JP3960755B2 - Manufacturing method of junction container - Google Patents

Manufacturing method of junction container Download PDF

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Publication number
JP3960755B2
JP3960755B2 JP2001024635A JP2001024635A JP3960755B2 JP 3960755 B2 JP3960755 B2 JP 3960755B2 JP 2001024635 A JP2001024635 A JP 2001024635A JP 2001024635 A JP2001024635 A JP 2001024635A JP 3960755 B2 JP3960755 B2 JP 3960755B2
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Prior art keywords
flange
friction stir
stir welding
flange portion
welding
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JP2002224861A (en
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公一 松本
誠二 笹部
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Kobe Steel Ltd
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Kobe Steel Ltd
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Description

【0001】
【発明の属する技術分野】
本発明はアルミニウム又はアルミニウム合金製の接合容器の製造方法に関し、特に、乗用車、トラック及びバス等の自動車若しくは二輪車等に使用される燃料タンク、又は半導体製造装置用の真空チャンバ等に好適な接合容器の製造方法に関する。
【0002】
【従来の技術】
従来、2輪自動車、乗用車、トラック、バス及び特殊車等の自動車に使用される燃料タンクは、鋼製、合成樹脂、アルミニウム及び各種クラッド板により形成されている。このような燃料タンクとして、特開平8−323487号公報には鋼製のものが開示されている。この公報に記載された従来の鋼製燃料タンク(従来例1)においては、鋼板で形成され開口部を有する2つの箱状の部材を有し、この2つの箱状の部材の開口部周縁に外向きにフランジ部が形成されており、2つの箱状の部材の開口部のフランジ部が重ね合わせられ、このフランジ部がシーム溶接により溶接されている。
【0003】
また、実開平5−273号公報には、トラック及び産業機械等に取り付けられ、ガソリン又は軽油等の液体燃料を貯蔵するためのアルミニウム又はアルミニウム合金製の燃料タンクが開示されている。この公報に記載された燃料タンク(従来例2)においては、アルミニウム又はアルミニウム製の円筒状のタンク本体及びタンク本体の両開口部を閉鎖する2つの鏡板を有し、この鏡板の周縁には内側に略直角に折り曲げられた内向きフランジが形成されている。更に、このフランジ部にはタンク内側に向かって傾斜角が15゜程度で傾斜する溶接継手が設けられており、この溶接継手にタンク本体開口端が付き当てられて、イナートガスアーク溶接により溶接固定されている。このように構成された従来例2の燃料タンクは、タンク本体と鏡板との寸法誤差を吸収することができ、サイズ合わせが簡単で、きれいな溶接部を得ることができる。
【0004】
【発明が解決しようとする課題】
しかしながら、従来例1の技術においては、鋼製の箱状の部材のフランジ部を重ねて抵抗シーム溶接すると入熱量が多いという問題点がある。特に、鋼製ではなく、アルミニウム又はアルミニウム合金製のフランジ部を有する部材をシーム溶接すると、入熱量が多いためにアルミニウム又はアルミニウム合金板が歪み、寸法精度が低下してしまう。例えば、燃料タンクとして、アルミニウム又はアルミニウム合金製の箱状の部材を使用し、シーム溶接により溶接した場合に、寸法精度が下すると、気体及び液体等の密閉性が劣化するという問題点がある。燃料タンクはガソリン等の液体燃料を貯蔵するため、液体燃料と共に液体燃料から揮発するガス成分も密閉する必要があり、気密性が劣化すると極めて危険である。また、シーム溶接では、フランジ部同士の接触面が平坦でなかったり、酸化膜等が形成されていると、抵抗が高くなったり、抵抗が不均一になるため、熱流量が更に大きくなり、溶接部の熱影響部が大きくなるという問題点もある。
【0005】
また、従来例2の技術においては、燃料タンクの本体と鏡板とを突き合わせてイナートガスアーク溶接により溶接固定しているが、このように、アルミニウム製の部材を重ね合わせて溶接するには、アーク又はレーザ等の熱源を直接受ける表面部だけでなく、部材同士が接する面の表面性状にも留意が必要で、これを怠った場合は溶接部に欠陥が発生したり、更に溶込みが安定せず、気体及び液体等の密閉性が不十分になったりするという問題点がある。溶融部において気泡が発生すると、これが浮上するより早く溶接部が固まり、この気泡がブローホール欠陥として残ってしまうため、ブローホール欠陥が多く生じた場合は欠陥部分が連なったり、また、その欠陥部に機械的な応力が加わると亀裂が生じたりして気体及び液体等の密閉性を劣化させてしまう。また、アーク溶接は溶接による熱影響部が比較的大きいため、母材の熱影響部が広い範囲に生じる。このため、継手近傍の母材の軟化が激しく、母材が変形して必要な密閉性を得ることが難しいという問題点がある。
