JP4923970B2 - Friction spot joint evaluation method and apparatus - Google Patents

Description

  The present invention relates to a method and an apparatus for evaluating a joint portion of a friction point joint in which a rotating tool is pressed against a superposed metal member, softened by frictional heat, and plastically flowed to join.

  Conventionally, in order to reduce the weight for the purpose of improving the fuel consumption of automobiles, aluminum alloy materials have been frequently used as body materials for automobiles and the like. Along with this, there are increasing opportunities to join a member made of, for example, an aluminum alloy and a member made of an iron material or the like.

  However, when members made of such dissimilar metal materials are joined by fusion welding such as arc welding, there is a problem that a brittle intermetallic compound is generated and the joining strength is lowered. In addition, the cost of the joining such as rivet joining becomes high.

  Therefore, a joining method called friction spot joining has attracted attention as a method capable of joining members made of different metal materials at low cost. For example, as shown in Patent Document 1, this bonding method includes a first metal member made of an aluminum alloy material or the like, and a second metal member made of an iron material or the like having a melting point higher than that of the first metal member. The tip of the rotating tool that rotates about the axis is pushed from the side of the first metal member against the stacked workpiece, and the first is generated by the frictional heat generated by the rotation of the rotating tool and the pressing operation on the first metal member. By softening and plastically flowing the metal members, both metal members are solid phase welded (solid phase bonding) at a temperature below the melting point.

  By the way, after performing such friction point joining, the quality of the joining state is evaluated as necessary, for example, for the purpose of inspection or the like. Patent Document 2 discloses an evaluation method for joining aluminum alloy plates together. In this method, a detecting means is provided on a receiving base that is disposed on the opposite side of the rotary tool with respect to the workpiece and receives the pressing force of the rotary tool. And since this receiving pressure is equal, the pressing force of a rotary tool acts equally and it is considered that favorable joining was performed.

As the detection means, firstly, a concave portion (a convex portion is also allowed) provided in the cradle is cited. The metal member that comes into contact with the cradle by the pressing force of the rotary tool leaves an indentation at a location where the metal member comes into contact with the recess. It is detected that the pressure is applied evenly when the indentations remain evenly. As the second detecting means, a pressure sensor provided on a cradle is cited.
JP 2005-34879 A JP 2003-334671 A

  However, the evaluation method disclosed in Patent Document 2 is not always a practical method. For example, when the metal that contacts the cradle is made of a material that is considerably harder than an aluminum alloy plate such as a steel plate, no impression remains suitable for evaluation, and even if a pressure sensor is used, sufficient accuracy cannot be expected. .

  Therefore, in such a case, in reality, we had to rely on the chisel inspection and the destruction measurement. The chisel inspection is a non-destructive inspection method generally performed in spot welding, and is a method in which the chisel is press-fitted between two metal plates to measure the diameter of the peripheral portion of the weld nugget (joint portion). The fracture measurement is, for example, a strength test using a load tester.

  However, nondestructive measurement such as chisel inspection could not directly evaluate the joint quality of the friction spot joint. Further, in the case of non-destructive measurement, since it is inevitably a sampling inspection, it cannot be adopted when a total inspection is necessary. In any case, these methods are difficult to automate, and an increase in inspection man-hours is inevitable.

  An object of this invention is to provide the method and apparatus which can evaluate the joining quality of a friction point joining part easily and highly accurately by non-destructive in view of the above situations.

The invention according to claim 1 for solving the above-mentioned problem is a first metal member made of an aluminum alloy plate, and a steel plate having a melting point higher than that of the first metal member and having a metal plating layer formed on the surface. Two metal members are overlapped, and the first metal member and the first metal member are extruded by extruding the metal plating layer from the joint portion by softening and plastically flowing the first metal member with frictional heat by rotating and pressing the rotary tool. This is a method for evaluating a joint part of a friction spot joint in which two metal members are joined in a solid state, and a burr shape range that satisfies the joint quality is allowed in advance for the burr generated at the peripheral edge of the concave part of the joint part. It is set as a burr range, the burr shape to be evaluated is measured, and whether the measured burr shape is within the allowable burr range or not is evaluated as to whether or not the bonding portion is bonded. Kosuten the evaluation method of the bonded portion.

  According to a second aspect of the present invention, in the method for evaluating a frictional spot joint according to the first aspect, the allowable burr range is that at least a deviation of a radial thickness in a plan view of the burr is not more than a predetermined reference value. It is characterized by including.

According to a third aspect of the present invention, the first metal member and the second metal member having a melting point higher than that of the first metal member are overlapped, and the first metal member is softened by frictional heat by the rotation and pressing of the rotary tool, thereby being plastic. An apparatus for evaluating a joint part of a friction spot joint that causes the first metal member and the second metal member to join in a solid phase by flowing, and joins a burr generated at a peripheral edge of a concave portion of the joint part. A storage means for preliminarily storing a burr shape range satisfying quality as an allowable burr range, a measurement means for measuring the burr shape to be evaluated, and comparing the measured burr shape with the permissible burr range. Evaluation means for evaluating whether or not the joining portion is good depending on whether or not it is within an allowable burr range, and the measuring means includes an imaging means for picking up the joint portion in a plan view. Based on the plane image of Evaluation device of the friction spot joining portions, characterized by measuring the burr shape

According to a fourth aspect of the present invention, in the friction spot joint evaluation apparatus according to the third aspect, the allowable burr range is that at least a deviation of a radial thickness in a plan view of the burr is not more than a predetermined reference value. It is characterized by including.

