JPH11285845A - Method and device for joining metallic member - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve the service life of an electrode by providing an inlet of a cooling medium to cool the inside of the electrode in one of an abutting part side of the electrode on a metallic member and its opposite side, and providing an outlet on the remaining side to flow the cooling medium in one direction and to surely cool the abutting part side. SOLUTION: A cooling passage 37 in which a cooling water to cool the inside of an upper electrode 24 flows is extended in the vertical direction inside an electrode tip 36 of the upper electrode 24, and a cooling water inlet is provided in an upper end part of the cooling passage 37 of an electrode body 35. A cooling water outlet 37a is provided in a lower end part of the cooling passage 37 of the electrode tip 36. That is, the cooling water inlet is provided on the side opposite to an abutting part of the upper electrode 24 on a valve seat 3, and the cooling water outlet 37a is provided on the abutting part side on the valve seat 3, respectively, and the energization is achieved while cooling the upper electrode 24, in particular, the electrode tip 36 which becomes hot by passing the cooling water in one direction from the inlet to the outlet 37a.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a metal member for joining a first metal member and a second metal member by heating and pressurization caused by energization between the two metal members using electrodes. Belongs to the technical field related to the joining method and the joining apparatus.

[0002]

2. Description of the Related Art Conventionally, there have been various methods for joining metal members to each other, for example, in a case where a valve seat is joined to a peripheral portion of an opening of an intake and exhaust port of a cylinder head body in an engine cylinder head. It has been known.

[0003] For example, Japanese Patent Application Laid-Open No. H8-100
No. 701, the valve seat and A
It has been proposed that an l-type cylinder head body is brazed and joined with an Al-Zn-based brazing material and a fluoride-based flux.

Further, as disclosed in Japanese Patent Application Laid-Open No. 58-13481, for example, a method is known in which metal members are joined to each other by resistance welding utilizing contact resistance heating at a joint surface of both members. In this resistance welding, as shown in, for example, Japanese Patent Application Laid-Open No. 6-58116, a metal is infiltrated into holes of a valve seat formed of a sintered material, thereby generating heat inside the sintered material. Reducing the amount of heat to increase the amount of heat generated at the joint surface,
For example, as disclosed in Japanese Patent Application Laid-Open No. Hei 8-270499, it has been proposed to form a film on the surface of a valve seat and to melt the film at the time of coupling with a cylinder head body.

Further, as disclosed in, for example, Japanese Patent Application Laid-Open No. H8-200148, a molten reaction layer is formed while forming a plastically deformable layer on the joint surface of the cylinder head body with the valve seat and the cylinder head body. It has been proposed that solid-phase diffusion bonding (pressure welding) be performed without the need.

[0006]

By the way, as in the above-mentioned joining method by resistance welding and solid-phase diffusion joining method, the metal members are connected to each other by the heat and pressure caused by energization between the two metal members using electrodes. When joining, it is desirable to cool the inside of the electrode with a cooling medium such as cooling water in order to prevent the electrode itself from becoming hot and softening.

Therefore, conventionally, a cooling pipe for flowing a cooling medium from the side opposite to the contact portion with the metal member to the contact portion side in each electrode is provided between the entire peripheral surface and the inner wall surface of the electrode. Provided with a gap, the cooling medium flowing out of the end of the cooling pipe at the contact portion side with the metal member returns to the side opposite to the contact portion through the gap between the cooling pipe side peripheral surface and the electrode inner wall surface. It is configured as follows. That is, a forward path and a return path of the cooling medium are respectively formed inside and outside the cooling pipe, and the inlet and the outlet of the cooling medium are both located on the opposite side to the contact portion of the electrode with the metal member. ing.

However, in such a configuration, both forward and backward spaces are required in a direction substantially along the contact portion with the metal member (in a direction substantially perpendicular to the cooling pipe), and the space in that direction is small. In the electrodes, the flow rate of the cooling medium is so small that a sufficient cooling effect cannot be obtained. In particular, since the contact portion side with the metal member is a portion where the temperature is highest in the electrode, sufficient cooling is required, but the size tends to be smaller according to the shape and size of the metal to be joined. Therefore, it becomes even more difficult to sufficiently cool.
When the space is small only on the contact portion side with the metal member as described above, a method of not providing the cooling pipe on the contact portion side so as not to separate the outward path and the return path can be considered, In such a configuration, the cooling medium does not flow smoothly and stays on the contact portion side, and a sufficient cooling effect cannot be obtained.

The present invention has been made in view of the above points, and an object thereof is to provide a first metal member and a second metal member.
When the metal member is joined by heat and pressure generated by energization between the two metal members using the electrode, by improving the cooling method of the electrode, the contact portion of the electrode with the metal member is improved. An object of the present invention is to surely cool the contact portion side even if the space in the direction substantially along is small, and to improve the life of the electrode.

[0010]

In order to achieve the above object, according to the present invention, there is provided a cooling device for cooling the inside of an electrode at one of a contact portion side of a metal member and a side opposite to the contact portion. An inlet for the medium was provided, and an outlet for the cooling medium was provided on the other side, and the cooling medium was allowed to flow in one direction from the inlet to the outlet.

More specifically, according to the first aspect of the present invention, the first metal member and the second metal member are joined by heat and pressure generated by energization between the two metal members using electrodes. Target method.

[0012] An inlet of a cooling medium for cooling the inside of the electrode is provided on one of the contact side of the electrode with the first metal member or the second metal member and one of the side opposite to the contact portion, An outlet for the cooling medium is provided on the other side, and the current is supplied while the cooling medium flows in one direction from the inlet to the outlet of the electrode.

With this configuration, the space for flowing the cooling medium in one direction only needs to be in the electrode, so that a sufficient amount of the cooling medium can be supplied even if the space in the direction substantially along the contact portion of the electrode with the metal member is small. The cooling medium can flow, and can flow smoothly without causing the cooling medium to stay. Therefore,
The electrode can be reliably cooled by a simple method, and the life of the electrode can be improved by suppressing the softening of the electrode.

According to a second aspect of the present invention, in the first aspect of the present invention, the second metal member has a lower melting point than the first metal member and the second metal member on the joint surface of the first metal member. The brazing material layer is formed via a diffusion layer of a brazing material having a eutectic composition with the member and the first metal member, and the first metal member and the second metal member are separated from each other. By the heating and pressurization to a temperature equal to or higher than the melting point of the brazing material due to energization between the metal members, a diffusion layer of the brazing material and the second metal member is formed and the molten brazing material is joined to the joining surface of the two metal members While being discharged from the space, bonding is performed in a liquid phase diffusion state via the two diffusion layers.