【0006】
本発明はかかる問題点に鑑みてなされたものであって、継手の表面性状によらず接合時の入熱量が小さいと共に接合強度が高く、高い気体及び液体等の密閉性を得ることができる接合容器の製造方法を提供することを目的とする。
【0007】
【課題を解決するための手段】
本発明に係る接合容器の製造方法は、下方が開口しその開口部の全周縁に亘って外部に突出するフランジ部が形成されたアルミニウム又はアルミニウム合金製上部容器部材と、上方が開口しその開口部の全周縁に亘って外部に突出するフランジ部が形成されたアルミニウム又はアルミニウム合金製下部容器部材とをそのフランジ部同士で重ね合わせ、前記フランジ部を仮止めする工程と、表面にネジが形成されたツールにより前記フランジ部を全周縁に沿って摩擦撹拌接合を行う工程とを有する接合容器の製造方法において、前記摩擦撹拌接合を行う工程は、前記ネジが前記フランジ部中に進入する方向の回転方向を順回転方向としたとき、前記ツールを前記上部容器部材の本体部分の周囲を順回転方向で公転させながら前記摩擦撹拌接合を行う工程を有することを特徴とする。
【0008】
本発明においては、ツールを順回転方向で、即ち、ネジが左ネジの場合には、ネジは左回転でフランジ部に進入するので、本体部分が常に左側にあるような方向(左回転方向)で、ネジが右ネジの場合には、ネジは右回転でフランジ部に進入するので、本体部分が常に右側にあるような方向(右回転方向)で、公転させながらフランジ部同士を摩擦撹拌接合しているので、摩擦撹拌接合による利点だけでなく、熱拡散等の影響により接合部及びその近傍において、高い強度を確保することができる。
【0009】
なお、前記フランジ部を仮止めする工程は、自己穿孔型リベット若しくはメカニカルクリンチングを使用して機械的に接合するか、抵抗スポット溶接により溶接するか、又は前記フランジ部を重ねたまま折り曲げ加工する工程とすることができる。
【0010】
【発明の実施の形態】
以下、本発明の実施例に係る接合容器の製造方法について、添付の図面を参照して具体的に説明する。図1は本発明の実施例に係る接合容器の製造方法における各部材を示す斜視図である。
【0011】
本実施例においては、図1に示すように、下方が開口された上部容器部材1と上方が開口された下部容器部材2とを接合して接合容器を製造する。上部容器部材1及び下部容器部材2は、いずれもアルミニウム又はアルミニウム合金製である。下部容器部材2には、その開口部2cの全周縁に亘って下部容器本体2bから外側に略90゜折れ曲がって突出したフランジ部2aが一体成形されている。同様に、上部容器部材1にもその開口部の全周縁に亘って上部容器本体1bから外側に略90゜折れ曲がって突出したフランジ部1aが一体成形されている。
【0012】
本実施例においては、先ず、上部容器部材1及び下部容器部材2の両フランジ部を重ね合わせる。次いで、摩擦撹拌接合をより確実に行うため、重ね合わせた両フランジ部を仮止めする。両フランジ部を重ね合わせて摩擦撹拌接合する前に行う仮止め方法としては、自己穿孔型リベット若しくはメカニカルクリンチング等を使用して機械的に接合する方法又は抵抗スポット溶接等の溶接により行う方法等がある。本実施例においては、自己穿孔型リベットを使用し、このリベットを重ねられたフランジ部において、開口部の周囲に複数個打ち込むことにより仮止めを行う。
【0013】
その後、仮止めされたフランジ部をその全周縁に沿って摩擦撹拌接合により接合する。図2は本発明の実施例において使用する摩擦撹拌接合(FSW)用ツールを示す正面図である。図3は本発明の実施例におけるFSW用ツールと上部容器本体1b及び下部容器本体2bとの位置関係を示す図であって、(a)は上面図、(b)は(a)におけるA−A線に沿った断面図である。
【0014】
本実施例において使用するFSW用ツール20には、基部10及びこの基部10の先端に形成されたピン部11が設けられている。ピン部11の直径は基部10のそれよりも小さく、その表面にはネジ部12が形成されている。ネジ部12は、例えば左ネジである。左ネジは左回転により素材中に進入するものであるから、この場合、順回転とは左回転、逆回転とは右回転である。
【0015】
本実施例においては、図3に示すように、FSW用ツール20を、常にその左側に上部容器本体1bが存在するような方向を進行方向として移動させながら、仮止めされたフランジ部をその全周縁に沿って摩擦撹拌接合を行う。なお、上部容器部材1及び下部容器部材2の開口部の形状に沿って開口部の周囲全てに摩擦撹拌接合を行ってもよい。図4は接合容器の上部容器部材1からみた上面図であって、フランジ部を示す拡大図である。摩擦撹拌接合は、図4に示すように、例えば上部容器部材1のフランジ部1aと下部容器部材2のフランジ部2aとを重ね合わせて仮止めしたリベット5aの上を通過するようにして行う。
【0016】