  According to the first aspect of the present invention, as will be described below, it is possible to easily and accurately evaluate the joint quality of the frictional spot joints in a non-destructive manner.

When the friction spot welding is performed, a recess is formed in the joint pressed by the rotary tool. And the burr | flash is formed in the peripheral part by the metal member pushed away by the rotary tool. The inventor of the present application has found that there is a particularly close relationship between the burr shape and the joining quality in joining the aluminum alloy plate and the steel plate on which the metal plating layer (for example, zinc plating) is formed. In such a joining form, the burr shape and the joining quality are closely related by the following mechanism. When joining an aluminum alloy plate and a steel plate on which a metal plating layer is formed by friction point joining, the rotary tool is usually pressed from the aluminum alloy plate. The aluminum alloy is softened and plastically flowed by frictional heat. At that time, it is important to sufficiently remove the metal plating layer existing at the joint interface of both members from the joint interface to obtain a good joint. Become. This is because if the metal plating layer remains, solid phase bonding between aluminum and iron is hindered.
When observing the relationship between the burr shape and the removal status of the metal plating layer, it was found that when the burr was properly formed, the metal plating layer flowed greatly and it was completely removed. It was found that when the burrs are small or uneven and are not formed properly, the flow of the metal plating layer is small and the removal thereof is incomplete. As described above, the burr shape has a close relationship with the removal of the metal plating layer from the bonding interface, which has a great influence on the bonding quality. Therefore, the bonding quality can be evaluated with high accuracy by measuring this.

  Therefore, if the burr shape range that satisfies the joining quality is set in advance as the allowable burr range, and it is determined whether or not the burr shape of the joint to be evaluated is within the allowable burr range, it is easy and highly accurate. In addition, the quality of the bonding quality can be evaluated. Moreover, according to this evaluation method, since only the burr | flash shape of a junction part is measured, it can carry out by nondestructive and can also respond easily to automation or 100% inspection.

  The allowable burr range may be digitized data, or the burr shape itself or image data obtained by performing image processing thereon.

  According to the invention of claim 2, an effective allowable burr range can be set. The inventor of the present application has found that the deviation of the radial thickness in the plan view of the burr is particularly closely related to the bonding quality. That is, when this deviation is large, the bonding quality is deteriorated. Therefore, for example, it is effective to set an allowable burr range such as “the ratio between the maximum thickness and the minimum thickness of the burr is a predetermined reference value (eg, 2.0) or less”.

  The present invention is not intended to exclude other allowable burr range settings. Examples of other allowable burr range settings include “maximum burr thickness not greater than a predetermined reference value” and “minimum burr thickness not less than a predetermined reference value”. You may make it raise.

  Therefore, when observing the relationship between the burr shape and the removal status of the metal plating layer, it was found that when the burr was properly formed, the metal plating layer flowed greatly and it was completely removed. It was found that when the burrs are small or uneven and are not formed properly, the flow of the metal plating layer is small and the removal thereof is incomplete.

  As described above, the burr shape has a close relationship with the removal of the metal plating layer from the bonding interface, which has a great influence on the bonding quality. Therefore, the bonding quality can be evaluated with high accuracy by measuring this.

  The application of the relationship between the burr shape and the bonding quality is not limited to the case where a metal plating layer is interposed. For example, even in the case where an oxide film is formed on one or both metal surfaces at the bonding interface, it is important to sufficiently destroy the oxide film. There is a relationship.

According to the invention of claim 3 , it is possible to easily measure the burr shape in a non-destructive and non-contact manner only by imaging the joint portion with the imaging means. The imaged burr shape is transformed into a form that can be compared with the allowable burr range as necessary (for example, noise removal, digitization of burr thickness, etc.). When the allowable burr range is image data or the like that defines the range of the burr shape itself, the evaluation may be performed by superimposing the captured image and the image data of the allowable burr range.
According to a fourth aspect of the invention, the friction point joint evaluation device has the same effect as that of the second aspect of the invention.

  Embodiments of the present invention will be described below with reference to the drawings. Prior to describing the evaluation method and apparatus for a frictional spot joint according to the present embodiment, an outline of a frictional spot joint suitable for the present embodiment will be described.

  FIG. 1 is a perspective view schematically showing friction point welding suitable for this embodiment. In this friction point joining, the first metal member 11 and the second metal member 12 having a melting point higher than that of the first metal member 11 are joined. As the first metal member 11, for example, an aluminum alloy plate is suitable, and as the second metal member 12, a steel plate on which a metal plating layer (galvanization layer Z shown in FIG. 3 in this embodiment) is formed is suitable. Hereinafter, the first metal member 11 and the second metal member 12 are collectively referred to as a workpiece 10.

  First, as shown in FIG. 1, the 1st metal member 11 and the 2nd metal member 12 are piled up, and the junction point 13 is set to the 1st metal member 11 side (low melting-point metal member side) of the superposition | polymerization part. Then, the substantially cylindrical rotary tool 16 is pressed around the axis (arrow A1) and pressed against the joining point 13 in the axial direction (arrow A2).

  Further, a receiving tool 17 having the same diameter as or larger than that of the rotary tool 16 is disposed coaxially with the rotary tool 16 on the opposite side of the rotary tool 16 with the workpiece 10 interposed therebetween. The receiving member 17 moves in a direction approaching the rotary tool 16 with the workpiece 10 interposed therebetween, and at least the tip thereof is brought into contact with the second metal member 12 until pressing by the rotary tool 16 is started. When the rotary tool 16 is pressed, the pressing force is received.

