JP7445007B2 - 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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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、ショルダ先行プロセスが採用される例を示している。もちろん、本開示ではピン先行プロセスも採用可能である。
摩擦攪拌点接合は、アルミニウム合金のような金属部材同士の接合に汎用されている。接合対象が金属部材である場合、その重なり部30へのツール1の圧入深さは、比較的浅く設定される。図4は、第1部材31及び第2部材32がアルミニウム合金である場合の摩擦攪拌点接合において、一般的に形成される攪拌接合部4Aを示す断面図である。図4では、第1部材31をツール1が対向する上側部材、第2部材32を下側部材とする二層の重なり部30において、図2に示すショルダ先行プロセスによって形成された攪拌接合部4Aを例示している。
図7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、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を含む重なり部30の接合方法であって、次の工程S1~S5を含む。
・工程S1:第1部材31及び第2部材32を含む重なり部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:ショルダ12の重なり部30への圧入を開始させる。
・工程S4:ショルダ12を所要の圧入深さだけ圧入して摩擦攪拌を行う。
・工程S5:ピン11を下降させて、材料の埋め戻しを行う。
・工程S6:摩擦攪拌部のならしを行う。
・ケース(1);第1厚さt1=第2厚さt2
・ケース(2);第1厚さt1<第2厚さt2
・ケース(3);第1厚さt1>第2厚さt2
図14A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3aを示す断面図である。接合体3は、重なり方向、つまり上下方向の一端側に第1部材31が、他端側に第2部材32が配置されるように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4aとを備えている。重なり部30において、第1部材31の一部と第2部材32との一部とが、合わせ面BDで互いに当接した状態で重なり合っている。攪拌接合部4aは、第1部材31と第2部材32とが、摩擦攪拌点接合により接合された部分である。
接合強度の比較のため、本開示に係る摩擦攪拌点接合方法が適用された接合体(実施例1)と、非適用の接合体(比較例1、2)とを製作し、引張せん断試験を行った。実施例及び比較例1、2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。各接合体の重なり部30は、第1部材31をツール1が最初に圧入される側に、第2部材32をツール1が最後に圧入される側に配置してなる二層構造とした。重なり部30の摩擦攪拌は、図2に示すショルダ先行プロセスにて行った。
以上説明した、本実施形態に係る摩擦攪拌点接合方法によれば、攪拌接合部4が、第1部材31に対して厚さ方向の全長である第1厚さt1に亘って接するだけでなく、第2部材32に対しても厚さ方向の全長である第2厚さt2若しくは第1厚さt1以上に亘って接するように形成される。つまり、ツール1が最後に圧入される第2部材32において、その厚さ方向の全長若しくは第1厚さt1以上の接合幅をもって、攪拌接合部4の側周面41と第2部材32とが厚さ方向に融着接合される。攪拌接合部4の先端領域TAは、熱可塑性樹脂部材同士を摩擦攪拌点接合させた場合に低接合強度となる。また、攪拌接合部4においては、第1部材31と第2部材32との合わせ面BD付近が応力集中部SCとなり、破壊の起点部となり易い。しかし、本実施形態によれば、応力集中部SCから先端領域TAを十分に離間させ、且つ、攪拌接合部4の側周面41と母材部分とを融着させることができる。従って、第1部材31と第2部材32との接合強度を向上させることができる。
Claims (9)
- 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、第1部材及び第2部材を含む熱可塑性樹脂部材の重なり部を接合する摩擦攪拌点接合方法であって、
第1厚さを有する前記第1部材を前記ツールが最初に圧入される側に、第2厚さを有する前記第2部材を前記ツールが最後に圧入される側に各々配置して、前記重なり部を形成し、
少なくとも前記ピン又は前記ショルダを軸回りに回転させながら、前記ピン又は前記ショルダの一方を前記重なり部へ圧入すると共に、前記圧入で溢れた樹脂材料を逃がすように他方を前記重なり部から退避させ、
前記圧入を、前記ピン又は前記ショルダが前記第1部材を貫通し、且つ、前記第2部材を貫通若しくは前記第2部材の前記第1厚さ以上に相当する深さに到達するまで継続し、
前記ピン又は前記ショルダのうち、前記圧入を行った前記一方を前記重なり部から退避させると共に、退避させた前記他方を前記重なり部に接近させることで、逃がした前記樹脂材料を前記圧入の領域に埋め戻すことで、前記第1部材と前記第2部材とを摩擦攪拌点接合によって接合した部分であって、摩擦攪拌接合されていない前記第1部材および前記第2部材である母材部分に対する境界となる側周面を有する攪拌接合部と、前記側周面と前記第2部材とが融着した縦接合部と、を形成する、
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、
前記重なり部が前記第1部材及び前記第2部材の二層で構成され、且つ、前記第1厚さと前記第2厚さとが同一の厚さであるとき、
前記圧入の深さを前記第1厚さの2倍に設定することで、ピン又は前記ショルダが前記第1部材及び前記第2部材の双方を貫通するまで、前記圧入を継続させる、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、
前記重なり部が前記第1部材及び前記第2部材の二層で構成され、且つ、前記第2厚さが前記第1厚さよりも厚いとき、
前記圧入の深さを前記第1厚さの2倍以上に設定することで、ピン又は前記ショルダが前記第1部材を貫通し、且つ、少なくとも前記第2部材の前記第1厚さ以上に相当する深さに到達するまで、前記圧入を継続させる、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、
前記重なり部が前記第1部材及び前記第2部材の二層で構成され、且つ、前記第2厚さが前記第1厚さよりも薄いとき、
前記圧入の深さを前記第1厚さと前記第2厚さの加算値に設定することで、ピン又は前記ショルダが前記第1部材及び前記第2部材の双方を貫通するまで、前記圧入を継続させる、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、
前記重なり部が、前記第1部材と前記第2部材との間に、1以上の熱可塑性樹脂部材を介在させて形成される重なり部である、摩擦攪拌点接合方法。 - 請求項1~5のいずれか1項に記載の摩擦攪拌点接合方法において、
少なくとも前記第1部材及び前記第2部材の一方が、前記ツールの圧入方向に重ねられた複数枚のプレートからなる、摩擦攪拌点接合方法。 - 熱可塑性樹脂成形体からなる第1部材と第2部材とを含む接合体であって、
第1厚さを有する前記第1部材が重なり方向の一端側に、第2厚さを有する前記第2部材が重なり方向の他端側に配置されるように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部材とを摩擦攪拌点接合によって接合する部分であって、摩擦攪拌接合されていない前記第1部材および前記第2部材である母材部分に対する境界となる側周面を有する攪拌接合部と、
前記側周面と前記第2部材とが融着した縦接合部と、を備え、
前記攪拌接合部は、前記第1部材を貫通し、且つ、前記第2部材を貫通若しくは前記第2部材の前記第1厚さ以上に相当する深さに到達している、接合体。 - 請求項7に記載の接合体において、
前記重なり部が、前記第1部材と前記第2部材との間に、1以上の熱可塑性樹脂部材を介在させて形成される重なり部である、接合体。 - 請求項7又は8に記載の接合体において、
少なくとも前記第1部材及び前記第2部材の一方が、前記重なり方向に重ねられた複数枚のプレートからなる、接合体。
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