次に、摩擦撹拌接合について更に詳しく説明する。図3(b)に示すように、先ず、フランジ部1a及びフランジ部2aを重ね合わせた後、重ね合わせた両フランジ部のうち、下部容器部材2のフランジ部2a側を裏当て材(定盤)(図示せず)上に載置する。次いで、ピン部11に左ネジのネジ部12が形成されたツール20を、例えば右回転(逆回転)で自転させながら重ねられたフランジ部1a及び2aの板厚方向上方からフランジ部1aに突き立てる。そして、回転するピン部11とフランジ部1aとの接触部分を、ピン部11とフランジ部1aとの摩擦熱により軟化可塑化させ、ピン部11により撹拌させつつ圧入し、フランジ部1a及び2aを塑性流動させる。更に、ピン部11が回転している状態で、上部容器部材1及び下部容器部材2の全周縁に沿って、一定の圧力を加えながらフランジ部1a及び2aに対してツール20を「左回転(順回転)」で相対移動(公転)させて摩擦撹拌接合する。これにより、フランジ部1aとフランジ部2aとが接合されて接合部5が形成され、図4に示すように、フランジ部1a及び2aの接合位置に接合線4が形成される。本実施例において摩擦撹拌接合に使用するツール20における基部10の直径T1は、例えば10mm、ピン部11の直径T2は、例えば4mm、ピン部11の長さhは、例えば1.8mmであり、ツール20の回転速度は、例えば3000rpm、送り速度は、例えば400mm/分である。
【0017】
このような第1の実施例によれば、ピン部が圧入されるフランジ部1a及び2aの表面及びフランジ部同士が接触する面の性状について、接合のための特別な配慮をすることは特に必要なことではなくなる。従って、これらの面の性状に関係なく安定した継手性能を発揮することができる。また、摩擦撹拌接合するため、アーク溶接等の溶融溶接と比べて入熱量が小さく、接合部材の熱による歪等の影響が小さい。従って、本実施例のようなタンク等の箱状の製品等、気体及び液体等の密閉性が要求される接合容器の接合に適しており、極めて優れた気体及び液体等の密閉性を得ることができる。
【0018】
また、フランジ部1a及び2aを有する開先を重ね合わせて溶接するため、上下容器部材1及び2は互いに平面で接触する。従って、適切に固定しなければ溶接中に口開きの変形及びフランジ部の面上での滑り等が発生しやすくなる場合も考えられるが、本実施例においては、摩擦撹拌接合前に仮止めを行っているため、上下の容器部材1及び2が横滑りすることはない。また、口開きの等の変形を抑制して安定した継手及び所望の寸法精度を確保することができる。更に、摩擦撹拌接合は溶加材を使用しないため、仮止めをした部分にそのまま摩擦撹拌接合しても、上下容器部材1及び2の素材であるアルミニウム又はアルミニウム合金の成分等を変化させることなく安定した継手を作成することができる。
【0019】
更に、仮止めしたリベット5a上に行うため、接合線4により仮止めの後が残らない。更に、リベットの素材として適当な素材を選択すれば、例えば打ち込んだリベットをフランジ部と共にピン部11で撹拌することにより、摩擦撹拌接合部の強度を向上させることができる。このように、強度を向上させる仮止め用のリベット又はクリンチングの素材としては、フランジ部の素材よりも高強度のものであれば特に限定されるものではないが、リサイクルの観点からいえば、例えば2000系又は7000系等の高強度のアルミニウム合金とすることが好ましい。
【0020】
更にまた、ピン部11に形成されるネジ部12を左ネジとし、摩擦撹拌接合の進行方向(公転の回転方向)を常に上部容器本体1bの外壁が左側にある方向としているので、摩擦撹拌接合時の熱伝達等の影響により接合部5の周囲において高い強度を確保することができる。なお、第1の実施例では、FSW用ツール20の自転の回転方向を右回転(逆回転)としているが、これを左回転(順回転)とした場合には、塑性流動した部分のFSW用ツール20の回転に伴う上向き対流を抑制して、フランジ部1a及び2aの界面の上方への持ち上がりを防止することができる。このため、接合部5近傍におけるフランジ部1aの強度をより高く維持することができ、より好ましい。
【0021】
なお、ネジ部12を右ネジとする場合には、摩擦撹拌接合の進行方向(公転の回転方向)を常に上部容器本体1bの外壁が右側にある方向とすればよい。この場合にも、FSW用ツール20の自転の回転方向は、右回転及び左回転のいずれでもよいが、上述の界面の持ち上がりを防止する観点から順回転、即ちこの場合には右回転とすることがより好ましい。
【0022】
また、接合線4を形成する予定の位置よりもフランジ部1aの端部側においてリベット5bで仮止めを行うか、又は上部容器本体1b側においてリベット5cで仮止めを行っておいて、摩擦撹拌接合による接合線4が仮止めしたリベット5b又は5c上を通過しないようにしてもよい。なお、メカニカルクリンチング又は抵抗スポット溶接の場合も、同様にいずれの位置においても仮止めを行うことができる。更に、リベット5b等による仮止め位置を摩擦撹拌接合した接合線4の外側になるようにすると、摩擦撹拌接合により、重ねられたフランジ部1a及びフランジ部2aの端部がめくれて重ね合わせの精度が低下することを防止することができる。なお、仮止めとして、本実施例のように機械的に接合するのではなく、スポット溶接する場合には、例えば、基体の直径が16mm、先端半径が75mmの電極を使用し、加圧力を2.7kN、溶接電流を25kAとして溶接することができる。また、このような仮止めを行わず、上下容器部材を重ね合わせた後、直接、摩擦撹拌接合してもよい。更に、仮止めの方法は、摩擦撹拌接合する際に上下の容器部材の位置がずれない程度に固定できる方法であれば上述の方法に限られるものではない。
【0023】
更に、本実施例においては、フランジ部1a及び2aを水平に設置した状態でフランジ部1a及び2aに回転するFSW用ツール20を突き立てて摩擦撹拌接合を行っているが、例えば、図1に示す2個の容器部材をそのフランジ部が垂直になるような状態に設置して、フランジ部同士を摩擦撹拌接合してもよい。
【0024】
