JP6498651B2 - Manufacturing method of hollow container - Google Patents

Description

The present invention relates to a method for manufacturing a hollow container .

  Friction welding has the advantage that the distortion of the workpiece is small and the machining speed is high. However, although friction welding is a solid phase bonding, it involves a dynamic process, so that there is a problem that water tightness and air tightness at the joint are likely to be unstable, and burrs are generated at the joint. For example, Patent Document 1 proposes an outer burr cutting device for a friction welding machine that is improved so that a cutting blade can be automatically positioned with respect to the outer burr.

Japanese Patent Laid-Open No. 07-51902 JP 2005-251595 A Japanese Patent Laid-Open No. 08-215863

  Further, in Patent Document 2, high-frequency induction heating is performed that facilitates high-frequency induction heating of the entire burr by high-frequency induction heating prior to burr removal by cutting, thereby facilitating and improving the efficiency of subsequent burr cutting removal. Coil devices have been proposed.

  Furthermore, a method for eliminating the need to remove burrs generated during friction welding has been proposed. For example, in Patent Document 3, in a friction welding method in which a pair of base materials gripped opposite to each other are brought into contact with each other while being rotated relative to each other to generate heat, and after the base material contact end portion is melted, the base materials are further pressed to join each other. There has been proposed a friction welding method including a step of pressing and forming a burr generated at a base material joint when the base materials are pressed against each other in a direction in which the burrs are generated.

  However, in these methods, the mechanism of the apparatus for realizing the method is complicated, and the number of steps is increased by one, which increases the cost.

From such a point of view, an object of the present invention is to provide a method for manufacturing a hollow container capable of improving the bonding quality while removing burrs generated by friction welding.

In order to solve such a problem, the present invention provides a friction welding process of friction welding the first metal member and the second metal member, and at least one outer surface of the first metal member and the second metal member. A welding step in which only the outer surfaces are laser welded using the generated burr as a filler material, and the first metal member and the second metal member are formed of an aluminum alloy, and the first metal member And a concave portion is formed on each of the opposing surfaces of the second metal member, and in the friction welding process, the flat end surfaces of the first metal member and the second metal member are pressed toward each other. state, a method for producing a hollow container, characterized in that to relatively and move linearly reciprocate the first metal member and the second metal member.

According to this method for manufacturing a hollow container, the water tightness and air tightness of a product composed of the first metal member and the second metal member can be improved. Moreover, it can weld easily by performing laser welding, and a finished surface can also be made beautiful. Even if a joint defect occurs in the friction welding process, the joint defect can be repaired in the welding process.

According to the method for manufacturing a hollow container according to the present invention, it is possible to improve bonding quality while removing burrs generated by friction welding.

It is a perspective view of the 1st metal member and the 2nd metal member concerning this embodiment. (A) is sectional drawing which shows the friction welding process which concerns on this embodiment, (b) is sectional drawing which shows the welding process which concerns on this embodiment. It is a figure which shows the test bodies A and B which concern on an Example, (a) is a top view, (b) is II sectional drawing of (a). It is a figure which shows the test bodies C-F which concern on an Example, (a) is a top view, (b) is II-II sectional drawing of (a). (A) shows the welding conditions of the test bodies A and B, (b) shows the welding conditions of the test bodies C and D, and (c) shows the welding conditions of the test bodies E and F. (A) is a schematic cross-sectional view of a healthy part after the friction welding process of the specimen A. (B) is a schematic cross-sectional view of a portion including a bonding defect after the friction welding process of the specimen A. (C) is a schematic cross-sectional view after the welding process of the specimen A. It is a table | surface which shows the conditions and pressure reduction rate of an Example.

  A joining method according to an embodiment of the present invention will be described in detail with reference to the drawings. As illustrated in FIG. 1, the joining method according to the present embodiment exemplifies a case where a metal hollow container 1 having a hollow portion therein is manufactured. First, the first metal member 2 and the second metal member 3 to be joined will be described. “Upper” and “Lower” in the following description are based on the states of FIGS. 1 and 2 for convenience, and do not limit the direction during friction welding or welding.