[0015] With this, the first metal member and the second metal member are liquid-phase diffusion-bonded in a state where the brazing material is discharged and the two diffusion layers are interposed therebetween, so that the surface of the second metal member is oxidized. The coating and dirt are discharged together with the brazing material, and the two diffusion layers are directly joined without interposing the brazing material layer. Further, although the melting point of the brazing material is generally low and the heat resistance of the joint is low, the ratio of the components of the brazing material is changed by alloying the brazing material and the second metal member in the present invention. Can be increased in melting point. Therefore, strength and heat resistance higher than the used brazing material can be imparted. In the liquid phase diffusion bonding method having such an unprecedented advantage, it is necessary to increase the current supply time and increase the current value as compared with resistance welding or the like in order to reliably melt and discharge the brazing material. For this reason, the temperature of the electrode tends to be higher, and its life tends to be shortened. However, according to the present invention, no problem arises because the electrodes can be effectively cooled. Therefore, the joining strength of both metal members can be reliably improved.

According to a third aspect of the present invention, in the second aspect of the invention, the first metal member is made of an Fe-based material, the second metal member is made of an Al-based material, and the brazing material is a Zn-based material. Shall consist of

According to the present invention, since the melting point of the Zn-based brazing material is relatively low, the melting and discharging of the brazing material can be performed easily and reliably. In addition, the Zn-based brazing material easily forms the Fe-based first metal member and the Fe-Zn diffusion layer, and the Al-based second metal member and the Al-Zn diffusion layer, respectively. Further, since the bonding is performed via both diffusion layers, the generation of a brittle intermetallic compound of Fe-Al can be effectively prevented. Therefore, an optimum combination of materials for the joining method according to the second aspect of the present invention can be obtained.
By using a Zn-Al eutectic composition for the brazing material, (1) the melting point can be minimized, so that it can be melted in a short time and the joining time can be shortened. Since eutectic does not occur during the joining process as in (1), the stability of the joining can be improved, and (3) a brittle metal layer can be prevented from being generated.

According to a fourth aspect of the present invention, in the second or third aspect, the first metal member in the brazing material bath is coated with a brazing material by applying ultrasonic vibration to the first metal member. A brazing material layer and a diffusion layer of the brazing material and the first metal member are formed on the metal member.

By doing so, the oxide film and the plating layer on the surface of the first metal member are destroyed by the cavitation action by the ultrasonic wave, so that the brazing material is rubbed against the surface of the first metal member. The brazing material can be more reliably diffused to the first metal member side than the method using the effective friction. Further, a post-process for removing the flux as in the case of performing brazing using the flux is unnecessary. Therefore, the diffusion layer between the brazing material and the first metal member can be reliably formed by a simple method, and the joining strength between the two metal members can be further improved.

According to a fifth aspect of the present invention, in any one of the first to fourth aspects of the present invention, the first metal member is a sintered material, and a high electrical conductivity material is previously provided inside the first metal member. To infiltrate.

As a result, it is possible to reduce the internal resistance of the sintered material by reducing the resistance value inside the sintered material, suppress the internal heat generation during energization, and improve the bonding strength by effectively generating heat at the bonding surface. Further, it is possible to prevent the temperature of the electrode from increasing, and it is possible to more effectively suppress the softening of the electrode.

According to a sixth aspect of the present invention, in any one of the first to fourth aspects of the present invention, the first metal member is a sintered material obtained by sintering a powder material in which a high electric conductivity element is dispersed. There is.

According to the present invention, unlike the infiltration material in which Cu or the like is infiltrated, vacancies exist as they are inside the first metal member, but the high electrical conductivity element is dispersed in advance and fired. Since the connection is made, the resistance value inside the first metal member can be suppressed almost as low as the infiltration material. For this reason, even if the first metal member has pores therein, it is possible to suppress the internal heat generation at the time of energization and to perform the bonding satisfactorily as well as the electrode, as in the invention of claim 5. Temperature rise can be suppressed and the life thereof can be effectively improved. On the other hand, since the thermal conductivity becomes smaller than that of the infiltration material due to the heat insulating effect of the pores, when the first metal member is a valve seat or the like used at a high temperature, the heat shrinkage is appropriately suppressed and the oxide film is formed. It is formed. Therefore, while performing good joining,
The life of the electrode can be improved, and the manufacturing cost can be reduced by omitting the infiltration step. In addition, when used at a high temperature after joining, the wear resistance of the first metal member can be improved. Here, the “high electric conductivity element” means that the electric resistivity is 3 × 10 ⁻⁸ Ω · m.
Refers to the following elements.

According to a seventh aspect of the present invention, in the sixth aspect, the high electric conductivity element is Cu. Thus, the resistance value inside the first metal member can be effectively reduced while keeping the cost low.

According to an eighth aspect of the present invention, in any one of the first to seventh aspects of the present invention, the first metal member and the second metal member are joined by plastically flowing the joint surface of the second metal member. To do.

By doing so, the oxide film on the surface of the second metal member is effectively destroyed, so that it is not necessary to particularly protect the surface of the second metal member. On the other hand, the plastic flow of the second metal member can be easily performed by utilizing the pressing force when pressing the first and second metal members, and no special means is required. In particular, in the inventions of claims 2 to 7, the oxide film and dirt on the surface of the second metal member are discharged together with the brazing material, so that the brazing material can be surely diffused to the second metal member side, and a simple structure can be obtained. By this method, the diffusion layer between the brazing material and the second metal member can be reliably formed. Therefore, the joint strength between the two metal members can be further improved.

According to a ninth aspect of the present invention, an electrode is provided, and the first metal member and the second metal member are joined by heat and pressure caused by energization between the two metal members using the electrode. It is an invention of an apparatus for joining metal members.

According to the present invention, the flow of the cooling medium for cooling the inside of the electrode is provided on one of the contact side of the electrode and the first metal member or the second metal member and on the side opposite to the contact portion. An inlet is provided, and an outlet for the cooling medium is provided on the other side, and the cooling medium is configured to flow while flowing in one direction from the inlet to the outlet of the electrode. Thus, the same function and effect as the first aspect of the invention can be obtained.

According to a tenth aspect of the present invention, in the ninth aspect of the present invention, the brazing material having a lower melting point than the first and second metal members and having a eutectic composition with the second metal member is used. A first metal member on which the brazing material layer is formed via a diffusion layer with the first metal member, and the second metal member;
By heating and pressing to a temperature equal to or higher than the melting point of the brazing material between the two metal members, a diffusion layer of the brazing material and the second metal member is formed and the molten brazing material is removed from between the joining surfaces of the two metal members. It is configured so as to join in a liquid phase diffusion state via the two diffusion layers while discharging. By doing so, the same operation and effect as the second aspect of the invention can be obtained.

