrusion direction of the profile 110 and the extrusion direction of the profile group (130, 140) are orthogonal to each other, there is a protrusion 117b at the joint of the profile 110, but the profile group 130 (140) is abutted. The part does not have a protrusion corresponding to the protrusion 117b . Ribs 133 which constitute the profile 130 (140) (143), the ribs orthogonal to the face plates, the protruding pieces, cutting to take dividing Iteiru. The ribs 133 and 143 of the profile group (130, 140) correspond to the rib 113 in FIG. 5, and the protruding piece 116b of the profile 110 corresponds to the protruding piece 116 in FIG. The ribs 115b of the profile 110 correspond to the ribs 115 in FIG. The protruding piece 116b of the profile 110 is inserted on the back side of the face plate 131 (141) of the profile 130 (140). The end portion of the face plate 131 (141) of the profile 130 (140) is abutted at a position shifted from the extension line of the plate thickness of the rib 115b of the profile 110 in FIG. The relationship between the profile 110 and the profile 160 and the relationship between the profile 170 and the profiles 100 and 110 are the same.
[0034]
First, in FIGS. 7 to 8, temporary bonding is performed using the rotary tool 200. This temporary fixing joining is performed continuously over the entire length of the joining line by inserting the rotary tool 200 into the protrusion 117b and then moving it along the joining line. The insertion allowance of the rotary tool 200 is the same as in the temporary joining of the shape members 100 and 110. There is a gap between the lower end of the large diameter portion 202 and the upper surface of the face plate 131 (141) so that the lower end of the large diameter portion 202 does not contact the face plate 131 (141) of the shape member 130 (140). By this joining, the material of the protrusion 117b is moved to the upper surface side of the face plate 131 (141). That is, the face plate 131 (141) is piled up. If there is a gap in the butted portion, the softened metal in the protruding portion is filled in the upper portion of the gap. W2 is a joining bead by friction stir welding.
[0035]
Note that the intermittent temporary bonding shown in FIGS. 1 to 3 may be performed before the continuous temporary bonding.
[0036]
Next, in FIG. 9, friction stir welding with the rotary tool 220 is performed over the entire length.
[0037]
The insertion allowance of the rotary tool 220 (in this case, the position of the lower end of the large diameter portion 222) is set to the position of the lower end of the large diameter portion 202 of the rotary tool 200 or below it. As a result, the rotary tool 220 is in contact with or below the upper surface of the friction stir welding portion by the rotary tool 200. For this reason, even if there is a gap between the two shape members, the entire gap can be filled with metal. In order to prevent the occurrence of defects, it is preferable to insert the lower end of the large diameter portion 222 of the rotary tool 220 into the bead W2.
[0038]
The same applies to the joining of the shape member 110 and the shape member 160.
[0039]
For joining the shape member 170 and the shape member group (100, 110), and the shape member 170 and the shape member 160, first, temporary joining is performed. The joining of the profile group (100, 110) and the profile 170 is a continuous temporary joining similar to the joining of the profile group (130, 140) and the profile 110. The joint between the shape member 170 and the shape member 160 is intermittent provisional joining similar to the joining of the shape members 100 and 110 since both the joint portions have protrusions. Next, continuous joining with the rotary tool 220 is performed from one end side of the profile 170.
[0040]
Next, it is turned upside down and joined in the same manner. The protrusions 107, 117, 117b and the bead W2 located on the outer surface side of the vehicle body are cut at some point after the final joining to finish the same surface as the face plate.
[0041]
Next, MIG welding with the roof structure 60 or the like is performed.
[0042]
Next, hairline processing is performed on the outer surface of the vehicle body.
[0043]
According to the above, the temporary bonding is performed not by arc welding but by friction stir welding. For this reason, since there is no supply of other metals, there is no discoloration in the joint, the appearance can be improved, and the finish can be finished without painting.
[0044]
In addition, in joining the abutting portion between the end portion with the protruding portion and the end portion without the protruding portion, continuously performing temporary fixing bonding, and after moving the metal of the protruding portion to the end portion side without the protruding portion, Continuous joining.
