JP5685461B2 - Hole repair method using friction stir spot welding - Google Patents

Description

  The present invention relates to a hole repair method using friction stir spot welding, and more particularly to a hole repair method that can be suitably used in the aircraft field.

  For example, in manufacture or maintenance of transportation equipment, a metal part or an assembled structure (collectively referred to as a metal material) may be perforated. This drilling operation basically includes the possibility of causing defects in the state of the holes formed due to various factors. For example, there are problems such as simple work mistakes, defects in drilling equipment for drilling work, deformation of metal materials, etc., the positions where holes should be formed are shifted, and the dimensions of the holes formed are different. Can be mentioned.

  If the above problem occurs, the hole is usually repaired by some method. As a method for repairing the hole, for example, (1) filling the hole with a filler, (2) filling the hole by build-up welding, (3) mechanically blocking the hole with a plug member such as a rivet, (4 ) Change of target fastener size, (5) Reinforcement by doubler (reinforcement plate), re-drilling of holes, and the like.

  If the transport device is an automobile or a railway vehicle, the method (1) or (2) can be used, although it depends on the type of component or structure. On the other hand, if the transport equipment is an aircraft, the method (1) or (2) cannot be used. Generally, the method (3), (4) or (5) is used. Will be used. This is because an aircraft is used in a harsh environment compared to other transportation equipment.

  For example, even if a hole defect such as that described above has occurred during drilling operations on an aircraft, and the formed hole is filled with a filler (method (1) above), the elastic modulus of the filler is the metal of the base metal. Unlike that, the strength of the base material does not recover. Further, in a harsh environment, there is a high possibility that the filler will come out of the hole. In addition, when trying to fill the formed hole by overlay welding (method (2) above), the welded metal material and the surrounding crystal structure change, and the strength of the metal material decreases or is welded. Many aircraft high-strength materials are unacceptable for welding due to cracking. Therefore, the method of (3), (4) or (5) is selected for repairing the hole in the aircraft.

  In an aircraft, if the metal material with the hole is a removable part, the part itself is manufactured again and replaced. In the following description, this part replacement is regarded as a method (6) for repairing the hole.

  As a technique related to aircraft repair, for example, although not hole repair, Patent Document 1 discloses an apparatus used for repairing an aircraft honeycomb structural component. Moreover, although it is not repair of the hole produced | generated by the drilling operation | work, when the aircraft fuselage is damaged by the impact of a bird or another object, patent document 2 uses the aircraft fuselage damage used for repairing the said damage area. A method for cropping a region is disclosed.

JP-A-8-175498 JP-T 2009-537376

  By the way, since an aircraft is a transport device used in a harsh environment as described above, the main body or parts are required to have higher environmental resistance than other transport devices. Aircraft are also manufactured using special parts and materials compared to other transport equipment. Here, as a feature of aircraft structure, it is designed to minimize the weight by using the strength of the material to the limit, and is designed to be damage-tolerant, and from the viewpoint of maintainability of parts, large structural parts It is mentioned that the part employ | adopts the mechanical coupling | bonding by fasteners, such as a rivet and a bolt-nut. Because of this feature, drilling operations are more frequent when manufacturing or servicing aircraft than other transport equipment, and therefore there is a relatively high probability that defects will occur in the formed holes. It is in.

  However, the methods (3) to (6), which are generally used for repairing holes in aircraft, have the problem of incurring at least one of low repair efficiency, high cost, and increased aircraft weight. Have

  Specifically, according to the method (3), since the member whose hole is closed is only in contact with the base material, it contributes almost to maintaining or improving the strength of the base material. There is nothing. Therefore, the hole to be blocked is an originally unnecessary hole and is not close to the end or edge of another hole or part, and further, there is no problem in strength even if left untreated. It can be used only when Therefore, for example, when a problem occurs in the hole during the drilling of the hole necessary for joining the members, it is rare that this repair method can be applied. In this method, since the hole is closed with a rivet or the like, a member called a rivet is added. Therefore, the weight of the aircraft increases.

  In the method (4), when a flaw in the fastener hole for joining the members or a defect in the hole diameter occurs, the hole is shaped with a large drill and joined with a thick fastener. Often used as a treatment for However, since selection of fasteners suitable for repair is limited, procurement of the fasteners requires cost, time, and the like. In addition, since the enlarged fastener head interferes with surrounding members or structures, or the hole enlarges, the remaining part of the member decreases, causing a problem in strength. Depending on the situation, this method may not be applicable.

  In the method (5), the fastener and the member whose desired strength cannot be expected due to the enlargement of the hole diameter or the position error are covered with a doubler (reinforcement plate), and the load is shared with the surrounding fasteners to recover the strength. Although it is possible, the weight of the aircraft increases more than the method (3), and the performance of the aircraft may be deteriorated. Furthermore, if the member is, for example, a curved surface, it takes a great deal of cost, time, etc. to manufacture a doubler for covering the member. In addition, when the doubler is applied to the outer surface of the aircraft, the resistance of the aircraft will increase, which may cause further deterioration in performance, and the appearance quality of the aircraft will deteriorate. If there is, there is a risk that the value of the product will be significantly impaired.

  The method (6) is desirable from the viewpoint of aircraft strength, performance, quality, etc., but it can be applied only to replaceable parts, such as production of replacement parts and disassembly of subassemblies. Enormous costs and time. Moreover, in the case of drilling work on structural parts of an aircraft, even if this method is applied, a very large amount of cost, time, etc. are required.

  That is, in the drilling operation for the structural part, since it is necessary to realize a high-strength coupling of the fastener, there is almost no allowance between the hole diameter and the thickness of the fastener shaft portion, so there is a positional deviation between the holes of the member. Unacceptable. Therefore, in the case of drilling through the mutually coupled members such as the outer plate and the frame, the through holes are formed in a state where the respective members are temporarily fixed. Here, when replacing one of the perforated members with another member, the position of the hole must be copied to the other member so as to substantially match the position of the hole of the already perforated member. Don't be. However, the copying operation is a task that requires great skill, and the outer plate member of a general aircraft is coupled to the frame by several tens to several hundreds of fasteners per sheet. Therefore, this method wastes a lot of costs and time.