According to the eleventh aspect, in the ninth or tenth aspect,
In the invention, the first metal member and the second metal member are joined by plastically flowing the joint surface of the second metal member. With this, claim 8
The same operation and effect as those of the invention can be obtained.

[0031]

Embodiments of the present invention will be described below with reference to the drawings. However, first, a basic mode of a bonding apparatus and a bonding method of a metal member to which the present invention is applied will be described, and then, an embodiment of the present invention will be described focusing on differences from the basic mode.

(Basic Embodiment 1) FIG. 1 shows a main part of an engine cylinder head 1 as a joining metal member manufactured by a joining apparatus 20 (see FIG. 7) according to a basic embodiment 1 of the present invention. The head 1 has a substantially ring-shaped valve seat 3, 3,... At the opening peripheral portions of the four intake and exhaust ports 2b, 2b,. (First metal member) joined as described later. The periphery of the opening of each port 2b is the cylinder head 1.
Are arranged in a substantially square shape when viewed from the lower side, and each opening peripheral portion is a joint surface portion 2 a with each valve seat 3.

The inner peripheral surface of each of the valve seats 3 is formed as a valve abutting surface 3c, and is formed in a tapered shape in which the diameter decreases upward along the shape of the upper surface of the valve. The outer peripheral surface portion of each valve seat 3 is a first joint surface portion 3a with the cylinder head main body 2, is surrounded by the joint surface portion 2a of the cylinder head main body 2, and is formed in a tapered shape like the inner peripheral surface. ing. Further, the upper surface of each valve seat 3 is in the second position with the cylinder head body 2.
The joining surface portion 3b is inclined upward toward the inner peripheral side.

Each of the valve seats 3 is a sintered material made of an Fe-based material, and the pores inside are infiltrated with a Cu-based material as a high electrical conductivity material. As schematically shown in FIG. 2, the first and second joint surfaces 3 a and 3 b of each valve seat 3 with the cylinder head body 2 have Zn-
Al eutectic alloy (about 95 wt% Zn component and about 5 wt% Al
A diffusion bonding layer 5 (diffusion layer) is formed between the brazing material made of a component (a eutectic composition with a later-described material component of the cylinder head body 2) and the valve seat 3. That is, the diffusion bonding layer 5 is made of Fe—Zn formed by diffusing the Zn component of the brazing material to the valve seat 3 side.

On the other hand, the cylinder head main body 2 is made of an Al-based material, and a fusion reaction layer 6 (between the brazing material and the cylinder head main body 2) is formed on a joint surface 2a of the cylinder head main body 2 with each valve seat 3. Diffusion layer) is formed. That is, the molten reaction layer 6 is made of Zn of the brazing material.
It is made of Al-Zn formed by liquid phase diffusion of components in the molten state to the cylinder head main body 2 side.
The melting point of the brazing material is lower than that of each valve seat 3 and cylinder head body 2.

The valve seat 3 and the cylinder head main body 2 are connected to the diffusion bonding layer 5 and the molten reaction layer 6.
The diffusion bonding layer 5 and the molten reaction layer 6 have a total thickness of 1.0 μm or less. In FIG. 2, a brazing material layer 7 is formed between the diffusion bonding layer 5 and the molten reaction layer 6.
Is extremely small and can be considered to be practically negligible.

A method of manufacturing the cylinder head 1 by joining the valve seats 3 to the peripheral portions (joining surfaces 2a) of the ports 2b of the cylinder head main body 2 in the cylinder head 1 having the above-described structure will be described (note that the method will be described later). In the following manufacturing process, the top and bottom of the cylinder head body 2 and the valve seat 3 are reversed.

First, the valve seat 3 is manufactured by sintering Fe-based material powder. At this time, as shown in FIG. 3, the valve seat 3 is designed to withstand the pressing force at the time of joining the valve seat 3 and the cylinder head main body 2.
The inner peripheral side and the upper side (the lower side in FIG. 1) are formed so as to be thicker. That is, at this stage, the valve contact surface portion 3c is not formed, and the inner peripheral surface is formed to extend straight upward and the upper surface is formed to be substantially horizontal. Further, the taper angle (θ1 in FIG. 3) of the first joint surface 3a with the cylinder head body 2 is about 0.52 rad.
(30 °), and the inclination angle (θ2 in FIG. 3) of the second joint surface 3b is formed at about 0.26 rad (15 °). That is, the taper angle θ1 of the first joint surface 3a
Is too small, it is easy to embed the valve seat 3 in the cylinder head body 2, but the oxide film destruction effect on the joint surface 2a of the cylinder head body 2 is reduced. Since the embedding becomes difficult and the outermost diameter of the valve seat 3 becomes too large to make it possible to narrow the interval between the two ports 2b, 2b, it is set to about 0.52 rad (30 °).

A ring having substantially the same diameter as the valve seat 3 is manufactured by sintering a powder of a Cu-based material, and the ring is placed on the upper surface of the sintered valve seat 3 to be heated. Then, the Cu-based material is infiltrated into the interior of the valve seat 3 by being melted. Thereafter, the first and second joint surfaces 3a,
A Cu plating layer (about 2 μm) is applied to the entire surface including 3b from the viewpoint of preventing formation of an oxide film.

Subsequently, as schematically shown in FIG. 5A, the first and second joint surfaces 3a, 3b of the valve seat 3 are formed.
A brazing material layer 7 is formed on 3b via a diffusion bonding layer 5. In order to form the brazing material layer 7 and the diffusion bonding layer 5 on the valve seat 3, the surface of the valve seat 3 in the brazing material bath is coated with a brazing material by applying ultrasonic vibration (ultrasonic plating). That is, as shown in FIG. 6, one end of the diaphragm 11 is attached to the ultrasonic oscillator 12, and the valve seat 3 is placed on the upper surface of the other end of the diaphragm 11 in the bottomed container 13. In a brazing material bath 14. In this state, when ultrasonic vibration is applied to the valve seat 3 from the ultrasonic oscillator 12 via the diaphragm 11, a Cu plating layer on the surface of the valve seat 3 and a slight amount are formed by cavitation by the ultrasonic waves. The oxide film is destroyed, and the Zn component of the brazing material diffuses to the valve seat 3 side to reduce the Fe-Z
A diffusion bonding layer 5 made of n is formed, and a brazing material layer 7 is formed on the surface side of the diffusion bonding layer 5. This makes it possible to form the diffusion bonding layer 5 more reliably and easily than a method using mechanical friction in which a brazing material is rubbed against the surface of the valve seat 3. The conditions for the ultrasonic plating include, for example, a brazing material bath temperature of 400.
° C, ultrasonic output 400 W, ultrasonic vibration application time 20
Seconds can be set for each. Note that a hot-dip layer similar to the diffusion bonding layer 5 may be formed on the surface of the valve seat 3 while heating in a reducing atmosphere.