[0045]
Since bonding is performed twice, the amount of heat generated at one time in the bonded portion can be reduced. In this case, joining is performed with a small insertion allowance for the first time, but the insertion allowance is large for the second time. However, since it is not necessary to insert into the protruding portion, the total heat generation can be reduced. This is particularly effective when joining a member that is poor in heat dissipation, such as a hollow shape member, and is likely to melt due to heat accumulation. According to this, the defect which is easy to generate | occur | produce in a junction part at the time of high temperature can be prevented.
[0046]
In addition, the friction stir welding at the portion where the extrusion direction is orthogonal is performed by inserting one shape member into the other and supporting the other shape portion, so that deformation of the other shape member can be prevented.
[0047]
In Figure 1, the rotary tool 200, the bottom surface, and an inclined 204 provided toward the axial center. Due to this inclination, when the member to be joined and the rotary tool 200 are moved relative to each other by the joining, the metal that has been plastically flowed by the rotation of the rotary tool is pushed downward behind the rotary tool in the advancing direction. Becomes stronger. The inclined surface is the same in the rotary tool 220. The rotary tool 200 has a small diameter portion 201 having a small diameter on the shaft. The action of the small diameter portion 201 is to increase heat generation due to friction between the member to be joined and the rotary tool 200, and to facilitate plastic flow of the member to be joined.
[0048]
Another embodiment of the rotary tool 200 will be described with reference to FIGS. FIG. 11 shows a shape without the small diameter portion 201 of the rotary tool 200. In FIG. 12, the bottom surface of the rotary tool 200 is flattened, and a small diameter portion 201 is provided . It is desirable that the bottom surface has a rough surface so that the friction with the member to be joined generates more heat. FIG. 13 is obtained by removing the small diameter portion from the bottom surface portion of FIG.
[0049]
The embodiment of FIGS. 14 to 15 will be described. This embodiment corresponds to FIG. One profile 110 has a protrusion 117b, and the other profile 130 has no protrusion. The gap between the butted portions of the two shapes 110 and 130 is larger than in the case of FIG. That is, there is a gap that cannot fill the gap with the metal of the protrusion 117b.
[0050]
A plate-like filling material 250 is disposed in the gap between the butted portions. The upper surface of the filling material 250 is substantially at the same position as the upper surface of the face plate 131. At least the upper surface of the filling material 250 is on the inner surface side of the top of the projecting portion 117 b. The material of the filling material 250 is an aluminum alloy.
[0051]
In this state, temporary joining is performed over the entire length. FIG. 15 shows a state after temporary joining. Next, main joining is performed.
[0052]
According to this, the rotary tool 200 does not directly contact the filling material 250 during temporary joining. A large force is generated at the position where the rotary tool 200 is inserted. For this reason, if the filling material 250 contacts the rotary tool 200, the filling material 250 pops out upward. However, since the rotary tool 200 is not in contact with the filling material 250, an external force does not act on the filling material 250 and does not jump out.
[0053]
By this joining, the filling material 250 is joined to the shape members 110 and 130, and the gap is filled. Therefore, even if the gap is large, it is possible to join to fill the gap.
[0054]
During the main joining, the filling material 250 is in contact with the rotary tool 220, but the upper part is covered with the beads W2 and the left and right parts are sandwiched between the shape members 110 and 130, so that they do not jump out.
[0055]
In the embodiment of FIG. 15, the filling material 250 does not contact the rotary tool 200, but can make contact. The insertion cost of the rotary tool 200 is small, the lower part of the filling material 250 is continuous, and the filling material 250 is located between the left and right shape members 110 and 130. For this reason, the filling material 250 is difficult to jump out and can be joined.
[0056]
This arrangement of the filling material 250 can also be applied when the left and right profiles have protrusions.
[0057]
In addition, although it demonstrated that the material which fills a clearance gap is the material of a protrusion part or a filling material, this is description for clarification. More correctly, the material filling the gap is a material softened by the rotary tools 200 and 220.
[0058]
Temporary bonding, main bonding, and bonding with the filler 250 disposed in the gap can be applied to bonding between plates.