次に、本発明の第2の実施例について説明する。第2の実施例においては、上部容器部材及び下部容器部材を重ね合わせた後、その重ね合わせたフランジ部の端部を折り曲げることにより仮止めを行う。図5は本発明の第2の実施例に係る接合容器の製造方法を示す断面図である。
【0025】
第2の実施例では、第1の実施例と同様にして、上部容器部材1及び下部容器部材2の両フランジ部1a及び2aを重ね合わせた後、フランジ部1a及び2aの各端部を、例えば上部容器部材1側に折り返してフランジ部1aの折り返されていない部位と接するように重ね合わせる曲げ加工を施す。その後、第1の実施例と同様に、折り返しによる重なりがないフランジ部の部位において、上部容器本体1bの開口部の形状に沿ってピン部を相対移動させて摩擦撹拌接合を行う。この際、ネジ部が左ネジであれば、公転の回転方向を左回転、即ち上部容器本体1bが常に左側にある方向とする。一方、ネジ部が右ネジであれば、公転の回転方向を右回転、即ち上部容器本体1bが常に右側にある方向とする。
【0026】
このような第2の実施例によっても、第1の実施例と同様に、上下容器部材1及び2の横滑り及び口開きの変形等を抑制して安定した継手及び所望の寸法精度を得ることができる等の効果を得ることができる。また、本実施例では、フランジ部1a及び2aの折り返された端部は4層構造になるため、より高い強度を得ることができる。
【0027】
このようにして第1及び第2の実施例によって製造された接合容器は、例えばアルミニウム又はアルミニウム合金製の自動車用燃料タンクに好適である。
【0028】
なお、2つの容器部材のフランジ部の厚さが異なる場合、摩擦撹拌接合を行うに当たって上側のフランジ部が厚くなるようにして配置することが好ましい。
【0029】
【実施例】
以下、本発明の実施例について、その特許請求の範囲から外れる比較例と比較して具体的に説明する。
【0030】
先ず、2つの容器部材を仮止めし、左ネジのネジ部が形成されているピン部を備えたツールを使用してこれらの容器部材を下記表1に示す条件の下で摩擦撹拌接合した。実施例1及び2では、容器部材の容器本体が常に左側にある方向(順回転)でツールを公転させながら溶接線を形成し、比較例3及び4では、容器本体が常に右側にある方向(逆回転)でツールを公転させながら溶接線を形成した。なお、各容器部材はJIS A5182−O材のアルミニウム合金製であり、ツールの自転方向は、逆回転方向とした。
【0031】
次いで、摩擦撹拌接合により形成された継手部の引張試験を行った。図6は引張試験における荷重部分及び荷重方向を示す模式図である。引張試験では、接合部23を挟んで上板21と下板22とを引っ張り破断位置及び破断荷重を測定した。この結果を、下記表2に示す。
【0032】
【表1】

Figure 0003960755
【0033】
【表2】
Figure 0003960755
【0034】
上記表2に示すように、本発明範囲に含まれる実施例1及び2によれば、高い破断強度を得ることができた。特に、上板21の方が厚い実施例2において、より高い破断強度が得られた。
【0035】
一方、本発明範囲からはずれる比較例3及び4では、高い破断強度は得られず、接合時に破断が生じる場合もあった。
【0036】
【発明の効果】
以上詳述したように、本発明によれば、摩擦撹拌接合によりフランジ部を接合するため、入熱量が小さいと共にフランジ部の表面及びフランジ部同士の接触面の性状に関係なく安定した継手性能を得ることができる。また、摩擦撹拌接合の進行方向を適切に規定しているので、高い接合強度を得ることができる。特に、乗用車、トラック及びバス等の自動車若しくは二輪車等に使用される燃料タンク、又は半導体製造装置用の真空チャンバ等の箱状の製品等に本発明を適用すると、極めて優れた気密性及び液密性等の密閉性を得ることができる。
【図面の簡単な説明】
【図1】本発明の実施例に係る接合容器の製造方法における各部材を示す斜視図である。
【図2】本発明の実施例において使用する摩擦撹拌接合(FSW)用ツールを示す正面図である。
【図3】本発明の実施例におけるFSW用ツールと上部容器本体1b及び下部容器本体2bとの位置関係を示す図であって、(a)は上面図、(b)は(a)におけるA−A線に沿った断面図である。
【図4】接合容器の上部容器部材1からみた上面図であって、フランジ部を示す拡大図である。
【図5】本発明の第2の実施例に係る接合容器の製造方法を示す断面図である。
【図6】引張試験における荷重部分及び荷重方向を示す模式図である。
【符号の説明】
1、2;容器部材
1a、2a;フランジ部
1b、2b;容器本体
2c;開口部
4;溶接線
5;接合部
5a、5b、5c;リベット
10;基部
11;ピン部
12;ネジ部
20;ツール
21;上板
22;下板
23;接合部[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a junction container made of aluminum or an aluminum alloy, and in particular, a junction container suitable for a fuel tank used for automobiles or motorcycles such as passenger cars, trucks and buses, or a vacuum chamber for a semiconductor manufacturing apparatus. It relates to the manufacturing method.