Next, the valve seat 3 is connected to the port 2 of the cylinder head body 2 which has been manufactured in advance by casting or the like.
b, which is joined to the periphery of the opening, that is, to the joint surface 2a with the valve seat 3. At this time, the joining surface portion 2a of the cylinder head main body 2 is different from the shape at the time of joining completion (the same shape as the first and second joining surface portions 3a and 3b of the valve seat 3) as shown in FIG. , About 0.79 rad (45 °).

In order to join the valve seat 3 to the joining surface 2a of the cylinder head main body 2, as shown in FIG. 7, a joining device 20 obtained by improving a commercially available projection welding machine is used. The joining device 20 has a substantially U-shaped support main body 21, and the upper and lower horizontal portions 21a and 21b of the support main body 21 are cantilevered and supported by only one vertical portion 21c. The side opposite to the portion 21c is open. A pressure cylinder 22 is provided below the upper horizontal portion 21a of the support body 21, and a cylinder rod 2 of the pressure cylinder 22 is provided below the pressure cylinder 22.
3 and a substantially cylindrical upper electrode 24 made of Cu and movable up and down on the same axis as the cylinder rod 23. On the other hand, on the upper side of the lower horizontal portion 21b, a lower electrode 25 made of Cu is provided so as to face the upper electrode 24 via a moving table 27, and a cylinder is provided on the obliquely upper surface of the lower electrode 25. The head main body 2 can be placed so that the joint surface 2 a is located above the cylinder head main body 2. The horizontal position of the movable base 27 with respect to the lower horizontal portion 21b and the inclination of the upper surface of the lower electrode 25 can be adjusted, and the center axis of the joint surface 2a for joining the valve seat 3 is vertical and The adjustment is made so as to substantially coincide with the central axis of the electrode 24.

The upper and lower electrodes 24 and 25 constitute a pair of pressure heads and are connected to a welding power source 26 housed in the vertical portion 21c of the support body 21, respectively. Cylinder head body 2 on top surface
The upper electrode 24 is brought into contact with the upper surface of the valve seat 3 in a state in which the valve seat 3 is placed on the joint surface 2a of the valve cylinder 3 so that the valve seat 3 and the cylinder head main body 2 are pressurized.
When the welding power source 26 is turned on while pressurizing by the pressure 2, a current flows from the valve seat 3 to the cylinder head body 2. 8A and 8B, the lower surface of the upper electrode 24 in contact with the upper surface of the valve seat 3 is opposite to the vertical portion 21c of the support body 21 (support body). A cut-out portion 28 is formed on the opening side of opening 21 as a non-conducting portion.

The cylinder head main body 2 is placed on the upper surface of the lower electrode 25 of the joining device 20, and the movable base 26 is moved in the horizontal direction so that the center axis of the joining surface 2 a joining the valve seat 3 substantially coincides with the upper electrode 24. After adjusting the position and the inclination of the upper surface of the lower electrode 24, the valve seat 3 is placed on the joint surface 2a. At this time, as shown in FIG. 4A, only the corners of the first and second joint surfaces 3a and 3b of the valve seat 3 are in contact with the joint surface 2a of the cylinder head body 2. That is, the valve seat 3 and the cylinder head body 2 are in line contact.

Next, the upper electrode 24 is moved downward by the operation of the pressurizing cylinder 22 to come into contact with the upper surface of the valve seat 3, and pressurization of the valve seat 3 and the cylinder head body 2 is started from this state. . This pressure is 294
About 20N (3000 kgf) is desirable. Then, as shown in FIG. 9, while maintaining this pressing force, the welding power source 26 is turned on about 1.5 seconds after the start of pressurization, and the resistance heat generated by energization between the valve seat 3 and the cylinder head body 2 is generated. As a result, heating is performed to a temperature equal to or higher than the melting point of the brazing material in the brazing material layer 7, and the brazing material is melted. This current value is desirably about 70 kA.

At this time, about 95% by weight of Zn component and about 5%
As shown in FIG. 11, the melting point of the brazing filler metal having the eutectic composition with the Al component of weight% is extremely low at about 380 ° C., and is melted immediately after the start of energization. Further, the joining surface 2a of the cylinder head main body 2 is softened by the above-described resistance heat, and the joint surface 2a of FIG.
As shown in (b), the first of the valve seat 3 is
The valve seat 3 is embedded in the cylinder head main body 2 while the corner between the joint surface 3a and the second joint surface 3b causes the joint surface 2a of the cylinder head body 2 to plastically flow.
As a result, the oxide film on the joint surface portion 2a of the cylinder head body 2 is surely destroyed, and the Zn component of the molten brazing material diffuses in the liquid phase toward the cylinder head body 2 to form the molten reaction layer 6 made of Al-Zn. (See FIG. 5B).

On the other hand, as shown in FIG. 5C, almost all the brazing material of the brazing material layer
And, it is discharged together with the oxide film and the dirt from between the second joint surfaces 3a and 3b and the joint surface 2a of the cylinder head body 2. For this reason, the diffusion bonding layer 5 does not pass through the brazing material layer 7.
And the molten reaction layer 6 are directly joined to each other,
Diffusion between them is further promoted. In addition, the formation of a brittle intermetallic compound of Fe—Al can be effectively prevented through the two layers 5 and 6. Therefore, the valve seat 3 and the cylinder head body 2 are joined in a liquid phase diffusion state via the diffusion joining layer 5 and the molten reaction layer 6,
Its bonding strength is very high. Even if a small amount of the brazing material layer 7 remains, the Zn ratio of the brazing material decreases due to diffusion, and its melting point rises to about 500 ° C. or higher (see FIG. 11). For this reason, after joining, it has heat resistance higher than the melting point of the brazing material used.

Furthermore, since the inside of the valve seat 3 is infiltrated with a Cu-based material having a high electrical conductivity, the pores formed by sintering are filled with the Cu-based material, and a part of the pressure is applied. Is not used to crush the above-mentioned hole, and all of the pressing force is used to directly plastically flow the joint surface portion 2a of the cylinder head body 2 and to discharge the brazing material. The heat generation inside the valve seat 3 can be suppressed, and the brazing material can be effectively melted.