  Note that none of the techniques disclosed in Patent Document 1 or 2 is a technique for repairing a hole formed by a drilling operation, and thus an efficient and low-cost method for repairing a hole cannot be realized.

  Also, in fields other than aircraft, it may be preferable to repair holes by a method other than the method (1) or (2). In this case as well, the methods (3) to (6) above The same problem occurs when using.

  The present invention has been made in order to solve the above-mentioned problems, and is effective and low-cost after avoiding a significant decrease in the strength of the repaired portion of the hole in which a defect has occurred in the drilling operation. The purpose is to provide a repair method.

  As a result of intensive investigations in view of the above problems, the present inventors have further improved the friction stir spot joining technique used for overlapping and spot joining a plurality of metal plates, thereby effectively repairing holes. The inventors have found that they can be used independently and have completed the present invention.

That is, the hole repair method using the friction stir spot welding according to the present invention is a cylindrical shape that is configured to rotate around the axis and move forward and backward in the axial direction in order to solve the above-described problem. A pin member, and a cylindrical shoulder member that is positioned so as to surround the outside of the pin member, rotates around the same axis as the pin member, and is movable forward and backward in the axial direction . a hole repairing method of a metal material using a double-acting friction stir spot joining device, to fill the hole by inserting a filler material into the repair target hole formed in the metal material, and the hole filling process, the multiple The pin member or the shoulder member of the dynamic friction stir spot welding device is rotated while being brought into contact with a repair region including the hole on one surface of the metal material and rotating the pin member or the shoulder member. In the area Is input, a rotational pushing step, the pin member or the shoulder member with retracting from the repair area, by at least one of the pin member and the shoulder member, a recess formed in the rotary pushing step the repair area it returns filling, the mixing of the entire filler portion for filling the hole of the filling material so as to integrate a portion of the metal member, and a recess backfill step, a configuration including.

According to the above-described configuration, by performing the recess backfilling process, not only the recesses formed in the rotary push-in process are backfilled, but also the filling part of the filler filled in the hole filling process is made of a metal material. Can be mixed almost completely into the part. As a result, the hole can be repaired in a state of being integrated so that a boundary surface is not substantially formed between the metal material which is the base material and the filling portion, and therefore the strength of the repaired portion may be significantly reduced. In addition, it is possible to improve the efficiency of repair, reduce the cost of repair, avoid the increase in the weight of the metal material to be repaired, and the like.

Further, according to the configuration, than are used double acting friction stir spot joining device, at least one of the pin member and the shoulder member can be backfilled recesses with. In other words, since a plurality of members can be used for backfilling the recesses, not only can the filling portion be mixed substantially perfectly with a part of the metal material, but also by appropriately advancing and retracting these members. The surface of the metal material can be made substantially flat. As a result, it is possible to improve the appearance of the metal material after hole repair, in addition to improving the efficiency of repair, reducing the cost of repair, and avoiding an increase in weight.

In the hole repairing method, the double-acting friction stir spot welding device is located outside the pin member or the shoulder member, and faces the clamp member that clamps the metal material from one surface. A backing member provided at a position where the metal member is in contact with the other surface of the metal material, and pressing the outside of the repair region of the one surface of the metal material with the clamp member By doing, it is more preferable that it is the structure containing the metal material support process which supports the said metal material from both surfaces.

  According to the above configuration, the metal material is supported by the clamp member and the backing member, so that the stability and reproducibility of hole repair can be improved, and the efficiency of the rotary push-in process or the recess filling process is improved by the clamp member. Can be made.

  In the hole repairing method, the rotary push-in step and the recess backfilling step may be configured to be performed from one side or both sides of the metal material.

  Although the metal material used as the repair object by the hole repair method which concerns on this invention is not specifically limited, For example, it is mentioned as a preferable example that the said metal material is the components or structure which comprises an aircraft.

  As described above, in the present invention, it is possible to provide an efficient and low-cost method for repairing a hole in which a defect has occurred in a drilling operation while avoiding a significant decrease in the strength of the repaired portion. it can.

It is a schematic diagram which shows the principal part structure of the double-acting friction stir spot welding apparatus which is an example of the friction stir spot joining apparatus used in Embodiments 1 and 2 of the present invention. (A)-(c) is process drawing which shows the preparatory stage of the hole repair method which concerns on Embodiment 1 performed using the friction stir spot welding apparatus shown in FIG. (A)-(c) is process drawing which shows the surface repair stage of the hole repair method which concerns on Embodiment 1 performed using the friction stir spot welding apparatus shown in FIG. (A)-(c) is process drawing which shows transfer to the back surface repair stage from the surface repair stage of the hole repair method performed following FIG. 3 (a)-(c). (A)-(c) is process drawing which shows the back surface repair stage of the hole repair method performed following FIG. 4 (a)-(c). (A)-(e) is process drawing which shows an example of the hole repair method which concerns on Embodiment 2 of this invention. (A)-(f) is process drawing which shows the other example of the hole repair method which concerns on Embodiment 2 of this invention.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. In the following description, the same or corresponding elements are denoted by the same reference symbols throughout the drawings, and redundant description thereof is omitted.

(Embodiment 1)
[Friction stir spot welding equipment]
The hole repair method using friction stir spot welding according to Embodiment 1 of the present invention uses a double-acting friction stir spot welding device as a representative example of the friction stir spot welding device. A typical example of the double-acting friction stir spot welding device used in the present embodiment will be specifically described with reference to FIG. In the following description, double-action friction stir spot joining is abbreviated as FSJ as appropriate.

  As shown in FIG. 1, the FSJ apparatus 50 used in the present embodiment includes a rotary tool portion 51, a clamp member 54, and a backing member 55, and a support member that supports these, although not shown in FIG. A drive mechanism for driving the tool unit 51 is provided. The clamp member 54 is fixed to a support member (not shown) via the spring 41.