  The rotary tool 16 and the receiving tool 17 are mounted on a friction point joining device (not shown), and the rotational speed, pressing position, pressing force, pressurizing time, and the like are appropriately controlled. Although not shown in FIG. 1, jigs such as spacers and lift prevention plates are used as appropriate in order to prevent the first metal member 11 from lifting when the workpiece 10 is fixed in advance and the rotary tool 16 is pressed. It is done.

  FIG. 2 is an enlarged view of the distal end portion of the rotary tool 16. The left half shows a longitudinal section. The tip of the rotary tool 16 is positioned on the shoulder 16b facing the workpiece 10 and the rotational axis X of the rotary tool 16, which is the lower end surface of the cylindrical body 16a (the outline is circular). And a pin portion 16c that is smaller than the outer diameter of the shoulder portion 16b and protrudes by a predetermined length h from the shoulder portion 16b to the side facing the workpiece, and the shoulder portion 16b around the pin portion 16c. It is comprised by the annular recessed part 16d. The bottom surface of the annular recess 16d is inclined in a conical shape. As specific dimensions of the rotary tool 16, for example, the diameter D1 of the shoulder portion 16b is 10 mm, the diameter D2 of the pin portion 16c is 2 mm, the protruding length h of the pin portion 16c is 0.3 mm to 0.35 mm, an annular recess The inclination angle (shoulder inclination angle) θ of the bottom surface of 16d with respect to the shoulder portion 16b is set to 5 ° to 7 °.

  However, the optimum shape of the rotary tool 16 is not uniquely determined, and varies depending on the application, such as the material and thickness of the workpiece 10 and the number of workpieces 10 to be overlaid. Therefore, it is desirable to prepare a plurality of types of rotary tools 16 suitable for each application and use them by appropriately replacing them according to the application. The shape of the rotary tool 16 having the annular recess 16d as shown in FIG. 2 is suitable for use in joining different kinds of metal members having different melting points as in this embodiment.

  Next, the joining process by friction point joining will be described. Specifically, the friction point joining process is set to sequentially perform an initial movement process, a first pressing process, a second pressing process, and a third pressing process.

  First, in the initial movement step, the rotary tool 16 and the receiving member 17 are moved to a position sandwiching the joining point 13 of the workpiece 10 as shown in FIG. 1, and both are moved closer (arrows A2, A2). And the receiving tool 17 is made to contact | abut to the 2nd metal member 12, and the rotary tool 16 is moved to an initial position. This initial position is a position where the tip of the pin portion 16 c of the rotary tool 16 is slightly separated from the first metal member 11. In this initial movement process, the rotary tool 16 may be rotated or may not be rotated, but in the present embodiment, in order to be able to immediately shift to the next first pressing process, It is made to rotate at the same rotational speed (1st rotational speed) (arrow A1).

  In the subsequent first pressing step, as shown in FIG. 3, the rotating tool 16 is rotated at the first rotation speed, and the rotating tool 16 is rotated with the first pressure greater than the movement resistance value of the rotating tool 16 in the initial moving step. The 16 shoulder portions 16b and the pin portions 16c are pressed against the first metal member 11 during the first pressurizing time.

  The first pressing force is preferably set to be greater than or equal to 2.45 kN and less than or equal to 3.43 kN than the maximum value of the variation range of the moving resistance value. The first rotation speed is preferably set to 1500 rpm or more and 3500 rpm or less. Furthermore, the first pressurization time is preferably set to 0.2 seconds or more and 2.0 seconds or less. The first pressurizing force, the first rotation speed, and the first pressurizing time are such that the rotary tool 16 is part of the bottom surface of the annular recess 16d with respect to the first metal member 11 (the portion on the side of the rotation axis X having a deep depth). Are set so that the peripheral portion of the shoulder portion 16 b and the pin portion 16 c are pushed to the extent that they contact the first metal member 11 without contacting the first metal member 11.

In the first pressing step, the peripheral portion of the shoulder portion 16b and the pin portion 16c are pressed and contacted with the first metal member 11 while rotating around the rotation axis X of the rotary tool 16, so that the two contacts are made. Friction heat is generated at the part, and this frictional heat is quickly diffused to the part between the two contact parts of the work (the part where the bottom surface of the annular recess 16d is not in contact), and eventually to the entire joint P. The entire portion (joint portion P) facing the shoulder portion 16b in the first metal member 11 is softened well. Further, the galvanized layer Z applied to the surface of the second metal member 12 is also softened at the joint P. Thus, by setting the first pressurizing force, the first rotation speed, and the first pressurizing time within the preferable ranges, the first metal member 11 can be favorably softened without being sheared. become.

  Further, in the initial stage of the first pressing step, the pin portion 16c that protrudes by a predetermined length h from the shoulder portion 16b contacts the first metal member 11 before the shoulder portion 16b. By first bringing the pin portion 16c having such a small diameter into contact with each other, the rotary tool 16 is satisfactorily positioned with a small frictional resistance, and rotational runout in the direction perpendicular to the rotation axis X is suppressed (anchor function). .

  In the subsequent second pressing step, as shown in FIG. 4, while rotating the rotary tool 16 at the second rotational speed, the shoulder portion 16b and the pin of the rotary tool 16 with the second pressurizing force larger than the first pressurizing force. The part 16c is pushed into the first metal member 11 during the second pressurizing time.