[0002]
[Prior art]
Conventionally, fuel tanks used for automobiles such as two-wheeled vehicles, passenger cars, trucks, buses, and special vehicles are made of steel, synthetic resin, aluminum, and various clad plates. As such a fuel tank, Japanese Patent Laid-Open No. 8-323487 discloses a steel tank. The conventional steel fuel tank described in this publication (conventional example 1) has two box-shaped members formed of steel plates and having openings, and the opening peripheries of these two box-shaped members A flange portion is formed outward, the flange portions of the openings of the two box-shaped members are overlapped, and the flange portions are welded by seam welding.
[0003]
Japanese Utility Model Laid-Open No. 5-273 discloses a fuel tank made of aluminum or aluminum alloy for storing liquid fuel such as gasoline or light oil, which is attached to a truck and an industrial machine. The fuel tank described in this publication (conventional example 2) has a cylindrical tank body made of aluminum or aluminum and two end plates that close both openings of the tank body, and an inner side is provided at the periphery of the end plate. An inward flange bent at a substantially right angle is formed. Further, a welded joint that is inclined at an inclination angle of about 15 ° toward the inner side of the tank is provided at the flange portion, and an opening end of the tank body is attached to the welded joint and is welded and fixed by inert gas arc welding. ing. The fuel tank of Conventional Example 2 configured as described above can absorb a dimensional error between the tank body and the end plate, can be easily sized, and can provide a clean weld.
[0004]
[Problems to be solved by the invention]
However, in the technique of Conventional Example 1, there is a problem in that the amount of heat input is large when resistance seam welding is performed by overlapping the flange portions of a steel box-shaped member. In particular, when a member having a flange portion made of aluminum or aluminum alloy rather than steel is seam-welded, the amount of heat input is large, so that the aluminum or aluminum alloy plate is distorted and the dimensional accuracy is lowered. For example, when a box-shaped member made of aluminum or an aluminum alloy is used as a fuel tank and welded by seam welding, there is a problem in that the sealing performance of gas and liquid deteriorates when the dimensional accuracy is lowered. Since the fuel tank stores liquid fuel such as gasoline, it is necessary to seal the gas component that volatilizes from the liquid fuel together with the liquid fuel, and it is extremely dangerous if the airtightness deteriorates. Also, in seam welding, if the contact surface between the flanges is not flat or an oxide film or the like is formed, the resistance becomes higher or the resistance becomes non-uniform, so the heat flow is further increased and welding is performed. There is also a problem that the heat-affected zone of the section becomes large.
[0005]
In the technique of Conventional Example 2, the main body of the fuel tank and the end plate are brought into contact with each other and welded and fixed by inert gas arc welding. It is necessary to pay attention not only to the surface part that directly receives a heat source such as a laser, but also to the surface properties of the surfaces where the members are in contact with each other. If this is neglected, defects will occur in the welded part and the penetration will not be stabilized. In addition, there is a problem that the sealing performance of gas and liquid becomes insufficient. If bubbles occur in the melted part, the welded part solidifies faster than it rises, and the bubbles remain as blowhole defects, so if there are many blowhole defects, the defective parts are connected or the defective part When mechanical stress is applied to the metal, cracks may occur and the sealing properties of gas and liquid will deteriorate. Moreover, since the heat affected zone by arc welding is relatively large, the heat affected zone of the base metal is generated in a wide range. For this reason, there is a problem that the base material in the vicinity of the joint is greatly softened, and it is difficult to obtain a necessary sealing property due to the deformation of the base material.
[0006]
The present invention has been made in view of such a problem, and it is possible to obtain a high gas and liquid hermeticity with a small amount of heat input during joining and a high joining strength regardless of the surface properties of the joint. It aims at providing the manufacturing method of a container.
[0007]
[Means for Solving the Problems]
The method for manufacturing a bonded container according to the present invention includes an upper container member made of aluminum or aluminum alloy having a flange portion that is open to the outside and projecting to the outside over the entire periphery of the opening portion, and an opening that is open to the top. A step of superimposing the lower container member made of aluminum or aluminum alloy with a flange portion projecting to the outside over the entire periphery of the portion between the flange portions, temporarily fixing the flange portion, and forming a screw on the surface And a step of performing friction stir welding on the flange portion along the entire periphery with the tool made, the step of performing the friction stir welding is performed in a direction in which the screw enters the flange portion. When the rotation direction is the forward rotation direction, the friction stir welding is performed while the tool revolves around the main body portion of the upper container member in the forward rotation direction. It characterized by having a cormorants process.
[0008]
In the present invention, when the tool is in the forward rotation direction, that is, when the screw is a left-hand screw, the screw enters the flange portion by left-turning, so that the main body portion is always on the left side (left-turning direction). When the screw is a right-hand screw, the screw enters the flange part by rotating it to the right. Therefore, the flange parts are friction stir welded while revolving in the direction that the main body part is always on the right side (right-rotating direction). Therefore, not only the advantage of friction stir welding, but also high strength can be secured at the joint and its vicinity due to the influence of thermal diffusion and the like.
[0009]
The step of temporarily fixing the flange portion may be mechanically joined using self-drilling rivets or mechanical clinching, welded by resistance spot welding, or bent while the flange portion is overlapped. It can be a process.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the manufacturing method of the junction container concerning the Example of this invention is demonstrated concretely with reference to attached drawing. FIG. 1 is a perspective view showing each member in a method for manufacturing a bonded container according to an embodiment of the present invention.