  The rotary tool part 51 includes a pin member 11 and a shoulder member 12. The pin member 11 has a substantially cylindrical shape, and is rotated around an axis line Xr (rotation axis, one-dot chain line in the figure) by a drive mechanism (not shown), and also in the direction of the broken line arrow P1, that is, in the axis line Xr direction (vertical direction in FIG. 1). ) Along the shoulder member 12 is configured to be able to advance and retreat relative to the shoulder member 12. The shoulder member 12 has a substantially cylindrical shape with a hollow, and a pin member 11 is inserted into the hollow, and is supported by a support member (not shown) so as to surround the pin member 11 outside the pin member 11. Yes. The shoulder member 12 is configured to be rotated about the same axis Xr as the pin member 11 by a driving mechanism (not shown) and to be able to move forward and backward with the pin member 11 along the direction of the broken line arrow P2, that is, the axis Xr direction. ing.

  Accordingly, the pin member 11 and the shoulder member 12 both rotate integrally around the axis Xr, but are configured to be able to move forward and backward along the axis Xr direction. Further, since both the pin member 11 and the shoulder member 12 are members that are rotated by the rotation driving unit 532, they can be referred to as rotating members.

  The clamp member 54 is provided on the outer side of the shoulder member 12 and, like the shoulder member 12, is a cylindrical shape having a hollow, and the shoulder member 12 is inserted into the hollow. Therefore, the substantially cylindrical shoulder member 12 is located on the outer periphery of the pin member 11, and the substantially cylindrical clamp member 54 is located on the outer periphery of the shoulder member 12. In other words, the clamp member 54, the shoulder member 12, and the pin member 11 each have a coaxial core-like nested structure. The clamp member 54 presses the workpiece 60 from one surface, and is supported by the support member (not shown) via the spring 41 in the present embodiment as described above. Therefore, the clamp member 54 is configured to be movable back and forth in the direction of the broken line arrow P3 while being urged toward the backing member 55.

  The pin member 11, the shoulder member 12, and the clamp member 54 constituting the rotary tool portion 51 having the above-described configuration include a contact surface 11a, a contact surface 12a, and a contact surface 54a, respectively, and these contact surfaces 11a and 12a. , 54a are moved forward and backward by a drive mechanism (not shown), and can come into contact with the surface (first surface, one surface) of the workpiece 60 arranged between the backing member 55 and the backing member 55. Further, the backing member 55 is provided at a position facing the clamp member 54 (and the pin member 11 and the shoulder member 12), and is in contact with the back surface of the workpiece 60. In FIG. 1, it has a flat surface so that it may contact | abut on the back surface of the flat workpiece 60. FIG.

  The specific configuration of the rotary tool unit 51 in the present embodiment is not limited to the configuration described above, and a configuration known in the field of FSJ can be suitably used. Further, the specific configuration of the backing member 55 is not particularly limited as long as the shape matches the shape of the back surface of the workpiece 60. For example, in addition to the configuration having the flat surface shown in FIG. 1, the backing member 55 having a plurality of types of shapes may be separately prepared as a member that can be removed and replaced from the support member. Alternatively, the clamp member 54 and the backing member 55 may not be provided in the configuration of the FSJ apparatus 50, and may include other members not shown in FIG.

  In addition, the friction stir welding apparatus is not limited to the FSJ apparatus 50 having the above-described configuration, and may be a single-acting friction stir spot welding apparatus including only the pin member 11. The friction stir spot joining device may be configured to include the clamp member 54 outside the pin member 11, or may include other members not described in the FSJ device 50 described above. As will be described later, in the present invention, it is only necessary to perform a recessed portion backfilling step for filling the formed recessed portion after performing the rotational pushing step for causing the pin member 11 to enter one surface of the workpiece 60, As the friction stir welding apparatus, any structure can be suitably used as long as it can perform the recess backfilling step.

[Hole repair method using FSJ]
Next, about an example of the specific process of the hole repair method which concerns on this Embodiment, FIG. 2 (a)-(c), FIG. 3 (a)-(c), FIG. 4 (a)-(c) And it demonstrates concretely with reference to Fig.5 (a)-(c). In each of these drawings, for convenience of explaining the process of the hole repair method, the reference numerals of the contact surface 11a, the contact surface 12a, and the contact surface 54a shown in FIG. 1 are not shown.

  Further, arrows p1 and p2 in FIGS. 3 (a) to 3 (c), FIGS. 4 (a) and 4 (c), and FIGS. 5 (a) to 5 (c) indicate a pin member 11 and a shoulder constituting the rotary tool portion 51. The movement direction of the member 12 and the clamp member 54 is shown, the arrow p1 shows the upward movement, and the arrow p2 shows the downward movement. 3 (a) to 3 (c), FIG. 4 (c) and FIGS. 5 (a) and 5 (b), the arrow r indicates the rotation direction of the pin member 11 and the shoulder member 12 which are rotating members. 3 (a) to 3 (c), FIG. 4 (c), and FIGS. 5 (a) and 5 (b), the block arrow F is used as the workpiece 60 by the pin member 11, the shoulder member or the clamp member 54. The direction of the force applied to the metal material 61 is shown. In addition, the shoulder member 12 is hatched in order to clearly distinguish it from the pin member 11 and the clamp member 54.

  The hole repair method according to the present embodiment can be divided into three stages: a preparation stage, a front surface repair stage, and a back surface repair stage. The processes shown in FIGS. 2A to 2C correspond to the preparation stage, the processes shown in FIGS. 3A to 3C and 4A correspond to the surface repair stage, and FIG. , (C) and the steps shown in FIGS. 5A to 5C correspond to the back surface repair stage.

  In the preparation stage, first, as shown in FIG. 2A, the metal plate 61 (processed material 60) is formed with a hole 60c in which a defect has occurred in the drilling operation. In the following description, the defective hole 60c is referred to as a “defective hole 60c”. Next, as shown in FIG. 2 (b), a rivet 63 as a filler is inserted into the defective hole 60c, and the tip (the lower side in the figure) opposite to the rivet head 63b is caulked. A portion 63c is formed. In addition, this process (refer FIG.2 (b)) is called a "hole filling process."

  Here, in the hole filling step, the rivet 63 is not necessarily caulked. Further, the filler filling the defective hole 60 c is not limited to the rivet 63. For example, in the field of aircraft and the like, the outer diameter of the rivet 63 is approximately the same as the inner diameter of the hole to be inserted, and since it is equivalent to the base material (metal plate 61) in terms of material, etc. The rivet 63 is preferably used as the material, but any member other than the rivet 63 can be preferably used as long as the defective hole 60c can be filled with a columnar member.

