JP7369872B2 - 摩擦攪拌点接合方法及びこれを用いた接合体 - Google Patents
摩擦攪拌点接合方法及びこれを用いた接合体 Download PDFInfo
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- JP7369872B2 JP7369872B2 JP2022545658A JP2022545658A JP7369872B2 JP 7369872 B2 JP7369872 B2 JP 7369872B2 JP 2022545658 A JP2022545658 A JP 2022545658A JP 2022545658 A JP2022545658 A JP 2022545658A JP 7369872 B2 JP7369872 B2 JP 7369872B2
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Description
先ず、図1を参照して、本開示に係る摩擦攪拌点接合方法を実行可能な、複動式の摩擦攪拌点接合装置Mの構成例を説明する。摩擦攪拌点接合装置Mは、複動式の摩擦攪拌点接合用のツール1と、ツール1を回転及び昇降駆動するツール駆動部2と、ツール駆動部2の動作を制御するコントローラCとを含む。なお、図1には「上」「下」の方向表示を付しているが、これは説明の便宜のためであり、実際のツール1の使用方向を限定する意図ではない。
続いて、本実施形態で例示しているツール1のような、複動式の摩擦攪拌点接合用ツールの一般的な使用方法について説明しておく。前記使用方法としては、大略的に、ツール1のピン11を先行して接合部材の重なり部へ圧入させるピン先行プロセスと、ショルダ12を先行して接合部材の重なり部へ圧入させるショルダ先行プロセスとがある。なお、後述する本開示の実施形態では、ピン先行プロセスが採用される。
図4は、本開示の実施形態に係る摩擦攪拌点接合方法の工程チャートを示す図である。本実施形態の摩擦攪拌点接合方法は、繊維材が混合された熱可塑性樹脂成形体からなる第1部材31及び第2部材32の接合方法であって、次の工程S1~S5を含む。
・工程S1:接合対象となる第1部材31及び第2部材32の重なり部30を形成する。・工程S2:ツール1を重なり部30の点接合位置Wに配置および回転させる。
・工程S3:ピン11を重なり部30に圧入して摩擦攪拌を行う。
・工程S4:ショルダ12を下降させて、材料の埋め戻しを行う。
・工程S5:摩擦攪拌部のならしを行う。
図11Aは、本実施形態の摩擦攪拌点接合方法により形成された第1部材31と第2部材32との接合体3を示す断面図、図11Bは図11AのE1部拡大図である。接合体3は、第1部材31と第2部材32との一部が合わせ面BDで互いに当接した状態で重なり合う重なり部30と、重なり部30に設けられた攪拌接合部4とを備えている。この攪拌接合部4は、上記の工程S1~S5の摩擦攪拌点接合方法によって接合された接合部である。
続いて、上記実施形態の比較例として、繊維材が混合された熱可塑性樹脂成形体からなる第1部材31及び第2部材32の摩擦攪拌点接合に、図3に示したショルダ先行プロセスを適用した場合の不具合を説明する。図12は、比較例の摩擦攪拌点接合方法を示す図であって、上記実施形態と同様な第1部材31及び第2部材32の重なり部30へ、ツール1のショルダ12を先行して圧入する工程を示す断面図である。
図11に示す本開示の実施例に係るピン先行プロセスによる摩擦攪拌点接合により得られた接合体3と、図16に示す比較例に係るショルダ先行プロセスによる摩擦攪拌点接合により得られた接合体3Aについて、NASM1312-8の試験方法に準拠して、引き剥がし強度の試験を行った。実施例及び比較例において接合材となる第1部材31及び第2部材32としては、厚さ3.3mmの疑似等方積層型の連続繊維CFRTP(Carbon Fiber Reinforced Thermoplastics)材を用いた。