[0011]
In the present embodiment, as shown in FIG. 1, an upper container member 1 having a lower opening and a lower container member 2 having an upper opening are bonded to manufacture a bonded container. The upper container member 1 and the lower container member 2 are both made of aluminum or an aluminum alloy. The lower container member 2 is integrally formed with a flange portion 2a that is bent by about 90 ° and protrudes outward from the lower container body 2b over the entire periphery of the opening 2c. Similarly, the upper container member 1 is integrally formed with a flange portion 1a that is bent by approximately 90 ° and protrudes outward from the upper container body 1b over the entire periphery of the opening.
[0012]
In the present embodiment, first, the flange portions of the upper container member 1 and the lower container member 2 are overlapped. Next, in order to perform the friction stir welding more reliably, both the overlapped flange portions are temporarily fixed. As a temporary fixing method to be performed before the friction stir welding is performed by superimposing both flange portions, a method of mechanical joining using a self-drilling rivet or mechanical clinching or a method of welding by resistance spot welding or the like, etc. There is. In this embodiment, a self-piercing rivet is used, and a plurality of rivets are temporarily fixed by driving a plurality of rivets around the opening.
[0013]
Thereafter, the temporarily fixed flange portion is joined by friction stir welding along its entire periphery. FIG. 2 is a front view showing a friction stir welding (FSW) tool used in the embodiment of the present invention. FIG. 3 is a view showing the positional relationship between the FSW tool and the upper container body 1b and the lower container body 2b according to the embodiment of the present invention, where (a) is a top view and (b) is an A- It is sectional drawing along the A line.
[0014]
The FSW tool 20 used in this embodiment is provided with a base portion 10 and a pin portion 11 formed at the tip of the base portion 10. The diameter of the pin portion 11 is smaller than that of the base portion 10, and a screw portion 12 is formed on the surface thereof. The screw portion 12 is, for example, a left screw. Since the left screw enters the material by left rotation, in this case, forward rotation is left rotation and reverse rotation is right rotation.
[0015]
In this embodiment, as shown in FIG. 3, the FSW tool 20 is always moved with the direction in which the upper container main body 1b is present on the left side as the traveling direction, and the temporarily fixed flange portion is moved to the whole. Friction stir welding is performed along the periphery. Note that friction stir welding may be performed all around the opening along the shape of the opening of the upper container member 1 and the lower container member 2. FIG. 4 is a top view of the joining container as seen from the upper container member 1 and is an enlarged view showing the flange portion. As shown in FIG. 4, the friction stir welding is performed, for example, so as to pass over a rivet 5 a that is temporarily fixed by overlapping the flange portion 1 a of the upper container member 1 and the flange portion 2 a of the lower container member 2.
[0016]
Next, the friction stir welding will be described in more detail. As shown in FIG. 3B, first, after the flange portion 1a and the flange portion 2a are overlapped, the flange portion 2a side of the lower container member 2 among the overlapped flange portions is a backing material (surface plate). ) (Not shown). Next, the tool 20 in which the screw portion 12 of the left screw is formed on the pin portion 11 is projected to the flange portion 1a from above the overlapped flange portions 1a and 2a while rotating by, for example, right rotation (reverse rotation). . Then, the contact portion between the rotating pin portion 11 and the flange portion 1a is softened and plasticized by frictional heat between the pin portion 11 and the flange portion 1a, and press-fitted while being stirred by the pin portion 11, and the flange portions 1a and 2a are inserted. Make plastic flow. Further, in a state where the pin portion 11 is rotating, the tool 20 is "rotated counterclockwise (with respect to the flange portions 1a and 2a) while applying a certain pressure along the entire periphery of the upper container member 1 and the lower container member 2. Friction stir welding with relative movement (revolution) ". Thereby, the flange part 1a and the flange part 2a are joined, and the junction part 5 is formed, and as shown in FIG. 4, the joining line 4 is formed in the joining position of the flange parts 1a and 2a. In the present embodiment, the diameter T1 of the base 10 in the tool 20 used for friction stir welding is, for example, 10 mm, the diameter T2 of the pin portion 11 is, for example, 4 mm, and the length h of the pin portion 11 is, for example, 1.8 mm. The rotation speed of the tool 20 is, for example, 3000 rpm, and the feed speed is, for example, 400 mm / min.
[0017]
According to such a 1st Example, it is especially necessary to give special consideration for joining about the surface of the flange parts 1a and 2a in which a pin part is press-fit, and the property of the surface where flange parts contact. It ’s not a problem. Therefore, stable joint performance can be exhibited regardless of the properties of these surfaces. Further, since friction stir welding is performed, the amount of heat input is smaller than that of fusion welding such as arc welding, and the influence of distortion or the like due to heat of the joining member is small. Therefore, it is suitable for bonding of a container such as a box-shaped product such as a tank as in this embodiment, which requires sealing of gas and liquid, and obtains extremely excellent sealing of gas and liquid. Can do.
[0018]
Moreover, since the groove | channel which has the flange parts 1a and 2a is piled up and welded, the upper and lower container members 1 and 2 contact each other in a plane. Therefore, if it is not fixed properly, it may be possible that deformation of the opening and slipping on the surface of the flange portion are likely to occur during welding, but in this embodiment, temporary fixing is performed before friction stir welding. Since this is done, the upper and lower container members 1 and 2 do not slide. Further, it is possible to secure a stable joint and desired dimensional accuracy by suppressing deformation such as opening. Further, since the friction stir welding does not use a filler material, even if the friction stir welding is performed on the temporarily fixed portion as it is, without changing the components of the aluminum or aluminum alloy that is the material of the upper and lower container members 1 and 2. A stable joint can be created.