  Thereafter, as shown in FIG. 2C, the remaining portion protruding from the defective hole 60 c, specifically, the rivet head 63 b and the caulking portion 63 c are removed, and the defective hole 60 c is a part of the rivet 63. Fill with 63a. This step (see FIG. 2C) is referred to as a “residual portion removing step”, and this residual portion removing step is a residue on the surface of the metal plate 61 (upper side in FIG. 2A to FIG. 2C). It can be divided into a “front surface residual portion removing step” for removing a portion and a “back surface residual portion removing step” for removing a residual portion on the back surface (lower side in the figure).

  Note that the remaining portion removing step is not necessarily performed. That is, the removal of the remaining portion is not an essential step in the hole repair method of the present invention. Further, the state shown in FIG. 2C is merely a state in which the defective portion 60c is simply filled with the filling portion 63a, and does not contribute to maintaining the strength of the metal plate 61 that is the base material. 63a is in a state of being easily detached from the defective hole 60c. Therefore, the state shown in FIG. 2C cannot be a hole repair method.

  Further, as indicated by a broken line in FIG. 2C, the defective hole 60c and its periphery are defined as a “repair area Am”. As will be described later, this repair area Am is directly below the contact surface of the rotating member (that is, the contact surface 11a of the pin member 11 (see FIG. 1) and the contact surface 12a of the shoulder member 12 (see FIG. 1)). It is an area. Therefore, in the repair area Am, the defect hole 60c does not have to be located at the center, and it is sufficient that the repair area Am is a predetermined area that includes the defect hole 60c and abuts the contact surface of the rotating member.

  3 (a) to 3 (c) and FIG. 4 (a), the region on the surface side to be repaired, and FIGS. 4 (b), 4 (c), and 5 (a) to 5 (a). Although there is a region on the back surface side to be repaired in the back surface repair stage shown in (c), only one of these (upper surface in the drawing) is indicated by a broken line in FIG. . In FIGS. 2B and 2C, since the defective hole 60c is closed by the rivet 63, the defective hole 60c is not provided with a reference numeral. The same applies to FIGS. 3A to 3C, FIGS. 4A to 4C, and FIGS.

  Next, in the surface repair stage, first, the rotary tool part 51 is brought into contact with the surface of the metal plate 61. At this time, positioning is performed so that the rotary tool portion 51 properly contacts the repair area Am on the front surface side. This positioning is performed by, for example, rotating the metal plate 61 with the rotating tool portion 51 (the pin member 11 and the shoulder member 12 in a stationary state) and the backing member 55 that are not rotated while moving the metal plate 61. The work of pinching is mentioned.

  Next, when properly positioned, the backing member 55 is brought into contact with the back surface of the defective hole 60c, and the outside of the defective hole 60c on the surface is pressed by the clamp member 54 (see arrow p1 in FIG. 3A). ) To support the metal plate 61. The process of sandwiching and supporting the metal plate 61 by the backing member 55 and the clamp member 54 is referred to as a “metal material support process”. In this metal material support step, the metal material 61 is sandwiched between the clamp member 54 and the backing member 55, and a clamping force is generated by pressing by the clamp member 54 (see the block arrow F in FIG. 3A).

  Then, as shown in FIG. 3A, the contact surface 11a of the pin member 11 and the contact surface 12a of the shoulder member 12 are brought into contact with the positioned repair region Am while rotating (arrows in the figure). p1), rotating for a certain time (arrow r in the figure). In this state, the repair area Am is “preheated” by the rotating pin member 11 and the shoulder member 12. In FIG. 3 (a), both the contact surface 11a and the contact surface 12a are in contact with the repair area Am, but the present invention is not limited to this, and the contact surface 11a is used in order to avoid rotational shake. Alternatively, only one of the contact surfaces 12a may be brought into contact with the repair area Am.

  Next, as shown in FIG. 3B, the pin member 11 is made to enter (push in) toward the repair region Am of the metal plate 61. As a result, the metal material in the repair region Am softens and causes plastic flow, and a plastic flow portion 60a is generated on the surface of the metal plate 61. The plastic flow portion 60a includes a filling portion 63a that fills the defective hole 60c, It extends to the surface of the metal plate 61 located around the filling portion 63a. Accordingly, the metal material on the surface side of the filling portion 63 a and the metal material around the defective hole 60 c are agitated and softened as a whole, and the plastic flow portion 60 a is formed on the surface of the metal plate 61. Further, since the softened metal material of the plastic flow portion 60a is pushed away by the pushed pin member 11 (arrow p1 in the figure) and flows from directly below the pin member 11 to directly below the shoulder member 12, the shoulder member 12 is the pin member. It floats when viewed from 11 (arrow p2 in the figure). This process is referred to as a “rotary pushing process”.

  Next, as shown in FIG. 3C, the protruding pin member 11 is gradually retracted (drawn). Here, while the pin member 11 is pulled (arrow p2 in the figure), the pressing force (block arrow F in the figure) by the shoulder member 12 is pushed so as to be maintained (arrow p1 in the figure). The softened metal material 60 a flows from directly below the shoulder member 12 to immediately below the pin member 11. Thereby, the recessed part formed in the surface of the metal plate 61 is backfilled. Even if the pin member 11 is being pulled in (arrow p2 in the figure), the pressing force (block arrow F in the figure) is maintained. This process is referred to as a “recess filling process”.

  Thereafter, the abutting surface 11a (see FIG. 1) of the pin member 11 and the abutting surface 12a (see FIG. 1) of the shoulder member 12 are substantially aligned with each other so that there is almost no step between them (to be flush with each other). The surface of 61 is shaped. Thereby, the surface of the metal plate 61 becomes a substantially flat surface to the extent that no substantial concave portion is generated.

  Next, as shown in FIG. 4A, the rotary tool portion 51 and the backing member 55 are separated from the metal plate 61 (arrow p2 in the figure). At this time, the plastic flow part 60a on the surface of the metal plate 61 becomes the solid phase joint part 60b. Thereby, the site | part in which the malfunction hole 60c existed in the surface of the metal plate 61 was block | closed by the solid-phase junction part 60b.