Further, the upper and lower horizontal portions 21a,
The upper and lower horizontal portions 21a, 2b are cantilevered portions.
Due to the flexure of 1b, the pressing force is reduced on the opening side of the support main body 21, and the contact resistance of the joint surfaces 2a, 3a, 3b corresponding to the opening side of the support main body 21 is increased by that amount, so that the heat generation on the opening side is generated. If the amount becomes excessive, the cylinder head main body 2 may locally melt and a gap with the valve seat 3 may occur. In order to prevent this, as described above, the cutout 28 may be formed on the lower surface of the upper electrode 24 on the opening side of the support body 21. In this case, the current value is small in portions corresponding to the valve seat 3 and the opening side of the support main body 21 of the cylinder head main body 2. For this reason, there is no possibility that the opening side of the support body 21 in the cylinder head body 2 is locally melted and a gap is formed between the cylinder head body 2 and the valve seat 3. Further, since the center axes of the cylinder rod 23 of the pressurizing cylinder 22 and the upper electrode 24 coincide with each other,
Compared to a device in which they do not match, it is possible to reduce the difference in the pressing force in the entire upper electrode 24 and the change in the horizontal position of the upper electrode 24, and the degree of the notch in the notch 28 can be reduced. The misalignment of the valve seat 3 with respect to the joint surface 2a of the cylinder head main body 2 can be prevented. It should be noted that local melting of the cylinder head main body 2 can also be prevented by attaching an insulating member to the lower surface of the upper electrode 24 instead of providing the cutout 28.

Subsequently, when 1.5 to 2.5 seconds have elapsed from the start of energization, the welding power source 26 is turned off to stop energization.
The valve seat 3 is a joint surface 2a of the cylinder head body 2.
(See FIG. 4 (c)).
At this time, the pressurization is continued without stopping. That is, the pressing force is maintained until the molten reaction layer 6 is completely solidified and cooled, and the respective joint surfaces 2 a, 3 a,.
3b prevents peeling and cracking.

As shown in FIG. 10, it is more desirable to reduce the pressing force almost simultaneously with stopping the energization. That is, since there is a high possibility that cracks will occur in the joint surfaces 2a, 3a and 3b due to the pressure immediately after solidification where the deformability becomes small with a large pressing force, the pressing force is reduced to a level that can follow the shrinkage deformation, Cracks at the joint surfaces 2a, 3a, 3b after solidification by pressure are reliably prevented.

Thereafter, the pressure is stopped about 1.5 seconds after the energization is stopped, and the joining between the valve seat 3 and the cylinder head body 2 is completed. Subsequently, the same operation is repeated in the same cylinder head main body 2 so that the remaining 3
The valve seats 3 are joined to the two joining surfaces 2a, 2a,.

Finally, the inner peripheral surface portion and the upper surface portion of each valve seat 3 are cut to form a valve contact surface portion 3c and finished in a predetermined shape. Thus, the cylinder head 1 in which the valve seats 3 are joined to the peripheral portions of the openings of the ports 2b of the cylinder head body 2 is completed.

Therefore, in the first embodiment, the valve seat 3 and the cylinder head main body 2 are joined in a liquid-phase diffusion state via the diffusion joining layer 5 and the molten reaction layer 6 by the heat and pressure generated by energization. As a result, the cylinder head 1 having high bonding strength and heat resistance higher than that of the brazing filler metal used can be obtained in a short time. Further, since it is only necessary to set the pressing force and the current value so that the brazing material can be melted and discharged, the condition range in which high joining strength can be obtained is wide. In addition, the valve seat 3 can be made much smaller than the joining method by shrink fit,
The distance between the two ports 2b, 2b can be reduced or the throat diameter can be increased. Further, the thermal conductivity in the vicinity of the valve can be improved without forming a heat insulating layer, and the cooling water passage provided between the ports 2b, 2b can be made closer to the valve seat side. The temperature in the vicinity can be effectively reduced. In addition, connect a glow plug or injector to port 2
Even if it is arranged between b and 2b, the wall thickness between them can be sufficiently ensured. Therefore, the performance, reliability and design freedom of the engine can be improved.

In the first embodiment, each of the valve seats 3 is manufactured by sintering and the Cu-based material is infiltrated therein. However, the density inside each of the valve seats 3 may be secured to some extent. If so, it is not necessary to infiltrate. In addition, by forming each valve seat 3 as a sintered forged material obtained by forging after sintering, it is possible to eliminate voids inside the valve seat 3 in the same manner as infiltration. The material can be discharged effectively.

In the first embodiment, the brazing material is heated to a temperature equal to or higher than the melting point of the brazing material in the brazing material layer 7 by resistance heat generated by energization between the valve seat 3 and the cylinder head body 2. The brazing material may be melted by local heating such as high-frequency heating.

(Basic Mode 2) FIG. 12 shows a basic mode 2 of the present invention. The method of controlling the energization when the valve seat 3 and the cylinder head main body 2 are joined is different from the basic mode 1.

That is, in this basic mode, a current is not continuously supplied at a constant current value, but a pulse is applied by repeating a large and small current value. The current value on the larger side of the pulse current is constant at about 70 kA,
The smaller current value is set to zero. The energizing time of the large current value pulse is 0.25 to 1 second, and the energizing time of the small current value pulse (time during which no current is flowing) is 0.1 to 1 second.
It is about 0.5 seconds. Furthermore, the number of high current value pulses is 3 to
Nine pulses (four pulses in FIG. 12) are desirable. Note that the time from the start of pressurization to the start of energization of the first large current value pulse and the time from the stop of energization of the last large current value pulse to stop of pressurization are 1.5 seconds, which are the same as in the first embodiment.

FIG. 13 shows a change in the temperature of the valve seat 3 when such a pulse current is applied. That is, since the heat capacity of the valve seat 3 made of the Fe-based material is considerably small, the temperature rise due to the resistance heat generation of the valve seat 3 is remarkable. It is harder to dissipate heat than the upper and lower ends, and the contact resistance between the valve seat 3 and the cylinder head body 2 is high when the first large current value pulse is applied. The temperature at the center is equal to or higher than the A1 transformation point when the first large current value pulse is stopped. At this stage, since the valve seat 3 is almost completely embedded in the cylinder head main body 2, it is possible to completely stop the energization. However, the valve seat 3 is kept at a temperature above the A1 transformation point. Since it is rapidly cooled, its center in the vertical direction is baked and its hardness increases.

Therefore, when the temperature slightly decreases, the second large current value pulse is applied. At this time, unlike the first energization of the large current value pulse, the contact resistance is reduced by metallurgical bonding, the resistance heating value is reduced, and heat is also released, so even if the current value is the same as the initial value, the temperature is not so much By repeating this process without increasing the hardness, the valve seat 3 hardly increases in hardness.