  In the second pressing step, the applied pressure increases, so that the shoulder portion 16b and the pin portion 16c of the rotary tool 16 gradually enter the first metal member 11 and the entire bottom surface of the annular recess 16d, that is, the pin portion 16c. The entire shoulder portion 16b including the annular recess 16d contacts the first metal member 11. Accordingly, plastic flow is performed in addition to softening of the first metal member 11 (in the figure, the plastic flow Q is schematically indicated by a broken line).

  Further, in the plastic flow Q, since the annular recess 16d is provided in the shoulder portion 16b (particularly, the annular recess 16d has a conical shape), the first metal member 11 that plastically flows flows in the vertical direction in the figure. Thus, it is possible to suppress the flow from the portion immediately below the rotary tool 16 (joint portion P) to the outside. In addition, the second pressurizing force is concentrated on the joint P by the annular recess 16d, and the plastic flow Q of the first metal member 11 is promoted. In addition, the softened galvanized layer Z is pushed out from the joint P at the joint interface between the first metal member 11 and the second metal member 12, so that the new surface of the second metal member 12 is exposed and illustrated. However, the oxide film formed on the surface of the first metal member 11 by oxygen in the air is destroyed at the joint P, so that the new surface of the first metal member 11 is exposed.

  The second applied pressure is preferably set to 3.92 kN or more and 5.88 kN or less. The second rotation speed is preferably set to 2000 rpm or more and less than 3000 rpm. Further, the second pressurization time is preferably set to 1.0 second or more and 2.0 seconds or less. The second pressure, the second rotation speed, and the second pressurization time are set so that the rotary tool 16 is not pushed deeper than the predetermined insertion position (pushing depth) into the first metal member 11. This indentation depth is a position where the first metal member 11 may become excessively thin and torn off when the rotary tool 16 enters deeper than that.

Although the joining step may be completed upon completion of the second pressing step, the third pressing step is further performed in this embodiment. In the third pressing step, as shown in FIG. 5, the shoulder portion 16b and the pin portion 16c of the rotary tool 16 are rotated with the third pressurizing force smaller than the second pressurizing force while rotating the rotary tool 16 at the third rotational speed. Is pressed against the first metal member 11 during the third pressurizing time.

  In the third pressing step, the pressing force is made smaller than that in the second pressing step, so that the rotary tool 16 is not pushed deeper than the pressing depth into the first metal member 11, and the second pressing step is completed. It will continue to press in position. This prevents the first metal member 11 from being excessively thin and torn and maintains the same temperature as in the second pressing step, and good plastic flow is performed for a long time. .

The third pressure is preferably set to be 0.49 kN or more and 1.47 kN or less than the first pressure. The third rotation speed is preferably set to 1500 rpm or more and 3500 rpm or less. Furthermore, the third pressurization time is preferably set to 0.5 seconds or more and 2.5 seconds or less. The third pressurizing force, the third rotation speed, and the third pressurizing time continue to press the rotary tool 16 against the first metal member 11 at the position when the second pressing step is completed, and the first metal member 11. Are set so as to cause plastic flow.

  In the third pressing step, the metal material extruded by the rotary tool 16 becomes a burr R and rises on the surface of the first metal member 11, and the galvanized layer Z is further extruded from the joint P, and is oxidized. The coating is further destroyed, and the exposed range of each new surface of the first metal member 11 and the second metal member 12 is expanded (the range indicated by x in FIG. 5). As a result, the mating surfaces of the first metal member 11 and the second metal member 12 are solid-phase bonded by friction point bonding, and the bonding strength is stably increased.

  Note that a metal mixture layer Y of a metal (aluminum alloy) constituting the first metal member 11 and a metal constituting the galvanized layer Z is generated in the vicinity of the joint P in the galvanized layer Z.

  Completion of this 3rd press process will complete | finish joining in the one junction part P. FIG. When the joining at the joining portion P is completed, the rotary tool 16 and the receiving tool 17 are separated from the workpiece 10. In the joint P after the completion of the frictional spot welding, as shown in FIG. 6, traces of the shoulder portion 16b and the pin portion 16c remain on the surface of the first metal member 11, and there are burrs around the shoulder portion 16b. R is generated. When proper bonding is performed, the burrs R are uniformly formed over the entire circumference with an appropriate radial thickness.

  Although the above-described joining process normally results in proper joining, improper joining may be performed for some reason and sufficient strength may not be obtained. The actual situation and cause of the defect will be described below.

  The inventor of the present application has noticed that there is a certain common feature in the joint P with insufficient joint strength. This is a feature that there is a bias in the radial thickness of the burr R in plan view.

  FIG. 7 is a view showing a sample of a joint obtained by the joining process, wherein (a) is a plan photograph of a joint (hereinafter referred to as a proper sample) that has been properly joined, and (b) It is a plane photograph of a typical joined portion (hereinafter referred to as a defective sample) that has not been properly joined. (C) and (d) are sketches of (a) and (b), respectively, and are drawn with particular attention to the characteristics of the burr R.

  The joints shown in FIGS. 7A to 7D are obtained under the following conditions.

・ Work 10
1st metal member 11 ... 6000 series aluminum alloy plate (thickness 1.4mm)
Second metal member 12 ... Zn-Al-Mg plated steel sheet (thickness 1.0mm)
・ Main dimensions of rotating tool 16 Shoulder diameter D1 ... φ10mm
Pin diameter D2 ... φ2mm
・ Joint conditions 1st, 2nd, 3rd rotational speed ... 2000rpm each
1st, 2nd, 3rd pressurization time ... Total 5s
Indentation depth 1.2mm

  The tensile shear strength of the obtained joint P was 4.8 kN for the appropriate samples in FIGS. 7A and 7C and 0.5 kN or less for the defective samples in FIGS. 7B and 7D. As is apparent from a comparison between FIGS. 7C and 7D, the appropriate sample has a uniform thickness in the radial direction of the burr R over the entire circumference, whereas the defective sample has a large bias. It is done. That is, in the state shown in FIG. 7D, the burr R is thick on the left side (area E1) and extremely thin on the right side.