・比較例(ショルダ先行);破断強度=1.46kN
図17Aは、実施例に係る接合体3の引き剥がし試験の状況を示す斜視図、図17Bは、引き剥がし試験後の断面図である。上側部材である第1部材31と下側部材である第2部材32とは、攪拌接合部4において剥離部41において離間している。注目すべきは、図17Aから観察されるように、第2部材32側の剥離片に攪拌接合部4から巻き込み繊維片38が付随している点である。巻き込み繊維片38は、第1部材31の連続繊維34である。
以上説明した、本開示に係る摩擦攪拌点接合方法によれば、複動式の摩擦攪拌点接合用のツール1を用い、ピン11を先行して第1部材31及び第2部材32の重なり部30に圧入させ、摩擦攪拌させる。ピン11の圧入領域は最終的に攪拌接合部4となる領域であり、重なり部30において少なくとも第1部材31に混合されている繊維材も樹脂と一緒に攪拌される。しかし、繊維材は、前記圧入領域とその周囲部分との境界部Dで綺麗に切断されず、境界部Dから一部が延び出した状態となる。つまり、ピン11の圧入領域の内周壁に延出繊維35が残存した状態が形成される。
Claims (4)
- ピンと、前記ピンが内挿される中空部を備えたショルダとを含む、複動式の摩擦攪拌点接合用のツールを用いて、繊維材が混合された熱可塑性樹脂成形体からなる第1部材と少なくとも熱可塑性樹脂を含む成形体からなる第2部材とを接合する摩擦攪拌点接合方法であって、
前記第1部材と前記第2部材とを、両者の少なくとも一部が互いに当接した状態で重なり合う重なり部が形成されるように配置し、
前記第1部材及び前記第2部材の重なり方向に前記ツールの回転軸が沿うように、前記重なり部に対して前記ツールを配置すると共に、少なくとも前記ピンを前記回転軸回りに回転させ、
前記ピンを前記第1部材側から前記重なり部へ圧入し、当該ピンの圧入領域の周囲に前記重なり部内の前記繊維材が延び出した延出繊維が残存するように摩擦攪拌を行う一方で、前記ショルダを前記重なり部に対して前記回転軸方向に退避させることで、前記ピンの圧入で溢れた樹脂成形体材料を前記退避によって生じた前記ピンの周囲領域に逃がし、
前記溢れた樹脂成形体材料が、前記周囲領域から前記圧入領域に埋め戻される際に前記延出繊維を巻き込むように、前記ショルダを前記重なり部に対して前記回転軸方向に接近させる一方で、前記ピンを前記重なり部から退避させる、
摩擦攪拌点接合方法。 - 請求項1に記載の摩擦攪拌点接合方法において、
前記第1部材及び前記第2部材は、連続繊維に熱可塑性樹脂を含浸させた成形体を含む、摩擦攪拌点接合方法。 - 請求項1又は2に記載の摩擦攪拌点接合方法において、
前記ツールは、前記ショルダが内挿される中空部を備えたクランプをさらに備え、
前記ピンの周囲領域は、前記クランプの前記中空部の内壁面と前記ピンの外周面との間に形成される環状領域であり、
前記溢れた樹脂成形体材料は、前記環状領域から前記圧入領域の中心へ向かう方向へ埋め戻される、摩擦攪拌点接合方法。 - 繊維材が混合された熱可塑性樹脂成形体からなる第1部材と、少なくとも熱可塑性樹脂を含む成形体からなる第2部材との接合体であって、
前記第1部材と前記第2部材との少なくとも一部が互いに当接した状態で重なり合う重なり部と、
前記重なり部に設けられ、前記第1部材と前記第2部材とが摩擦攪拌点接合によって接合された攪拌接合部と、を備え、
前記攪拌接合部は、当該攪拌接合部の周囲から前記重なり部内の繊維材が延び出した延出繊維が、前記攪拌接合部を構成する樹脂材の内部に進入して前記攪拌接合部と前記重なり部の母材部分とを橋絡した巻き込み部を備えている、接合体。
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