Therefore, in the basic embodiment 2, the temperature of the central portion in the vertical direction of the valve seat 3 is gradually decreased by the pulse current, so that the hardness of the valve seat 3 does not greatly increase. Deterioration in workability when cutting the peripheral surface portion can be prevented. In addition, it is possible to effectively suppress the valve from being easily worn due to the valve contact surface 3c being too hard.

In the second embodiment, the large current value of the pulse current is fixed and the small current value is set to 0. However, the present invention is not limited to this. For example, as shown in FIG. May be reduced stepwise, and as shown in FIG. 14B, the small current value may be set to an intermediate value between the large current value and 0 without being set to 0. Further, as shown in FIG. 14 (c), after applying the first large current value pulse and then applying the small current value pulse (0 in FIG. 14 (c)), the current value is proportional to time. Alternatively, any energization control may be performed as long as the valve seat 3 can be gradually cooled after the energization of the first large current value pulse is stopped.

In order to improve the heat radiation to the upper electrode 24 of the valve seat 3, it is desirable to cool the water through the cooling water through the upper electrode 24. further,
As shown in FIG. 15, a cylindrical projection 31 facing the inner peripheral surface of the valve seat 3 is provided below the upper electrode 24, and is provided on the outer periphery of the projection 31 at substantially equal intervals in the circumferential direction. The cooling water in the upper electrode 24 may be sprayed onto the inner peripheral surface of the valve seat 3 from the plurality of nozzles 32, 32,. This effectively cools the central portion in the vertical direction of the valve seat 3 and can prevent the valve seat 3 from being overheated to the A1 transformation point or higher.

(Basic Embodiment 3) FIG. 16 shows a basic embodiment 3 of the present invention, in which the method of controlling the energization at the time of joining the valve seat 3 and the cylinder head body 2 is different from the above-mentioned basic embodiments 1 and 2. .

That is, in this basic mode, the joining device 2
0 is a limit switch (not shown) as a seat position detecting means for detecting the position of the valve seat 3 in the height direction.
And the limit switch is operated at a joint position where the valve seat 3 is almost completely embedded in the cylinder head main body 2. Then, after the energization starts, when this limit switch operates,
The current is switched to a constant current value smaller than the initial current value (about 70 kA) at the start of energization. Then, the stop of the energization after the switching is performed in a time, and is stopped in 1.5 to 5 seconds from the start of the energization of the initial current value.

A description will now be given of the behavior in the case where the energization control of switching the current value to a small current value in a state where the valve seat 3 is almost completely embedded in the cylinder head body 2 as described above.

First, at the start of energization, as described in the basic embodiment 2, since the temperature of the valve seat 3 is much higher than that of the cylinder head body 2 made of an Al-based material, the coefficient of thermal expansion (linear expansion coefficient) is increased. Is smaller than the cylinder head body 2, but the thermal expansion amount is large. For this reason,
When energization is completely stopped in a state where the valve seat 3 is almost completely embedded in the cylinder head main body 2, since the contraction amount of the valve seat 3 is larger than that of the cylinder head main body 2, tensile thermal stress is generated in the valve seat 3. .

Therefore, when the current is switched to a current value smaller than the initial current value and the energization is performed, the temperature of the valve seat 3 gradually decreases as in the basic embodiment 2. On the other hand, since the temperature of the cylinder head body 2 rises due to the heat from the valve seat 3, the temperature difference between the valve seat 3 and the cylinder head body 2 becomes smaller. If the current supply is stopped in this state, the difference in the amount of contraction becomes small, and the thermal stress generated in the valve seat 3 can be reduced.

Therefore, in the basic mode 3, the valve seat 3 is switched to a current value smaller than the initial current value when the valve seat 3 is almost completely embedded in the cylinder head main body 2, so that the valve seat 3 and the cylinder head main body are switched. The difference in the amount of thermal expansion (shrinkage) caused by the difference between the heat capacity and the coefficient of thermal expansion of the second element can be reduced. Therefore,
The tensile thermal stress generated in the valve seat 3 can be reduced, and the occurrence of vertical cracks on the inner peripheral surface can be prevented.

In the third embodiment, the current value after switching by the operation of the limit switch is fixed. However, the present invention is not limited to this. For example, as shown in FIG. As shown in FIG. 17B, after the limit switch is actuated, the large current value is smaller than the initial current value, as shown in FIG. Pulse current may be applied. Further, even with the same energization control method as in the basic mode 2, the same operation and effect can be obtained.

In the third embodiment, the current value is switched by detecting the position of the valve seat 3 in the height direction by the limit switch. However, a position detecting means such as an optical sensor may be used. May be controlled instead of detecting the time. In this case, it is desirable to switch the current value within 0.25 to 1 second (more preferably, 0.25 to 0.5 second) from the start of energization. In this time, the valve seat 3 is almost completely connected to the cylinder head body 2. It will be switched in the state embedded in.

Further, before joining the valve seat 3 to the cylinder head main body 2, the cylinder head main body 2 is
It is desirable to preheat to about ° C. By doing so, the temperature difference between them becomes even smaller, and the thermal stress can be kept low. As a result, the valve seat 3
Can reliably be prevented from occurring, and switching of the current value after operation of the limit switch can be made unnecessary. In order to preheat the cylinder head body 2 in this manner, the above-described joining device 20 may be used. That is, the upper and lower electrodes 24 and 25 of the joining device 20 are replaced with carbon electrodes, and the welding power source is turned on with the cylinder head body 2 sandwiched between the electrodes 24 and 25 to perform preheating. . At this time, since both electrodes 24 and 25 are made of carbon, self-heating is large and the cylinder head body 2 can be efficiently preheated. In this way, it is possible to cope with inlining.

As shown in FIG. 18, an upper surface tapered portion 3 d whose height increases toward the inner peripheral surface is provided on the upper portion of the valve seat 3, while the valve seat 3 is provided on the lower portion of the upper electrode 24. A conical concave portion 34 into which the upper tapered portion 3d of the valve seat 3 substantially fits may be formed, and the pressure may be applied while the upper tapered portion 3d of the valve seat 3 is substantially fitted into the concave portion 34 of the upper electrode 24. . That is, when the pressure is applied in this manner, the pressing force acts also in the diameter reducing direction of the valve seat 3, so that even if the temperature of the valve seat 3 rises, the expansion can be prevented, and the cylinder head body 2 Is large, the difference in the amount of shrinkage is small. Therefore, even in this case, generation of a vertical crack in the valve seat 3 can be prevented.

Further, as shown in FIG. 19, chamfered portions 3e, 3e are formed at corners of the inner peripheral surface, the upper surface, and the lower surface in order to reduce stress concentration on the inner peripheral surface of the valve seat 3. It is desirable.