  FIG. 8 is a cross-sectional view (photograph) taken along line VIII-VIII of the defective sample shown in FIG. (A), (b) is a composition image, (c), (d) is a characteristic X-ray image of Zn. Further, (a) and (c) are photographs of the area E1 shown in FIG. 7 (d), and (b) and (d) are photographs of the area E2.

  As shown in FIG. 8A, in the area E1 where the burr R is thick, the plastic flow of the first metal member 11 (portion shown in gray) is large, and a large burr R is formed. FIG. 8C is an X-ray image of a portion corresponding to FIG. 8A, and the portion shown in white shows a portion containing a large amount of Zn (zinc), that is, the distribution of metal plating components. Two thin white lines extending in the horizontal direction in the lower position of the figure indicate the metal plating layer formed on the second metal member 12 from the beginning. A thick white line extending vertically in the vicinity of the center of the figure indicates a metal plating component that has been softened and extruded on the joint surface between the first metal member 11 and the second metal member 12 and moved to the outside of the joint P. As shown, this metal plating component is curved in an arch shape above. This indicates that the movement of the metal plating component greatly extends to the burr R portion. On the other hand, the metal plating layer on the surface in contact with the first metal member 11 is almost completely removed (the thin white line disappears) on the center side of the joint P (the right side portion in FIG. 8C). I understand. This portion is a portion corresponding to a cross in FIG. 5, and it is considered that the new surface of the second metal member 12 is exposed and proper solid phase bonding is performed.

  On the other hand, in the area E2 where the burr R is thin, as shown in FIG. 8B, the plastic flow of the first metal member 11 is less than that in the area E1, and a small burr R is formed. FIG. 8D is an X-ray image of a portion corresponding to FIG. 8B, but the white vertical line is thinner and thinner than the area E1. The arch shape extending to the burr R is also small. This indicates that there are few metal plating components that have been extruded from the center side and moved to the outside of the joint P. Further, the metal plating layer on the surface in contact with the first metal member 11 is not completely removed on the center side of the joint P (left side in FIG. 8D) and remains (thin white lines remain). I understand). That is, at this part, at least a sufficient new surface is not exposed on the second metal member 12, and it is considered that proper solid-phase bonding is not performed.

  The bonding strength of the workpiece 10 greatly depends on the area of the solid phase bonding at the bonding portion P. From the above observation results, although this defective sample seemed to be joined at the entire concave portion of the joint P, the proper solid-phase joining was performed only in the vicinity of the area E1, so the joining strength (tensile shear strength) ) Was small.

  This also shows that the quality of solid phase bonding and the shape of the burr R are closely related. That is, at the locations where the burrs R are small, the amount of movement of the metal plating layer is small, and there is a great possibility that sufficient solid phase bonding is not performed. In other words, if there are no extremely small burrs R and a uniform burr R is formed as a whole, it can be said that there is no insufficient portion of solid phase bonding and proper bonding is achieved as a whole.

  Next, the reason why the proper samples shown in FIGS. 7A and 7C may be obtained and the defective samples shown in FIGS. 7B and 7D may be obtained even under the same joining conditions will be described. . The primary cause of the bias in the burr R is the rotational runout of the rotary tool 16. The most worried about the deflection of the rotary tool 16 in the joining step is when the shoulder portion 16b and the first metal member 11 are in contact from the second half of the first pressing step to the first half of the second pressing step. At this time, due to a sudden increase in contact resistance, a certain amount of rotational shake may occur even with the anchor function of the pin portion 16c. As a countermeasure, a method for suppressing rotational runout by contriving the support structure of the rotary tool 16 and the support structure of the receiving member 17 is considered.

  However, as a factor that is often overlooked, sufficient consideration must be given to the installation state of the jig. In the actual joining process, various jigs for fixing the workpiece 10 are used. However, as shown below, the rotational runout of the rotary tool 16 may be deteriorated due to the installation state of the jig, for example, positional deviation. Because.

  FIG. 9 is a perspective view of a test piece 50 for testing the influence of the installation state of the jig on the bonding quality. The test piece 50 is supported by various jigs simulating actual equipment.

  The test piece 50 includes a strip-shaped aluminum alloy plate 51 (corresponding to the first metal member 11) and a galvanized steel plate 52 (corresponding to the second metal member 12) which is also a strip-shaped plate. It consists of. The aluminum alloy plate 51 and the galvanized steel plate 52 are arranged so as to partially overlap in the longitudinal direction. A joining point 55 is set at the approximate center of the overlapping portion in plan view.

  A step is formed between the overlapped portion and the non-polymerized portion of the aluminum alloy plate 51 and the galvanized steel sheet 52, and spacers 61 and 62 (collectively referred to as the spacer 60) are arranged as jigs for filling the step. Yes. The spacer 60 is a strip-like plate like the test piece 50. The spacer 61 is arranged so as to extend the galvanized steel plate 52 with the same thickness as the galvanized steel plate 52. The spacer 62 is disposed so as to extend the aluminum alloy plate 51 with the same thickness as the aluminum alloy plate 51. As a result, the test piece 50 and the spacer 60 form a single composite plate-like body as a whole.