[0059]
The technical scope of the present invention is not limited to the language described in each claim of the claims or the language described in the section of means for solving the problem, and extends to a range easily replaced by those skilled in the art. Is.
[0060]
【The invention's effect】
According to the present invention, when the gap between the pair of members to be joined is large, the temporary joining is performed after the filling material is disposed in the gap, and the main joining is performed. It is something that can be done.
[Brief description of the drawings]
FIG. 1 is a longitudinal sectional view for explaining temporary bonding according to an embodiment of the present invention.
FIG. 2 is a longitudinal sectional view after provisional joining according to FIG.
FIG. 3 is a perspective view after temporary joining according to FIG. 1;
4 is a longitudinal sectional view for explaining the main bonding after FIG. 1; FIG.
5 is a longitudinal sectional view of a combination of hollow shapes to be joined in FIG. 1. FIG.
FIG. 6 is a longitudinal sectional view of a combination of hollow members of another embodiment to be joined in the present invention.
7 is a longitudinal sectional view of a state in which the hollow shape member of FIG. 7 is temporarily joined.
8 is a longitudinal sectional view after provisional joining in FIG.
9 is a longitudinal sectional view for explaining the main joining after FIG. 8. FIG.
FIG. 10 is a perspective view of a vehicle body of a railway vehicle according to an embodiment of the present invention.
FIG. 11 is a longitudinal sectional view of a rotary tool according to another embodiment of the present invention.
FIG. 12 is a longitudinal sectional view of a rotary tool according to another embodiment of the present invention.
FIG. 13 is a longitudinal sectional view of a rotary tool according to another embodiment of the present invention.
FIG. 14 is a longitudinal sectional view of a joint portion according to another embodiment of the present invention.
15 is a longitudinal sectional view obtained by temporarily joining FIG.
[Explanation of symbols]
100, 110, 130, 140, 160, 170: Profile, 101, 111, 131, 141: Face plate, 107, 117, 117b: Protruding part, 115, 115b: Rib 200, 220: Rotating tool, 201: Small diameter part , 202: large diameter part, 250: filling material

Claims (3)

Each of the pair of long members to be joined has a butt portion that is continuous in the longitudinal direction, and of the pair of members to be joined, the butt portion of one member to be joined and the pair of members to be joined The abutting portion of the other member to be joined is abutted and disposed within the projection range in the axial direction of the rotary tool, and the rotating tool is rotated in the thickness direction of the abutting portion at each abutting portion of the pair of members to be joined. In the friction stir welding method of inserting while, and moving in the longitudinal direction of the members to be joined, friction stir welding
At least one member to be joined of the pair of members to be joined has a projecting portion projecting toward the insertion side of the rotary tool at the butting portion, and another joined member at the end of the joined member. A projecting piece projecting to the butted portion side of the member, and the projecting piece serves as a backing for the other joined member end when the pair of joined members are butted together,
When abutting each butted portion of the pair of members to be joined, a filler is disposed between both butted portions and the protruding piece,
The filler has a height lower than the plate thickness dimension of the protruding portion of one member to be joined,
In a state where the abutting portion and has position of the filler within the projection range of the rotary tool and the pair of members to be joined, inserting the protruding portion of the one member to be joined while rotating the rotary tool, this time, Inserting the large diameter portion of the rotary tool at a depth within the range of the thickness of the protruding portion, and performing a first friction stir welding that performs friction stir welding at a predetermined interval in the longitudinal direction;
Next, when the second friction stir welding is performed by inserting the butting portion of the filler and the pair of members to be joined while rotating the rotary tool, the plate thickness of the pair of the members to be joined is determined. Inserting a small diameter portion of the rotary tool to a depth for joining the entire range, and moving the rotary tool in the longitudinal direction of the member to be joined;
A friction stir welding method characterized by the above. In the friction stir welding method according to claim 1,
The friction stir welding method, wherein the first friction stir welding is performed continuously in a longitudinal direction of the pair of members to be joined . In the friction stir welding method according to claim 1 ,
The first friction stir welding forms a joining beat from a protruding portion of the butted portion of the one joining member, and covers the upper surface of the filler;
A friction stir welding method characterized by the above.

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