Further, since the inner peripheral surface side of the valve seat 3 is a part to be finally scraped off, only the part to be shaved can be sintered as an inexpensive material.

(Basic Mode 4) FIG. 20 shows a main part of a joining apparatus 20 according to a basic mode 4 of the present invention (note that the same parts as those in FIG. 7 are not described in detail, and only different points are described. This will be described), and the energization paths are different from those of the above-described basic modes 1 to 3.

That is, in this basic mode, the joining device 2
0 has a lower electrode 25 as in the above basic embodiments 1 to 3, but this lower electrode 25 is not connected to the welding power source 26 and is used to press the valve seat 3 and the cylinder head body 2. Only used. And the upper electrode 2
4 comprises two first and second electrodes 24a, 24b,
This first electrode 24a is the same as the above-described basic embodiments 1 to 3. On the other hand, the second electrode 24b can be vertically moved independently by another pressure cylinder similar to the pressure cylinder 22 for vertically moving the first electrode 24a. Also,
Unlike the first electrode 24a, the second electrode 24b is made of carbon, and both electrodes 24a and 24b are connected to a welding power source 26, respectively.

The first and second electrodes 24a and 24b are
In the same cylinder head body 2, it comes into contact with the upper surfaces of the unjoined valve seat 3 newly joined and the joined valve seat 3 joined previously, respectively. When the welding power source 26 is turned on, the current flows through the first electrode 24a, the unjoined valve seat 3, the cylinder head body 2, the already-joined valve seat 3, and the second electrode 24b in order.
It returns to the welding power source 26. Thus, the already-joined valve seat 3 serves as a return-side energization path when the unjoined valve seat 3 is joined.

Therefore, in the basic embodiment 4, when the unjoined valve seat 3 is joined, the resistance heating value is small on the already-joined valve seat 3 side and the internal temperature of the already-joined valve seat 3 is similar to that of the unjoined valve seat 3. However, since the second electrode 24b made of carbon self-heats, even if the already-sealed valve seat 3 is hardened and hardened as described in the basic embodiment 2, In addition, tempering can be performed appropriately. Moreover, the tempered valve seat 3 can be tempered without increasing the number of steps in-line. Therefore, it is possible to effectively suppress the thermal effect of increasing the hardness of the valve seat 3 at the time of joining.

In the basic mode 4, the second electrode 24b
Is made of carbon. However, since this is a material having the largest self-heating value, if the temperature of the joined valve seat 3 becomes too high, the second electrode 24b is made of, for example, iron or brass, and tempering is effective. What can be done can be selected.

(Fifth Embodiment) FIG. 21 shows a piston 41 of a diesel engine as a joining metal member according to a fifth embodiment of the present invention. Piston body 42
A wear-resistant ring 43 (first metal member) made of an Fe-based material is provided on the upper outer peripheral portion of the (second metal member).
The lip in the combustion chamber 42a provided at the upper center of
An e-based (for example, austenitic stainless steel) reinforcing member 44 (first metal member) is joined to each other.

That is, conventionally, the piston body 42 is cast by casting the wear ring 43, but the piston body 4
2 is T6 heat treated to improve its strength,
Since the brittle intermetallic compound of Fe-Al is generated when the wear ring 43 is cast, it is impossible to perform the T6 heat treatment. However, in this basic mode, the piston body 42 is subjected to T6 heat treatment in advance, and the piston body 42
Can be joined to the wear ring 43. Even if the wear ring 43 is joined to the piston main body 42 and then subjected to T6 heat treatment, the heat resistance is good and Fe-Al is hardly generated, so there is no problem. Therefore, both the wear resistance and the strength of the piston 41 can be improved.

On the other hand, the wall inside the combustion chamber 42a of the piston main body 42 has a problem that cracks tend to occur particularly at corners. However, in this basic mode, since the reinforcing member 44 is joined to the lip portion in the combustion chamber 42a, it is possible to prevent the occurrence of cracks in the wall portion in the combustion chamber 42a.

(Basic Embodiment 6) FIG. 22 shows a main part of an engine cylinder block 51 as a joining metal member according to a basic embodiment 6 of the present invention.
As in the first embodiment, a rib member 53 (first metal member) made of an Fe-based material is joined to an upper part of a water jacket 52a of a cylinder block body 52 (second metal member) made of an Al-based material. Be done. Reference numeral 54 denotes a cast iron liner fitted to the inner peripheral surface of the cylinder.

That is, conventionally, the cylinder block 51
In order to improve the rigidity of the cylinder block 52, a rib is integrally formed on the upper portion of the water jacket portion using a sand core at the time of casting of the cylinder block body 52. However, this method requires a long cycle time at the time of casting. And there is a problem that productivity is poor. However, in this basic mode, the casting of the cylinder block body 52 is facilitated while the rib members 5 are formed.
3 can be joined to the upper part of the water jacket 52a of the cylinder block main body 52 in a short time, and the rigidity of the cylinder block can be improved. For this reason,
The deformation of the liner 54 on the inner peripheral surface of the cylinder can be prevented, and the performance of the engine such as LOC and NVH can be improved. Also, it can be made linerless.

(Embodiment) An embodiment of the present invention will be described with reference to FIG. In this embodiment,
A description will be given of a case where the cylinder head body 2 and the valve seat 3 are joined as in the above-described basic embodiments 1 to 4. However, as in the above-described basic embodiments 5 and 6, the piston body 42 and the wear ring 4 are connected.
The present invention can be similarly applied to the case where the third member 3 is joined or the case where the cylinder block body 52 and the rib member 53 are joined.

In this embodiment, first, the material of the valve seat 3 is different from the above-mentioned basic form. That is, the valve seat 3 is a sintered material obtained by sintering an Fe-based powder raw material in which Cu as a high electrical conductivity element is substantially uniformly dispersed throughout, and has an internal In the hole of C
The joining is performed without infiltrating the u-based material. The valve seat 3 is immersed in a brazing material bath 14 to form a diffusion bonding layer 5 and a brazing material layer 7 between the brazing material and the valve seat 3 on the surface of the valve seat 3 by applying ultrasonic vibration. After that, the upper part of the valve seat 3 (the contact part of the upper electrode 24)
Is removed by cutting or the like in advance before the upper electrode 24 is brought into contact. In addition, not only the brazing material layer 7 but also the diffusion bonding layer 5 may be removed above the valve seat 3.