  On the synthetic plate-like body, a floating prevention plate 71 is polymerized as a further jig. The floating prevention plate 71 is a strip-like plate-like body similar to the test piece 50, and has a length that substantially includes a synthetic plate-like body composed of the test piece 50 and the spacer 60 in plan view. A circular opening 73 penetrating in the vertical direction is provided at substantially the center in the longitudinal direction of the lifting prevention plate 71. Therefore, the aluminum alloy plate 51 in the vicinity of the joining point 55 is exposed. A clamp position 75 is set at a location near the both ends in the longitudinal direction of the lifting prevention plate 71 where at least the composite plate-like body is formed.

  The test piece 50 is joined in the following procedure. First, the clamp position 75 is pressed by a clamp (not shown), and the test piece 50, the spacer 60, and the lifting prevention plate 71 are fixed in an integrated state. Thereafter, the test piece 50 is joined by the joining process using the rotary tool 16 and the receiving member 17.

  In fixing the test piece 50 and the like, the initial position (reference position) of the lifting prevention plate 71 is a position where the center of the opening 73 coincides with the joining point 55. In this test, the anti-lifting plate 71 was shifted by a predetermined amount, and a gap was intentionally generated between the center of the opening 73 and the joining point 55. By examining the bonding quality under the conditions, the influence of the displacement of the jig was verified. The test was conducted at two levels of conditions A and B.

(1) Conditions common to conditions A and B-Test piece 50
Aluminum alloy plate 51 ... 6000 series aluminum alloy plate (thickness 1.4mm)
Galvanized steel plate 52 ... Zn-Al-Mg plated steel plate (thickness 1.0mm)
・ Main dimensions of rotating tool 16 Shoulder diameter D1 ... φ10mm
Pin diameter D2 ... φ2mm
Shoulder inclination angle θ: 7 degrees (2-A) Condition A joining conditions: First, second, third rotational speed: 2500 rpm each
1st, 2nd, 3rd applied pressure ... 2.45kN, 4.90kN, 0.98kN in order
1st, 2nd, 3rd pressurization time ... 0.2s, 1.54s, 2.4s in order
Jig misalignment: 0 mm (reference position), 9 mm
(2-B) Condition B Joining Conditions First, Second, Third Rotational Speed: 2500 rpm each
1st, 2nd, 3rd applied pressure ... 2.45kN, 5.39kN, 0.98kN in order
1st, 2nd, 3rd pressurization time ... 0.2s, 2.0s, 2.4s in order
Jig misalignment: 0 mm (reference position), 4 mm, 9 mm

  As a result, in both conditions A and B, when the jig (lifting prevention plate 71) is set at the reference position, the thickness deviation of the burr R is small, and the burr R of the burr R increases as the jig shift amount increases. The thickness deviation became large. In other words, it was found that the installation position deviation of the jig had a strong correlation with the thickness deviation of the burr R.

  FIG. 10 is a graph showing the measurement results of the tensile shear strength of the joint for each of conditions A and B. The horizontal axis shows the amount of deviation (mm) of the jig (lifting prevention plate 71), and the vertical axis shows the tensile shear strength (kN) of the joint. The values of tensile shear strength are 3.6 kN when the jig deviation is 0 mm under condition A, 1.1 kN (NG level) when the jig deviation is 9 mm, and 4 k when the jig deviation is 0 mm under condition B. It was 3.8 kN at 2 kN and 4 mm, and 1.3 kN (NG level) at 9 mm. That is, it was found that there is a strong correlation that the tensile shear strength becomes weaker as the jig installation position shift is larger.

  From the above results, it can be said that in order to obtain better bonding quality, it is effective to appropriately set the shape and arrangement of the jig and to suppress the positional deviation of the jig in the bonding process.

  Further, the above results show that there is a close relationship between the bias of the burr R and the bonding quality (bonding strength), but the inventor of the present application has repeated such an experiment, and the shape of the burr R has a predetermined tolerance. When in the burr range Ba, it was confirmed that the joining quality of the joint P was satisfied.

  It is effective that the allowable burr range Ba satisfies the following judgment formula 1.

Burr thickness ratio Br <reference value G1 (judgment formula 1)
However, the burr thickness ratio Br = (maximum burr thickness Bmax) / (minimum burr thickness Bmin)
The burr thickness ratio Br is an index indicating the deviation of the radial thickness in a plan view of the burr R. Further, the reference value G1 may be appropriately set depending on the material and plate thickness of the workpiece 10 and other joining conditions. In this embodiment, the reference value G1 = 2.0 is appropriate.

  Although it may be determined that the burr R is within the allowable burr range Ba by satisfying (judgment formula 1), the burr R is determined to be combined with other conditions and when all or part of them is satisfied. It may be determined that it is within the allowable burr range Ba. For example, the following judgment formula 2 and judgment formula 3 may be added.

Maximum burr thickness Bmax <reference value G2 (judgment formula 2)
Minimum burr thickness Bmin> reference value G3 (judgment formula 3)
The reference values G2 and G3 may be set as appropriate according to the material and thickness of the workpiece 10, other joining conditions, and the like.

  The determination formulas 2 to 3 are also suitable for evaluating whether or not the pressing depth of the rotary tool 16 is within an appropriate range. The pressing depth of the rotary tool 16 is a value set in the second pressing step, but it may increase or decrease due to some factor. If this indentation depth is too shallow, good solid phase bonding cannot be obtained, and if it is too deep, the first metal member 11 may become too thin. Therefore, if it can be easily evaluated that the indentation depth is within the appropriate range, the evaluation accuracy can be further increased. As will be described below with reference to FIG. 11, according to the determination formulas 2-3, the evaluation can be performed by measuring the shape of the burr R.