  Next, in the back surface repair stage, first, as shown by an arrow v in FIG. 4B, the metal plate 61 is reversed or the FSJ device 50 is reversed (not shown), so that the back surface is turned to the rotary tool portion 51. The surface is made to face the backing member 55. Next, after positioning so that the rotary tool portion 51 corresponds to the repair area Am on the back surface side, the backing member 55 is brought into contact with the surface of the defective hole 60c, and the defective hole on the back surface is clamped by the clamp member 54. The outside of 60c is pressed (metal material support process).

  Next, as shown in FIG. 4 (c), the rotary tool 51 is brought into contact with the back surface of the metal plate 61, and the pin member 11 and the shoulder member 12 are rotated for a certain period of time in contact with the back surface of the metal plate 61. Then, as shown in FIG. 5A, the pin member 11 is pushed toward the metal plate 61 (rotary pushing step). After that, as shown in FIG. 5B, the protruding pin member 11 is gradually pulled in, and the recess is backfilled with the metal material that flows from directly below the shoulder member 12 to directly below the pin member 11 (recess backfilling step). ). Thereafter, the abutting surface 11a of the pin member 11 and the abutting surface 12a of the shoulder member 12 are combined to shape the back surface of the metal plate 61, and as shown in FIG. The member 55 is separated from the metal plate 61. At this time, the plastic flow part 60a on the back surface of the metal plate 61 becomes the solid phase joint part 60b. As a result, the portion where the defective hole 60c is present on the back surface of the metal plate 61 is also blocked by the solid-phase bonding portion 60b. As a result, the defective portion 60c is formed by the filling portion 63a being substantially integrated with the surrounding metal plate 61. It is blocked.

  As described above, in the present embodiment, in the metal plate 61 in which the defective hole 60c is formed, the defective hole 60c is filled with the filler (for example, the rivet 63), and the defective hole 60c is subjected to the friction stirring process from both sides. Thus, the defective hole 60c is repaired. Thereby, a substantial boundary surface does not occur between the metal plate 61 as the base material and the rivet 63 as the filler (strictly speaking, the filling portion 63a as a part of the rivet 63). Therefore, since the base material and the filler are substantially integrated, there is almost no possibility that the strength or the like of the repaired portion is reduced, so that the defective hole 60c is appropriately repaired.

  Since the conventional FSJ was intended to connect a plurality of metal plates and connect them by point joining, for example, a solid-phase joint may be formed between an upper metal plate and a lower metal plate. Therefore, it is not always necessary to backfill the recesses (for example, a general friction stir spot joining technique disclosed in Reference 1 and Japanese Patent No. 3429475). Further, it has not been known that the known through-dynamically operating FSJ (see, for example, Reference 2 and Japanese Patent No. 3709972) can be used to repair the formed through hole.

  On the other hand, in the present invention, as shown in FIGS. 2A to 2C, for example, the defective hole 60c of the metal plate 61 is filled with a filler (such as a rivet 63), and then, for example, FIG. )-(C), FIGS. 4 (a)-(c) and FIGS. 5 (a)-(c), the defective hole 60c is effectively repaired by performing FSJ from both sides. In particular, the recess formed by the pin member 11 formed in the rotary pushing process is performed by performing the recess backfilling process as shown in FIGS. 3B and 3C or FIGS. 5A and 5B. In addition to simply backfilling, the filling portion 63 a filled in the hole filling step can be mixed almost completely with a part of the metal material 61.

  In other words, in the present invention, in order to connect a plurality of metal plates, a part of them is stirred and mixed by friction stir spot welding, or FSJ is used to form a recess in the metal plate. The present inventors have completed the present invention based on an original technical idea that FSJ is used to mix a small amount of filler into a part of a metal plate almost completely. As a result, the hole can be repaired in a state of being integrated so that a boundary surface is not substantially formed between the metal plate which is the base material and the filler, so that the strength of the repaired portion may be significantly reduced. In addition, it is possible to obtain excellent advantages such as improvement in the efficiency of repair, reduction in cost of repair, or avoiding an increase in the weight of an object to be repaired.

[Conditions and modifications of hole repair method]
Here, specific conditions and the like of the respective steps in the present embodiment are not particularly limited. For example, in the hole filling step, a filler having the same composition as the base material may be filled, but if the defective hole 60c can be appropriately repaired, a filler having a composition different from that of the base material may be filled. . In the present embodiment, the rivet 63 corresponding to the inner diameter of the defective hole 60c is used as the filler, but a filler having a shape other than the rivet 63 may be used.

  As for the remaining portion removing step, in this embodiment, as shown in FIGS. 2B and 2C, the remaining portions (rivet head 63b and caulking portion 63c are simultaneously formed on both the front and back surfaces of the metal plate 61. ) May be removed, but only the remaining portion (rivet head 63b) on the front surface may be removed first, and the remaining portion (caulking portion 63c) on the back surface may be removed after the surface repair stage is completed. In this case, in the metal material supporting step, the backing member 55 is not a flat plate-like member, but can support the entire back surface of the metal plate 61 including the remaining portion (for example, at a location corresponding to the caulking portion 63c). A configuration in which a hole is formed, or a cup-type configuration that abuts around the caulking portion 63c may be used. Further, as described above, the formation of the caulking portion 63c is not essential, and the removal of the remaining portion is not essential.

  Further, the remaining portion removing step may be performed either before the metal material supporting step or after the recess backfilling step. If it is before the metal material support step, the rotary push-in step and the recess backfilling step are performed in a state where unnecessary fillers (the rivet head 63b of the rivet 63, the caulking portion 63c, etc.) are removed. be able to. Further, after the recess backfilling step, the occurrence of problems such as a shortage of filler can be eliminated, and the pin member 11 or the shoulder member 12 may penetrate through the metal material 61. Precise control of the push-in position is dependent on it. In any case, since the filler can be used in the minimum necessary amount (that is, it can be repaired only by the filling part 63a), it is possible to avoid an increase in the weight of the metal material 61.