  As shown in FIG. 1, the first metal member 2 is composed of a bottom portion 11 and a side wall portion 12 erected perpendicularly to the bottom portion 11. The side wall portion 12 has a rectangular frame shape in plan view, and its upper surface is flat. The dimension of the wall thickness T of the side wall portion 12 is the same for each wall. A recess 13 is formed in the center of the opposing surface of the first metal member 2 that faces the second metal member 3. In the present embodiment, the concave portion 13 is a hollow portion having a rectangular parallelepiped shape.

  The second metal member 3 includes a bottom portion 21 and a side wall portion 22 that stands vertically to the bottom portion 21. The second metal member 3 has the same shape as the first metal member 2. The side wall portion 22 has a rectangular frame shape in plan view, and its lower surface is flat. The dimension of the wall thickness T of the side wall 22 is the same for each wall. A recess 23 is formed in the center of the opposing surface of the second metal member 3 that faces the first metal member 2. In the present embodiment, the concave portion 23 is a hollow portion having a rectangular parallelepiped shape. Although the 1st metal member 2 and the 2nd metal member 3 will not be restrict | limited especially if it is a material which can be friction-welded, such as aluminum, an aluminum alloy, and copper, in this embodiment, all are formed with the aluminum alloy.

  Next, the joining method according to this embodiment will be described. In the joining method according to the present embodiment, a butt process, a friction welding process, and a welding process are performed.

  In the abutting step, as shown in FIG. 1, the first metal member 2 and the second metal member 3 are abutted while the concave portion 13 of the first metal member 2 and the concave portion 23 of the second metal member 3 are opposed to each other. . Specifically, the upper surface of the side wall portion 12 of the first metal member 2 and the lower surface of the side wall portion 22 of the second metal member 3 are brought into surface contact. As a result, an abutting portion J having a frame shape in plan view is formed at the contact portion of each member (see FIG. 2A).

  In the friction welding process, a friction process and a pressure welding process are performed. In the friction process, the first metal member 2 and the second metal member 3 are relatively reciprocally moved in a state where the first metal member 2 and the second metal member 3 are pressed in directions close to each other. The moving direction is not particularly limited, but in the present embodiment, the moving direction is linearly moved along a direction parallel to the long side portion of the side wall portion 12. In the present embodiment, the first metal member 2 is not moved, but only the second metal member 3 is linearly reciprocated.

  Conditions in the friction process may be set as appropriate. For example, the frequency is set to 100 to 260 Hz, the amplitude is set to 1.0 to 2.0 mm, and the friction pressure is set to 20 to 60 MPa. The time for the friction process is set to about 5 to 10 seconds.

  In the press-contacting process, after the friction process is finished, the first metal member 2 and the second metal member 3 are pressed toward each other without being relatively moved. The conditions in the pressure welding process may be set as appropriate, but for example, the pressure is set to 60 to 80 MPa. The time of the pressure contact process is set to about 3 to 5 seconds. Due to the friction welding process, burrs P are generated on the entire outer periphery or a part of the outer periphery on the outer surface 12 a of the side wall portion 12 and the outer surface 22 a of the side wall portion 22.

  In the welding process, as shown in FIG. 2B, the outer surfaces 12a and 22a are welded over the entire outer periphery of the side wall 12 and the side wall 22 using burrs P and P as filler materials. The type of welding is not particularly limited, but laser welding is performed in this embodiment. After the welding process, the weld metal Q is formed on the outer surfaces 12a and 22a. As described above, the hollow container 1 having a hollow portion therein is manufactured.

  According to the joining method according to the present embodiment described above, the burrs P are removed by welding the outer surfaces 12a and 22a to each other by using the burrs P and P inevitably generated in the friction welding process as a filler material. Bonding quality can be improved. Moreover, when manufacturing the hollow container 1 which has a hollow part inside like this embodiment, improving the water-tightness and airtightness of the hollow container 1 by performing a welding process in addition to a friction welding process. Can do.

  Moreover, according to this embodiment, the burr cutting process which has been conventionally performed can be omitted. Further, laser welding can be performed easily in the welding process, and the finished surface can be made clean. Even if a joint defect occurs in the friction welding process, the joint defect can be repaired in the welding process.