[0019]
Further, since the process is performed on the temporarily fixed rivet 5a, the bonding wire 4 does not leave behind the temporary fixing. Furthermore, if an appropriate material is selected as the rivet material, for example, the strength of the friction stir joint can be improved by stirring the driven rivet with the pin portion 11 together with the flange portion. Thus, the material of the temporary fixing rivet or clinching for improving the strength is not particularly limited as long as it is higher in strength than the material of the flange portion, but from the viewpoint of recycling, for example, It is preferable to use a high-strength aluminum alloy such as 2000 series or 7000 series.
[0020]
Furthermore, the screw portion 12 formed on the pin portion 11 is a left-hand thread, and the direction of friction stir welding (the direction of revolution) is always the direction in which the outer wall of the upper container body 1b is on the left side. High strength can be secured around the joint 5 due to the influence of heat transfer or the like. In the first embodiment, the rotation direction of the rotation of the FSW tool 20 is right rotation (reverse rotation). However, when this rotation is left rotation (forward rotation), the plastic flow portion for FSW The upward convection associated with the rotation of the tool 20 can be suppressed, and the upward lifting of the interface between the flange portions 1a and 2a can be prevented. For this reason, the intensity | strength of the flange part 1a in the junction part 5 vicinity can be maintained higher, and it is more preferable.
[0021]
In the case where the screw portion 12 is a right-hand thread, the traveling direction of friction stir welding (the rotational direction of revolution) may always be the direction in which the outer wall of the upper container body 1b is on the right side. Also in this case, the rotation direction of the rotation of the FSW tool 20 may be either the right rotation or the left rotation, but from the viewpoint of preventing the above-described lifting of the interface, it is assumed to be the forward rotation, in this case, the right rotation. Is more preferable.
[0022]
Also, frictional stirring is performed by temporarily fixing with the rivet 5b on the end side of the flange portion 1a from the position where the joining line 4 is to be formed, or by temporarily fixing with the rivet 5c on the upper container body 1b side. You may make it the joining line 4 by joining not pass on the rivet 5b or 5c temporarily fixed. In the case of mechanical clinching or resistance spot welding, temporary fixing can be similarly performed at any position. Further, when the temporary fixing position by the rivet 5b or the like is set to the outside of the joint line 4 which is friction stir welded, the end portions of the overlapped flange portion 1a and flange portion 2a are turned up by the friction stir welding and the accuracy of the overlap is achieved. Can be prevented from decreasing. In the case of spot welding instead of mechanical joining as in the present embodiment as temporary fixing, for example, an electrode having a base diameter of 16 mm and a tip radius of 75 mm is used, and the applied pressure is 2 It is possible to perform welding at 0.7 kN and a welding current of 25 kA. In addition, friction stir welding may be directly performed after the upper and lower container members are overlapped without performing such temporary fixing. Furthermore, the temporary fixing method is not limited to the above-described method as long as the upper and lower container members can be fixed to such an extent that they do not shift during friction stir welding.
[0023]
Furthermore, in this embodiment, the friction stir welding is performed by pushing the rotating FSW tool 20 to the flange portions 1a and 2a in a state where the flange portions 1a and 2a are horizontally installed. For example, FIG. The two container members shown may be installed in such a state that their flange portions are vertical, and the flange portions may be friction stir welded together.
[0024]
Next, a second embodiment of the present invention will be described. In the second embodiment, after the upper container member and the lower container member are overlapped, temporary fixing is performed by bending the end portion of the overlapped flange portion. FIG. 5 is a cross-sectional view showing a method for manufacturing a bonded container according to a second embodiment of the present invention.
[0025]
In the second embodiment, similar to the first embodiment, after the flange portions 1a and 2a of the upper container member 1 and the lower container member 2 are overlapped, the end portions of the flange portions 1a and 2a are For example, bending is performed so as to be folded back to the upper container member 1 side so as to be in contact with the unfolded portion of the flange portion 1a. Thereafter, as in the first embodiment, friction stir welding is performed by relatively moving the pin portion along the shape of the opening of the upper container body 1b at the flange portion where there is no overlap due to folding. At this time, if the threaded portion is a left-hand thread, the rotation direction of the revolution is the left rotation, that is, the direction in which the upper container body 1b is always on the left side. On the other hand, if the threaded portion is a right-hand thread, the rotational direction of revolution is the right rotation, that is, the direction in which the upper container body 1b is always on the right side.
[0026]
According to the second embodiment as well, similarly to the first embodiment, it is possible to obtain a stable joint and desired dimensional accuracy by suppressing side slip and opening deformation of the upper and lower container members 1 and 2. An effect such as being able to be obtained can be obtained. In the present embodiment, the folded end portions of the flange portions 1a and 2a have a four-layer structure, so that higher strength can be obtained.
[0027]
Thus, the joining container manufactured by the 1st and 2nd Example is suitable for the fuel tank for motor vehicles made from aluminum or aluminum alloy, for example.
[0028]
In addition, when the thickness of the flange part of two container members differs, it is preferable to arrange | position so that an upper flange part may become thick in performing friction stir welding.