  Moreover, about the rotation pushing process, pushing conditions, such as the rotation speed of the pin member 11 pushed in, a pushing force, pushing speed, and the maintenance time of pushing, are not specifically limited. Specifically, according to various conditions such as the type of the metal plate 61, the state of the front or back surface, the size or shape of the defective hole 60c, the type or filling state of the filler, and the size of the repair area Am, a known FSJ A suitable range can be set with reference to the indentation condition. Similarly, in the recess backfilling process, the backfilling conditions such as the rotational speed of the pin member 11 and the shoulder member 12, the pressing force, the forward / backward moving speed, the backfilling maintenance time, etc. are not particularly limited. A suitable range can be set with reference to known FSJ backfill conditions.

  Moreover, the specific structure of the rotating member used in the rotation pushing step and the recess backfilling step is not particularly limited. In the present embodiment, as schematically shown in FIGS. 3A to 3C, FIGS. 4A to 4C, and FIGS. 5A to 5C, the outer diameter of the pin member 11 is However, the present invention is not limited to this, and the outer diameter of the pin member 11 may be smaller than the inner diameter of the defective hole 60c. It has been experimentally verified that even if the outer diameter of the pin member 11 is small, the FSJ softens and stirs not only the pin member 11 but also the surrounding metal material (see examples described later). . In addition, the fact that the hole can be effectively repaired even if the dimension of the pin member 11 is small means that the alignment between the repair region Am and the rotating member becomes relatively easy.

  For the same reason, the size of the shoulder member 12, the size and fixing position of the clamp member 54, the area of the backing of the backing member 55, etc. are not particularly limited, and if the hole can be repaired, the shape of the metal material, It can be appropriately set according to various conditions such as the type or composition, the size or depth of the defective hole 60c, the type, shape or composition of the filler.

  Furthermore, the specific type of metal material to be repaired is not particularly limited. In the present embodiment, the metal plate 61 is illustrated, but a plate-like metal material may be used instead of such a plate-like material. When repairing the defective hole 60c formed in the massive metal material, it is only necessary to perform the surface repair stage shown in FIGS. Further, when repairing a massive metal material, depending on the shape or installation state of the metal material, in the metal material supporting step, only the clamp member 54 is brought into contact with the surface without using the backing member 55. But you can. In this case, the defective hole 60c is not a through hole as shown in FIG. 2 (a), but is a recess that does not penetrate (a hole that does not penetrate). Therefore, the hole repair method according to the present embodiment can be suitably used for repairing through holes and repairing recesses.

  In addition, in the hole repairing method according to the present embodiment, the specific configuration of the friction stir spot welding device used is not limited to the FSJ device 50 having the configuration shown in FIG. 1, but various configurations known in the field of FSJ. Can be used. For example, in the FSJ apparatus 50, the clamp member 54 and the backing member 55 for performing the metal material support process may not be provided in the FSJ apparatus 50, and a support apparatus for repairing holes is separately used together. It may be a simple configuration. Therefore, as a hole repairing method, the metal material supporting step may not be performed.

  However, if the metal plate 61 is supported by the clamp member 54 and the backing member 55, the state of the metal plate 61 that is the object to be repaired and the relative position of the repair region Am that is the repair symmetry point are stabilized, so Stability and reproducibility can be improved. Further, the clamp member 54 not only presses the surface of the metal plate 61, but also, as shown in FIG. 3B or FIG. 5A, the softened metal material constituting the plastic flow portion 60a is placed in the repair region Am. Therefore, the efficiency of the rotary push-in process or the recess back-filling process can be improved. Therefore, in the present embodiment, it is particularly preferable that the metal material supporting step is performed.

  In the hole repair process, the backing member may not be easily arranged. In this case, a backing member not included in the friction stir spot welding device can be used separately. Furthermore, in this case, the metal material 61, the FSJ device 50 (or other friction stir spot welding device), and the backing member need to be fixed, but another hole or the like formed in the metal material 61 is used. Then, it may be bolted, or vacuum suction may be performed using a member such as a suction cup.

  Further, in the FSJ apparatus 50 shown in FIG. 1, both the pin member 11 and the shoulder member 12 are configured to be movable back and forth. However, the present invention is not limited to this, and one of the pin member 11 or the shoulder member 12 is advanced or retracted. The structure which does not move may be sufficient. Further, a single-acting configuration in which the pin member 11 and the shoulder member 12 are integrated may be used. If the pin member 11 and the shoulder member 12 can be moved forward and backward independently as in the present embodiment, there is an advantage that the efficiency of the rotary push-in process or the recess filling process can be improved.

  The hole repair method according to the present invention including the above-described embodiment is widely used when repairing a hole when a defect occurs in the formed hole in a situation where a hole is formed in a metal object. Can be used. As a typical application object of the present invention, manufacturing or maintenance of transportation equipment can be cited. Examples of transportation equipment include automobiles, railway vehicles, ships, and airplanes, but the hole repair method according to the present invention can be suitably used particularly for the manufacture or maintenance of aircraft.

  Aircraft are used in harsh environments compared to other transportation equipment, so when repairing a defective hole in the manufacture or maintenance of an aircraft, the method used in the field of other transportation equipment (described above) (1) Filling holes with fillers or (2) Filling holes with build-up welding) cannot be used. In addition, a method conventionally used in the aircraft field ((3) mechanical blockage of a hole by a plug member such as rivet described above, (4) change of a target fastener size, (5) by doubler (reinforcement plate) In the case of (6) remanufacturing and exchanging a part in which a hole is formed, such as reinforcement and re-drilling of the hole, low repair efficiency, high cost, or an increase in the weight of the aircraft occur.

  On the other hand, for example, in the hole repair method according to the present embodiment, even if the defective hole 60c is formed in the part or structure constituting the aircraft, the above-described steps are performed using the FSJ apparatus 50. The defect hole 60c can be repaired appropriately. In addition, since the hole repair using the FSJ is completed in a relatively short time by a simple operation, high efficiency can be realized, and cost increase can be suppressed. In addition, since the remaining portion is removed after the defective hole 60c is filled with the filler, a member that causes an increase in weight at the time of repair is not left as it is. Therefore, an increase in the weight of the aircraft during hole repair can be avoided.