  Friction welding is a solid-phase welding, but involves a dynamic process, so the water-tightness and air-tightness at the joint are likely to be unstable, and there is a problem that burrs are generated at the joint, but the quality of the joint is There is an advantage that it is hardly affected by a cast hole inside the material to be joined, a gap at the butt surface, an oxide film, dirt, and the like.

On the other hand, since welding involves melting of the surface of the material to be joined and the material to be joined by a heat source such as an arc or laser, the joining quality is such as a cast hole inside the material to be joined, a gap in the butt surface, an oxide film, dirt, etc. Although there is a problem of being easily affected, there are advantages that the water tightness and air tightness are improved and the joint surface is relatively smooth.

  As in the present invention, by performing the friction welding first, it is possible to obtain a bonded portion having high bonding strength and relatively good bonding quality. Next, by welding to the outer surface of the joint portion, the burrs generated on the outer surface can be welded as a filler material, and the water-tightness and air-tightness are further improved, and the outer surface Becomes relatively smooth.

Even if there is a cast hole inside the material to be joined or a gap, oxide film, dirt, etc. on the butt surface before friction welding, these defects etc. are crushed by material agitation by friction welding. Or finely and uniformly dispersed. For this reason, generation | occurrence | production of welding defects, such as a blowhole, can be suppressed in a welding process. Moreover, even if the penetration in the welding process is not sufficient, the water tightness and the air tightness are further improved.

  In particular, in the case of laser welding, there are advantages in common with friction welding, in which the distortion of the workpiece is small and the processing speed is high. In other words, in the present invention, a hollow container having higher quality water tightness and air tightness is manufactured by making mutual use of the mutual advantages of the friction welding process and the welding process while mutually complementing each other. be able to.

  Although the embodiment of the present invention has been described above, it is not limited to the above-described joining method. For example, in this embodiment, the welding process is performed using the burrs P on both the outer side surface 12a of the side wall portion 12 and the outer side surface 22a of the side wall portion 22, but the burrs are applied only to one of the outer side surface 12a and the outer side surface 22a. When P does not occur, a welding process may be performed using the burr P.

  Moreover, although the form which has the recessed parts 13 and 23 in the 1st metal member 2 and the 2nd metal member 3, respectively was illustrated in this embodiment, the form provided with a recessed part in any one may be sufficient. Specifically, for example, the present invention may be applied when a hollow container with a lid is manufactured by friction welding the first metal member 2 and a metal plate. Moreover, the shape of the recessed parts 13 and 23 is not restricted to a rectangular parallelepiped, and may be other shapes.

  In addition, the present invention may be applied to the case where metal members that do not have a concave portion are joined together to produce a product that does not have a hollow portion. Further, in this embodiment, the amplitude direction in the friction welding process is set to be parallel to the long side portions of the side wall portions 12 and 22, but may be set to be parallel to the short side portion. You may set diagonally with respect to a long side part. In the present embodiment, the moving direction in the friction welding process is set to be linear. However, for example, when joining cylindrical or cylindrical metal members, the metal members are rotated to perform the friction welding process. May be.

  Next, examples of the present invention will be described. In the embodiment, six test bodies for the first metal member 2 and the second metal member 3 were prepared, and the joining method described above for each test body was performed by changing the size, material, welding conditions, etc. of the test body. Went. Moreover, the pressure drop rate before and after performing a welding process about each test body was measured and compared. The specimen F was subjected to only the welding process without performing the friction welding process, and the pressure drop rate was measured.

  As shown in FIG. 3, the test bodies A and B were obtained by joining metal members having a short length (first metal member 2 and second metal member 3). As shown in FIG. 4, the test bodies D to F were formed by joining metal members (first metal member 2 and second metal member 3) that are longer than the test bodies A and B. The unit of the dimension line is mm.

  As shown in FIG. 7, the material of the first metal member 2 of the specimen A is JIS: A6063 (Si; 0.20 to 0.60%, Fe; 0.35% or less, Cu; 0.10% or less). Mn: 0.10% or less, Mg: 0.45 to 0.90%, Cr: 0.10% or less, Zn: 0.10% or less, Ti: 0.10% or less, Al; balance) .