[0029]
【Example】
Examples of the present invention will be specifically described below in comparison with comparative examples that depart from the scope of the claims.
[0030]
First, two container members were temporarily fixed, and these container members were friction stir-joined under the conditions shown in Table 1 below using a tool having a pin portion on which a threaded portion of a left screw was formed. In Examples 1 and 2, the welding line is formed while revolving the tool in a direction in which the container body of the container member is always on the left side (forward rotation). In Comparative Examples 3 and 4, the container body is always in the direction on the right side ( The weld line was formed while revolving the tool in reverse rotation. Each container member was made of JIS A5182-O aluminum alloy, and the rotation direction of the tool was the reverse rotation direction.
[0031]
Subsequently, the tensile test of the joint part formed by friction stir welding was performed. FIG. 6 is a schematic diagram showing a load portion and a load direction in a tensile test. In the tensile test, the upper plate 21 and the lower plate 22 were pulled across the joint 23 to measure the breaking position and breaking load. The results are shown in Table 2 below.
[0032]
[Table 1]
Figure 0003960755
[0033]
[Table 2]
Figure 0003960755
[0034]
As shown in Table 2 above, according to Examples 1 and 2 included in the scope of the present invention, high breaking strength could be obtained. In particular, in Example 2 where the upper plate 21 is thicker, higher breaking strength was obtained.
[0035]
On the other hand, in Comparative Examples 3 and 4 deviating from the scope of the present invention, high breaking strength was not obtained, and breakage sometimes occurred during joining.
[0036]
【The invention's effect】
As described above in detail, according to the present invention, since the flange portion is joined by friction stir welding, the amount of heat input is small, and stable joint performance is obtained regardless of the properties of the surface of the flange portion and the contact surface between the flange portions. Obtainable. Moreover, since the advancing direction of friction stir welding is appropriately defined, high bonding strength can be obtained. In particular, when the present invention is applied to a fuel tank used in automobiles or motorcycles such as passenger cars, trucks and buses, or box-shaped products such as vacuum chambers for semiconductor manufacturing apparatuses, etc., extremely excellent airtightness and liquid tightness are obtained. The sealing property such as the property can be obtained.
[Brief description of the drawings]
FIG. 1 is a perspective view showing each member in a method for manufacturing a bonded container according to an embodiment of the present invention.
FIG. 2 is a front view showing a friction stir welding (FSW) tool used in an embodiment of the present invention.
FIGS. 3A and 3B are views showing a positional relationship between the FSW tool and the upper container body 1b and the lower container body 2b in the embodiment of the present invention, where FIG. 3A is a top view and FIG. It is sectional drawing along the -A line.
FIG. 4 is a top view of the joining container as seen from the upper container member 1 and is an enlarged view showing a flange portion.
FIG. 5 is a cross-sectional view illustrating a method for manufacturing a bonded container according to a second embodiment of the present invention.
FIG. 6 is a schematic diagram showing a load portion and a load direction in a tensile test.
[Explanation of symbols]
1, 2; Container members 1a, 2a; Flange portions 1b, 2b; Container body 2c; Opening portion 4; Weld line 5; Joint portions 5a, 5b, 5c; Rivet 10; Tool 21; upper plate 22; lower plate 23; joint

Claims (2)

下方が開口しその開口部の全周縁に亘って外部に突出するフランジ部が形成されたアルミニウム又はアルミニウム合金製上部容器部材と、上方が開口しその開口部の全周縁に亘って外部に突出するフランジ部が形成されたアルミニウム又はアルミニウム合金製下部容器部材とをそのフランジ部同士で重ね合わせ、前記フランジ部を仮止めする工程と、表面にネジが形成されたツールにより前記フランジ部を全周縁に沿って摩擦撹拌接合を行う工程とを有する接合容器の製造方法において、前記摩擦撹拌接合を行う工程は、前記ネジが前記フランジ部中に進入する方向の回転方向を順回転方向としたとき、前記ツールを前記上部容器部材の本体部分の周囲を順回転方向で公転させながら前記摩擦撹拌接合を行う工程を有することを特徴とする接合容器の製造方法。An upper container member made of aluminum or aluminum alloy in which a lower portion is opened and a flange portion is formed projecting to the outside over the entire periphery of the opening portion, and an upper portion is opened and projects to the outside over the entire periphery of the opening portion. The flange or the lower container member made of aluminum or aluminum alloy is overlapped with each other, the flange is temporarily fixed, and the flange is made around the entire periphery by a tool having a screw formed on the surface. And a step of performing friction stir welding along the friction stir welding, the step of performing friction stir welding is performed when the rotation direction of the direction in which the screw enters the flange portion is a forward rotation direction. And a step of performing the friction stir welding while revolving a tool around the body portion of the upper container member in a forward rotation direction. Method of manufacturing the container. 前記フランジ部を仮止めする工程は、自己穿孔型リベット若しくはメカニカルクリンチングを使用して機械的に接合するか、抵抗スポット溶接により溶接するか、又は前記フランジ部を重ねたまま折り曲げ加工する工程であることを特徴とする請求項1に記載の接合容器の製造方法。The step of temporarily fixing the flange portion is a step of mechanically joining using self-drilling rivets or mechanical clinching, welding by resistance spot welding, or bending the flange portion while overlapping. The method for manufacturing a bonding container according to claim 1, wherein the method is provided.
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