(Embodiment 2)
The hole repair method according to Embodiment 2 of the present invention is a method of repairing the defective hole 60c from only one surface (for example, the surface). That is, the present invention is not limited to the method of repairing the defect hole 60c from both surfaces of the metal plate 61 as in the first embodiment. An example of the hole repair method according to the present embodiment will be specifically described with reference to FIGS. 6 (a) to 6 (e) and FIGS. 7 (a) to 7 (e). In these drawings, the arrow indicating the direction of rotation or the direction of force overlaps with that of the first embodiment, and thus the description thereof is omitted.

  In the hole repairing method according to the first embodiment, the pin member 11 is pushed in the rotational pushing process, but in the present embodiment, the shoulder member 12 is pushed. Specifically, first, as shown in FIG. 6A, in the metal plate 61, the repair preparation stage is completed, and the defective portion is filled with the filling portion 63a. Next, the metal plate 61 is supported by the clamp member 54 and the backing member 55 (metal material support step), and the rotary tool portion 51 is aligned as shown in FIG. The rotating tool part 51 is brought into contact with the area Am and is rotated while pressing the rotating members (pin member 11 and shoulder member 12).

  Here, as shown in FIG. 6C, the shoulder member 12 is pushed toward the metal plate 61 in the rotation pushing step. At this time, the shoulder member 12 is not pushed so as to reach the back surface of the metal plate 61, but is as highly accurate as possible from the back surface to the position of the interval C0 in FIG. It is preferable to push it in. As a result, the metal material plastically flows due to softening in substantially the entire thickness direction of the metal plate 61 extending from the front surface to the back surface of the repair region Am, so that the plastic flow portion 60a is not only directly below the shoulder member 12 but also directly below the pin member 11. Occurs. Further, the softened metal material of the plastic flow portion 60 a is pushed away by the shoulder member 12 and flows directly under the pin member 11, so that the pin member 11 is lifted when viewed from the shoulder member 12. In addition, the specific numerical value of the space | interval C0 is not specifically limited, Even if the rotation member has not reached the back surface by FSJ, it should just be the thickness of the metal material of the back surface vicinity so that it may plastically flow by softening. Therefore, the interval C0 is appropriately set according to conditions such as the thickness of the metal plate 61, the inner diameter of the defective hole, the area of the repair region Am, and the like.

  Thereafter, as shown in FIG. 6 (d), the protruding shoulder member 12 is gradually drawn, so that the recess formed on the surface of the metal plate 61 flows from directly below the pin member 11 to directly below the shoulder member 12. The metal material is backfilled (recess backfilling step). Thereafter, the contact surface 11a of the pin member 11 and the contact surface 12a of the shoulder member 12 are combined to shape the surface of the metal plate 61. Thereby, the surface of the metal plate 61 becomes a substantially flat surface to the extent that no substantial concave portion is generated.

  Next, as shown in FIG. 6E, the rotary tool portion 51 and the backing member 55 are separated from the metal plate 61. At this time, the plastic flow part 60a of the metal plate 61 becomes the solid phase joint part 60b. As a result, the solid phase joint 60b is formed from the front surface to the back surface in the portion where the defective hole of the metal plate 61 was present. Therefore, the filling portion 63a can be simply repaired from the front surface. Can be substantially integrated with the surrounding metal plate 61 to close the defective hole.

  Alternatively, as shown in FIG. 7A, the metal plate 61 is the same as the method according to the first embodiment in that the rivet 63 is inserted into the defective hole 60c. Is inserted from the side (see FIG. 2 (b)) on which the abuts.

  Next, as shown in FIG. 7 (b), the rotary tool portion 51 is aligned and clamped with at least the rivet head 63b left without removing or removing the caulking portion (not shown). The member 54 is brought into contact with the metal plate 61 from the surface. Further, on the back surface, a backing member 57 having a shape that can be pressed including the rivet head 63b is brought into contact. Then, the rotating members (the pin member 11 and the shoulder member 12) are brought into contact with the repair region Am of the metal plate 61 and rotated while being pressed.

  Next, as shown in FIG. 7C, similarly to the step shown in FIG. 6C, the shoulder member 12 is pushed toward the metal plate 61 in the rotary pushing step. At this time, the shoulder member 12 is not pushed so as to secure the interval C0 but is pushed so as to extend beyond the back surface of the metal plate 61 to the rivet head 63b. As a result, the metal material plastically flows due to softening not only in the entire thickness direction of the metal plate 61 but also to the metal plate 61 side of the rivet head 63b, and the plastic flow portion 60a extending from the surface of the metal plate 61 to the rivet head 63b. Occurs. Then, the softened metal material of the plastic flow portion 60 a is pushed away by the shoulder member 12 and flows directly below the pin member 11, and the pin member 11 is lifted when viewed from the shoulder member 12.

  Then, as shown in FIG.7 (d), it is backfilled with the metal material which flowed directly under the shoulder member 12 from directly under the pin member 11, and the surface of the metal plate 61 is shaped (recess backfilling process). Thereafter, as shown in FIG. 7 (e), when the rotary tool 51 and the backing member 57 are separated from the metal plate 61, the plastic flow portion 60a of the metal plate 61 and the rivet head 63b becomes a solid-phase joint 60b. . In this state, the rivet head 63 b remains on the back surface of the metal plate 61. Therefore, as shown in FIG. 7 (f), the rear surface residual portion removing step is performed to remove the rivet head 63b and a part of the solid-phase joint 60b connected thereto. As a result, the solid-phase joint 60b is formed from the front surface to the back surface at the site where the defective hole 60c of the metal plate 61 was present, and the defective hole is closed.

  In the state shown in FIG. 7B, the surface residual portion removing step may not be performed depending on the size of the caulking portion of the rivet 63 (the volume of the metal material forming the caulking portion). That is, the rotating member can be brought into contact with the caulking portion remaining, and the process can be shifted to the rotational pushing process. In this case, the hole repairing method can be simplified because it is only necessary to perform the back surface residual portion removing step after the recess backfilling step.

  As described above, in the present invention, the rotating member that is pushed into the metal material in the rotating pushing step is not limited to the pin member 11 as in the first embodiment, but the shoulder member as in the present embodiment. 12 may be sufficient. Therefore, in the recess backfilling step, the rotating member pulled out from the metal material may be the pin member 11 or the shoulder member 12. In any case, in the concave portion backfilling step, the concave portion formed in the rotary pushing step may be backfilled by both the rotating members while pulling out the pin member 11 or the shoulder member 12.