  FIG. 11 is a graph showing the relationship between the burr thickness and the indentation depth of the rotary tool 16. The indentation depth (mm) is shown on the horizontal axis, and the burr thickness (mm) is shown on the vertical axis. In addition, the thickness of a burr | flash is shown with the average value of four radial direction thickness (B1-B4 shown in FIG. 13) for every 90 degrees of internal angles. The maximum value and the minimum value are shown as the upper and lower limit ranges. The joining conditions other than the indentation depth of the rotary tool 16 were the same.

  As shown in FIG. 11, when the push-in amount is 0.5 mm, 0.8 mm, 0.9 mm, and 1.15 mm, the thickness of the burr is 1.4 mm, 1.7 mm, 1.9 mm, and 2.08 mm (1 .8 to 2.2 mm). The burr thickness ratios Br were 1.0, 1.0, 1.0, and 1.22, respectively. All of them satisfied the standard in light of the above-described judgment formula 1, and were OK levels. In addition, the actual tensile shear strength was 3.0 kN, 4.6 kN, 4.2 kN, 3.8 kN in this order, confirming the OK level.

  As is clear from FIG. 11, the thickness of the burr increases as the pushing depth of the rotary tool 16 increases, and there is a close relationship between the two. By using this relationship and measuring the thickness of the burr, the indentation depth can be estimated. And if the upper and lower limits of the burr thickness corresponding to the upper and lower limits of the indentation depth are the above-mentioned reference values G2 and G3, the indentation depth of the rotary tool 16 is within the appropriate range by satisfying the judgment formulas 2-3. Can be evaluated.

  FIG. 12 is a block diagram of a friction point joint evaluation device 90 (hereinafter referred to simply as “evaluation device 90”) in accordance with the friction point joint evaluation method. As a schematic configuration of the evaluation apparatus 90, a camera 92 (imaging means) that captures an image of the joint portion P of the workpiece 10 in plan view, a monitor 93 that displays an image captured by the camera 92, and a predetermined program that includes the above-described evaluation expressions The control unit 94 (evaluation means) that performs the control of the entire evaluation apparatus 90 and the reference values G1 to G3 input in advance are stored, and the measurement results and the determination results are stored. Data storage device 95 (storage means). The camera 92 and the control unit 94 constitute measuring means for measuring the shape of the burr R.

  FIG. 13 is an explanatory diagram showing a burr R measuring method by the measuring means of the evaluation apparatus 90. The joint P imaged by the camera 92 is subjected to necessary image processing (such as noise removal) by the control unit 94, and then the shape of the burr R is measured by image analysis.

  First, for example, the center of the indentation mark of the pin portion 16c is determined as the center of the joint portion P, and four measurement areas (first, second, third, and fourth areas F1, F2, F3, F3) are spaced at 90 ° central angles. F4) is set. And the radial direction thickness (1st, 2nd, 3rd, 4th burr thickness B1, B2, B3, B4) of the burr | flash R in each measurement area is measured. Of these measured values, the maximum value is the maximum burr thickness Bmax and the minimum value is the minimum burr thickness Bmin.

  FIG. 14 is a flowchart of an inspection process using the evaluation apparatus 90. The operation of the evaluation apparatus 90 and the flow of the inspection process performed by the evaluation apparatus 90 will be described with reference to this flowchart.

  First, the joint P is imaged by the camera 92 (step S1). Next, noise is removed from the image by the control unit 94 (step S2), and contrast correction is performed (step S3). The image that has been subjected to the image processing in this way and has the burr R shape made clearer may be displayed on the monitor 93 as necessary. Thereby, the operator can easily perform a visual check as necessary.

  Subsequently, the burr R shape is measured by image analysis by the control unit 94 (step S4). In the present embodiment, the first to fourth burr thicknesses B1 to B4 are measured by the above procedure. Next, the above-described judgment formulas 1 to 3 are calculated (step S5). Specifically, the shape measurement value of the burr R and the reference values G1 to G3 read from the data storage device 95 are substituted into the judgment formulas 1 to 3, and the success / failure judgment is made.

  Subsequently, the control unit 94 determines whether or not the shape of the burr R is within the allowable burr range Ba (step S6). In this embodiment, when all of the determination formulas 1 to 3 are satisfied, YES is determined in step S6. If YES in step S6, an OK determination is displayed on the monitor 93 (step S7), and if NO, an NG determination is displayed (step S8). In any case, each measured value, determination result, etc. are stored in the data storage device 95 (step S9), and the inspection is completed.

  After completion of the inspection, the camera 92 or the workpiece 10 is moved, and the next joint P is inspected. If an NG determination is made in step S6, the transition to the next joint P may be suspended.

  As is clear from the above description, according to the method for evaluating the frictional spot joint of this embodiment, it is possible to easily and accurately evaluate the quality of the joint quality. Moreover, according to this evaluation method, since only the burr | flash shape of a junction part is measured, it can carry out nondestructively. Therefore, the evaluation apparatus 90 to which the evaluation method is applied can easily cope with automation and 100% inspection.

  As mentioned above, although embodiment of this invention was described, this invention is not limited to said each embodiment, It can change suitably in a claim.