  The material of the first metal member 2 of the test bodies B to F is JIS: A1050 (Si; 0.25% or less, Fe; 0.40% or less, Cu; 0.05% or less, Mn; 0.05% or less. Mg: 0.05% or less, Zn: 0.05% or less, V: 0.05% or less, Ti; 0.03% or less, Al; 99.50% or more).

  The material of the second metal member 3 of the test bodies A to F is JIS: ADC12 (Cu; 1.5 to 3.5%, Si; 9.6 to 12.0%, Mg; 0.3% or less, Zn 1.0% or less, Fe; 1.3% or less, Mn; 0.5% or less, Ni; 0.5% or less, Ti; 0.3% or less, Pb; 0.2% or less, Sn; 0 2% or less, Al; balance).

  In the friction process related to the friction welding process of the test body C and the test body D, the test was performed with the friction load of the test body D larger than that of the test body C and with a longer friction time.

  In the welding process according to the test bodies A and B, welding was performed using the low-power YAG laser welding apparatus under the conditions shown in FIG. In the welding process concerning the test bodies C and D, welding was performed using the fiber laser welding apparatus under the conditions of FIG. In the welding process according to the specimens E and F, welding was performed using the high-power YAG laser welding apparatus under the conditions shown in FIG.

  The pressure drop rate means the pressure reduction rate from the stage where air is supplied from a hole drilled in a part of the hollow container and the air is shut off. In this example, a hole was made in a part of the hollow container, air was supplied from the hole at 500 kPa, and the time from when the supply of air was shut off until the internal pressure of the hollow container reached 100 kPa was measured. The measurement time was up to 60 seconds, and when the internal pressure did not reach 100 kPa even after exceeding 60 seconds, the internal pressure when 60 seconds elapsed was measured.

The pressure drop rate (kPa / sec) is expressed by the following formula 1.
Pressure drop rate = (P ₀ −P _min ) / T (Formula 1)
P ₀ : Initial pressure (500 kPa)
P _min : Minimum pressure T: Time from pressure supply shut-off until reaching the minimum pressure In short, the lower the pressure drop rate, the higher the water tightness and air tightness.

  FIG. 6A is a schematic cross-sectional view of a healthy part after the friction welding process of the specimen A. On the other hand, FIG. 6B is a schematic cross-sectional view of a portion including a bonding defect after the friction welding process of the specimen A. In both (a) and (b) of FIG. 6, burrs P are generated on the inner surface and the outer surface of the side wall portion 12. In FIG. 6A, the abutting portion J is cleanly joined, but in FIG. 6B, it can be seen that a joining defect R has occurred in the abutting portion J. In the specimen A, since the second metal member 3 is harder than the first metal member 2, it is considered that the burrs P are generated only from the first metal member 2.

  FIG. 6C is a schematic cross-sectional view after the welding process of the specimen A. In FIG. 6C, the weld metal Q formed by the welding process covers the outer surfaces 12a and 22a in the vicinity of the abutting portion J. Moreover, the burr | flash P of the outer side of the side wall part 12 has disappeared. Further, the bonding defect R is also repaired.

  As shown in FIG. 7, it was confirmed that the pressure drop rate was considerably lower after performing the welding process than before performing the welding process for both of the test bodies A to E. That is, the watertightness and airtightness of the hollow container can be greatly improved by performing the welding process in addition to the friction welding process. Further, when the pressure drop rates of the test body F and other test bodies are compared, the water tightness and the air tightness can be improved by performing the friction welding process and the welding process rather than performing only the welding process.

DESCRIPTION OF SYMBOLS 1 Hollow container 2 1st metal member 3 2nd metal member 11 Bottom part 12 Side wall part 12a Outer side surface 21 Bottom part 22 Side wall part 22a Outer side surface J Butt part P Burr Q Weld metal T Wall thickness

Claims (1)

A friction welding process of friction welding the first metal member and the second metal member;
A welding step in which only the outer surfaces are laser welded with a burr generated on at least one outer surface of the first metal member and the second metal member as a filler material,
The first metal member and the second metal member are formed of an aluminum alloy,
A recess is formed in each of the opposing surfaces of the first metal member and the second metal member,
In the friction welding process, the first metal member and the second metal member are relatively straightened in a state in which the flat end surfaces of the first metal member and the second metal member are pressed in directions close to each other. The hollow container is manufactured by reciprocally moving.

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