  In the present invention, the rotation pushing step and the recess backfilling step may be performed from both the front and back surfaces of the metal material as in the first embodiment, or only the front surface as in the present embodiment. You may go from. Furthermore, the remaining portion removing step may be performed on both the front and back surfaces or one surface before the metal material supporting step, or may be performed only on the back surface after the recessed portion backfilling step.

  When the remaining portion removing step is performed before the metal material supporting step (in the case of the first embodiment or the method shown in FIGS. 6 (a) to 6 (e)), the rotary pressing is performed with unnecessary fillers removed. A process and a recessed part backfilling process are performed. The remaining portion removing step is not necessarily performed as described above. However, if the remaining portion is effectively removed, the stability or reproducibility of the hole repair method can be improved. Further, when the residual portion removing step is performed after the recess backfilling step (method shown in FIGS. 7A to 7F), the hole can be repaired with the minimum necessary filler, so that the weight of the metal material is increased. Can be avoided.

  The present invention will be described more specifically based on examples, but the present invention is not limited to this. Those skilled in the art can make various changes, modifications, and alterations without departing from the scope of the present invention.

(Example 1)
First, as the FSJ apparatus 50, a double-acting FSJ robot system manufactured by Kawasaki Heavy Industries, Ltd. is used. As the rotary tool portion 51, a pin member 11 having an outer diameter of 5 mm, a shoulder member 12 having an outer diameter of 10 mm and an inner diameter of 5.1 mm, A clamp member 54 having an inner diameter of 10.05 mm and an outer diameter of 16 mm was used.

  Next, an aluminum material (AL2024C-T3, spec AMS-QQA-250 / 5) having a thickness of 0.080 inch (about 2.032 mm) is used as the metal plate 61, and as shown in FIG. A defective hole 60c of 4.85 mm was drilled in the metal plate 61, and an aluminum rivet 63 (AL-ALY2117-T4) was hammered into the defective hole 60c as shown in FIG. 2 (b). Thereafter, as shown in FIG. 2C, the rivet head 63b and the caulking portion 63c were removed (completion of the preparation stage).

  Next, as shown in FIGS. 3A to 3C and FIG. 4A, each step in the surface repair stage is performed using the FSJ apparatus 50 having the above-described configuration, and FIGS. 4B and 4C are performed. And as shown to Fig.5 (a)-(c), the metal plate 61 was turned upside down and each process of the back surface repair stage was performed. At this time, the rotational speed of the rotating members (the pin member 11 and the shoulder member 12) was set to 1500 rpm, and the pressing force was set to 4500N.

  As a result of observing the cross section of the obtained metal plate 61 after repair with an electron microscope, the boundary surface between the base material (metal plate 61) and the filler (filling portion 63a of the rivet 63) over the entire thickness direction of the metal plate 61. Disappeared substantially, and it was confirmed that they were integrated. Further, in the cross section of the metal plate 61 after the repair, the micro Vickers hardness was measured, but it was revealed that all the locations with the defective hole 60c had sufficient hardness, and the location corresponding to the filling portion 63a. In some cases, the hardness was equal to or higher than that of the filler before insertion.

(Example 2)
The pin member 11 has an outer diameter of 4 mm, the shoulder member 12 has an outer diameter of 8 mm and an inner diameter of 4.05 mm, and the clamp member 54 has an inner diameter of 8.05 mm and an outer diameter of 14 mm. Except for the above, the defect hole 60c of # 10 was repaired in the same manner as in Example 1.

  As a result, as in the first embodiment, the boundary surface between the base material (metal plate 61) and the filler (filling portion 63a of the rivet 63) substantially disappears over the entire thickness direction of the metal plate 61, so that it is integrated. It was confirmed that

  It should be noted that the present invention is not limited to the description of the above-described embodiment, and various modifications are possible within the scope of the claims, and are disclosed in different embodiments and a plurality of modifications. Embodiments obtained by appropriately combining the technical means provided are also included in the technical scope of the present invention.

  INDUSTRIAL APPLICABILITY The present invention can be widely used in the field of repairing a hole in which a defect has occurred in a drilling operation of a metal material, and can be preferably used particularly in the field of aircraft manufacturing or maintenance.

11 Pin member (Rotating member)
12 Shoulder member (Rotating member)
50 FSJ device 51 Rotating tool part 54 Clamp member 55 Backing member 57 Backing member 60c Fault hole 61 Metal plate (metal material)
63 Rivet (filler)
63a Filling part (filler)
63b Rivet head (residual part)
63c Caulking part (residual part)

Claims (4)

A cylindrical pin member that is configured to rotate around the axis and be movable back and forth in the axial direction, and is positioned so as to surround the outside of the pin member, and rotates about the same axis as the pin member. And a hole repair method for a metal material using a double-acting friction stir spot joining device including a cylindrical shoulder member configured to be movable back and forth in the axial direction ,
A hole filling step of filling the hole by inserting a filler into the hole to be repaired formed in the metal material;
While rotating the pin member and the shoulder member of the double-acting friction stir spot joining device in contact with the repair region including the hole on one surface of the metal material, the pin member or the shoulder member is rotated. A rotational push-in step for entering the repair area;
Together retract the pin member or the shoulder member from the repair area, by at least one of the pin member and the shoulder member, to return to fill the recess formed in the rotary pushing step the repair area, of the filler A concave portion backfilling step, wherein the whole filling portion filling the hole is mixed so as to be integrated with a part of the metal material ,
Hole repair method using friction stir spot welding. The double-acting friction stir spot welding device is located outside the pin member or the shoulder member, and a clamp member that presses the metal material from one surface;
A backing member provided at a position facing the clamp member,
A metal material that supports the metal material from both sides by bringing a backing member into contact with the other surface of the metal material and pressing the outside of the repair region of the one surface of the metal material with the clamp member. The hole repair method according to claim 1 , further comprising a supporting step. The hole repairing method according to claim 1 or 2 , wherein the rotation pushing step and the recess backfilling step are performed from one side or both sides of the metal material. The hole repair method according to any one of claims 1 to 3 , wherein the metal material is a part or a structure constituting an aircraft.

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