  For example, although the case where an aluminum alloy plate was used as the first metal member 11 and a galvanized steel plate was used as the second metal member 12 was shown in the above embodiment, such a combination is not necessarily required, and the first metal member 11 is not necessarily used. The second metal member 12 can be applied to any other metal member as long as the second metal member 12 has a higher melting point. For example, a magnesium alloy plate or the like may be used as the first metal member 11. The metal plating applied to the second metal member 12 is not limited to galvanization. Further, a surface film other than the metal plating layer may be formed. Moreover, it is not limited to the positively formed surface film. For example, in the case of a steel sheet that has not been subjected to any surface treatment, an oxide film is naturally formed on the surface. In order to perform proper solid-phase bonding, it is necessary to sufficiently destroy the oxide film, and the present invention is effective as a method and apparatus for evaluating whether or not this is done.

  Further, in the above embodiment, the determination formulas 1 to 3 are used to determine whether or not the burr R is within the allowable burr range Ba. However, it is not always necessary to use all of these, and even a part thereof may be used. Alternatively, another determination formula may be used.

  Moreover, in the said embodiment, although the shape of the measured burr | flash R was digitized as 1st-4th burr | flash thickness B1-B4, and it was made to evaluate with a judgment formula, it does not necessarily do so and it is not necessary to do so. You may make it evaluate directly from the image data which gave the image process to it. For example, in the evaluation device 90, image data as the allowable burr range is stored in the data storage device 95 in advance, and the evaluation may be performed by superimposing the captured image and the image data of the allowable burr range. good.

  As the imaging means, instead of the camera 92 that performs normal imaging, a laser beam (slit laser) that has passed through a slit may be applied to the joint P obliquely and receive the reflected light. According to this imaging means, since the burr R can be recognized in three dimensions, an improvement in measurement accuracy can be expected.

It is a perspective view which shows typically the friction point joining suitable for embodiment of this invention. It is an enlarged view of the front-end | tip part of the rotary tool used for the said friction spot joining. It is explanatory drawing of the 1st press process of the said friction point joining. It is explanatory drawing of the 2nd press process following the said 1st press process. It is explanatory drawing of the 3rd press process following the said 2nd press process. It is a figure which shows the state which friction point joining was completed after the said 3rd press process. It is a figure which shows the sample of a junction part, Comprising: (a) is a plane photograph of the junction part in which appropriate joining was made | formed, (b) is a plane photograph of the typical junction part in which proper joining was not made. . (C) and (d) are sketches of (a) and (b), respectively. It is the VIII-VIII sectional view taken on the line of the malfunction sample shown in FIG.7 (d). (A) and (b) are composition images, and (c) and (d) are X-ray images of Zn characteristics. Further, (a) and (c) are photographs of the area E1 shown in FIG. 7 (d), and (b) and (d) are photographs of the area E2. It is a perspective view of the test piece for testing the influence of the installation state of the jig | tool in joining quality. It is a graph which shows the measurement result of the tensile shear strength of a junction part. It is a graph which shows the relationship between the thickness of a burr | flash, and the indentation depth of a rotary tool. It is a block diagram of the evaluation apparatus of a friction point junction part. It is explanatory drawing which shows the measuring method of the burr | flash by the measuring means of the said evaluation apparatus. It is a flowchart of the inspection process using the said evaluation apparatus.

Explanation of symbols

DESCRIPTION OF SYMBOLS 11 1st metal member 12 2nd metal member 16 Rotary tool 90 Friction point junction evaluation apparatus 92 Camera (imaging means, measurement means)
94 Control unit (measuring means, evaluation means)
95 Data storage device (storage means)
B1 to B4 First to fourth burr thickness (radial thickness in a plan view of burr)
Ba Allowable burr range P Joint R Burr Z Zinc plating layer (metal plating layer)

Claims (4)

A first metal member made of an aluminum alloy plate and a second metal member made of a steel plate having a melting point higher than that of the first metal member and having a metal plating layer formed on the surface are superposed on each other by rotating and pressing the rotary tool. The first metal member is softened and plastically flowed by frictional heat, and the metal plating layer is extruded from the joint portion to thereby join the first metal member and the second metal member in a solid state. A method for evaluating a joint,
About the burr generated at the peripheral edge of the concave portion of the joint part, a range of the burr shape satisfying the joint quality is set as an allowable burr range in advance,
Measure the burr shape to be evaluated,
A method for evaluating a frictional point joint, wherein the joint quality of the joint is evaluated based on whether or not the measured burr shape is within the allowable burr range.   2. The method for evaluating a friction point joint according to claim 1, wherein the allowable burr range includes at least a deviation of a radial thickness in a plan view of the burr being a predetermined reference value or less. The first metal member and a second metal member having a melting point higher than that of the first metal member are overlapped, and the first metal member is softened by frictional heat and plastically flowed by the rotation and pressing of the rotary tool to cause the first metal member to flow. An apparatus for evaluating a joint part of a friction point joint that joins a member and the second metal member in a solid phase state,
Storage means for storing in advance a burr shape range satisfying the bonding quality as an allowable burr range with respect to the burr generated at the peripheral edge of the concave portion of the bonding part,
Measuring means for measuring the burr shape to be evaluated;
Comparing the measured burr shape with the allowable burr range, and comprising an evaluation means for evaluating whether or not the bonded portion is bonded according to whether it is within the allowable burr range,
2. The friction point joint evaluation apparatus according to claim 1, wherein the measuring means includes an image pickup means for picking up the joint portion in a plan view, and measures the burr shape based on the picked-up planar image of the joint portion. 4. The friction point joint evaluation apparatus according to claim 3, wherein the permissible burr range includes at least a deviation of a radial thickness in a plan view of the burr being a predetermined reference value or less .

Images