Secondly, the difference from the above basic form is the taper angle of the joint surface 2a of the cylinder head body 2 before the valve seat 3 is joined, which is about 0.79 rad (45 °).
Instead, the same as the taper angle θ1 of the first joint surface 3a of the valve seat 3 with the cylinder head main body 2 is about 0.5.
It is set to 2 rad (30 °). That is, in the above-described basic form, while the valve seat 3 and the cylinder head body 2 are in line contact with each other in advance and the energization and pressurization are performed to make surface contact from the middle of the joining, the valve seat 3 The energization and pressurization are performed in a state where the 1 joining surface 3a and the joining surface 2a of the cylinder head body 2 are in surface contact. Here, the term “surface contact” means that the contact area is 40 to 200 mm ² (preferably 40 to 100 mm ² ).
It means that.

Third, the structure of the upper electrode 24 of the joining device 20 is different. The upper electrode 24 is composed of an electrode body 35 and a substantially cylindrical electrode tip 36 attached to the tip of the electrode body 35 by screwing. It consists of At the center of the lower surface of the electrode chip 36, a protruding portion 36a projecting from the lower surface of the electrode chip 36 (the surface in contact with the valve seat 3) to the valve seat 3 side is formed. This protrusion 36a
Is a tapered side peripheral surface 36 that can be substantially fitted to the inner peripheral surface portion of the valve seat 3 and has a diameter that gradually decreases toward the distal end.
It is formed in a substantially cylindrical shape having b. When the lower surface of the electrode tip 36 is in contact with the valve seat 3, the protrusion 36 a is formed on the inner peripheral surface of the valve seat 3 (side surface along the pressing direction) on the entire peripheral surface 36 b of the protrusion 36 a. ). This protrusion 3
When the valve seat 3 is pressurized on the lower surface of the electrode chip 36 at a position (base end) having substantially the same height as the contact surface with the valve seat 3 over the entire side peripheral surface 36b of 6a. A positioning portion 36c that regulates movement in the horizontal direction (direction substantially perpendicular to the pressing direction) is set. Positioning portion 36 on side peripheral surface 36b of protrusion 36a
The amount of gap between c and the inner peripheral surface of the valve seat 3 is such that the valve seat 3 may move in a substantially horizontal direction (for example, 0.1 m).
m), the gap between the portion of the side peripheral surface 36b of the protruding portion 36a other than the positioning portion 36c and the inner peripheral surface of the valve seat 3 is such that the inner peripheral surface of the valve seat 3 is inwardly pressurized. The deformation is set to such a degree that the deformation is hardly restrained even if it is deformed to the side where the inner peripheral surface portion diameter becomes smaller.

The electrode tip 36 of the upper electrode 24
Inside, a cooling passage 37 through which cooling water (cooling medium) for cooling the inside of the upper electrode 24 flows is formed so as to extend in the vertical direction. The upper end of the cooling passage 37 is connected to the lower end of a cooling passage (not shown) provided in the electrode body 35 so as to extend in the vertical direction. An inlet is provided. on the other hand,
At the lower end of the cooling passage 37 of the electrode tip 36, an outlet 37a for cooling water that opens to the side of the electrode tip 36 is provided. That is, an inlet of the cooling water is provided on the side of the upper electrode 24 opposite to the contact portion with the valve seat 3, and an outlet 37 a of the cooling water is provided on the side of the contact portion with the valve seat 3. The cooling water is flowed in one direction from the outlet 37a to the upper electrode 24 (particularly, the electrode tip 36 having a high temperature).
The power is supplied while cooling. The outlet 37a has a discharge pipe 38 for discharging the cooling water.
Are connected by screwing.

Therefore, in the above-described embodiment, the material of the valve seat 3 is a sintered material obtained by sintering an Fe-based powder material in which Cu as a high electric conductivity element is dispersed, and the pores in the sintered material are formed. Since the joining is performed without infiltrating the Cu-based material, the resistance value of the valve seat 3 is made substantially the same as that in which the Cu-based material is infiltrated by the Cu dispersed in advance even if the holes exist. It can be kept low. For this reason, similarly to the above-described basic mode, it is possible to suppress the internal heat generation at the time of energization and to perform the joining satisfactorily. On the other hand, since the thermal conductivity is lower than that of the infiltrated hole due to the heat insulating effect of the pores, the heat release of the valve seat 3 is appropriately suppressed during the operation of the engine, and an oxide film is formed. Can be improved in abrasion resistance.

Since the thermal conductivity of the valve seat 3 is low as described above, if the energization and the pressurization are performed in a state where the valve seats are brought into line contact in advance as in the above-described basic form, each of the joining surfaces 2a, 2a, The amount of heat generated at 3a and 3b becomes considerably large, and the valve seat 3 is easily overheated. Moreover,
Since the strength is relatively small due to the presence of the holes, the first and second joint surfaces 3a and 3b of the valve seat 3 are easily deformed. For this reason, the plastic flow in the joint surface 2a of the cylinder head main body 2 is not sufficient, and the effect of breaking the oxide film cannot be sufficiently obtained. However, in this embodiment,
Since the first joint surface 3a of the valve seat 3 and the joint surface 2a of the cylinder head body 2 are brought into contact with each other in advance in a state where they are in surface contact with each other, the respective joint surfaces 2a, 3a,
Overheating can be prevented by setting the heat value in 3b to an appropriate value. Accordingly, it is possible to prevent the valve seat 3 from being excessively hardened even when the valve seat 3 is rapidly cooled due to the stop of the energization, and the first and second joint surfaces 3a, 3 of the valve seat 3.
The deformation of b can be prevented, and the joining can be performed more favorably.

Further, a predetermined gap is provided between the lower surface of the electrode chip 36 of the upper electrode 24 and the entire inner peripheral surface of the valve seat 3 when the lower surface of the electrode chip 36 is in contact with the valve seat 3. A substantially cylindrical protruding portion 36a is formed, and a positioning portion 36c set on the entire circumference of the base end portion of the side peripheral surface 36b of the protruding portion 36a restricts the movement of the valve seat 3 in a substantially horizontal direction during pressurization. Therefore, by setting the gap amount to an appropriate value, even if the inner peripheral surface portion of the valve seat 3 is deformed inward during pressurization, it is possible to reliably restrict the movement of the valve seat 3 in almost all directions in the horizontal direction. In addition, almost no force acts on the valve seat 3 in the radially increasing direction. For this reason, the valve seat 3 does not crack, and the surface of the protruding portion 36a does not rub against the valve seat 3 when the upper electrode 24 is separated from the valve seat 3 after joining. The protrusion 36a
Is formed in a tapered shape whose diameter decreases toward the tip of the protruding portion 36a, so that the protruding portion 36a can be more smoothly removed from the inner peripheral surface portion of the valve seat 3. Therefore, the valve seat 3 can be favorably positioned with respect to the cylinder head main body 2 while preventing the occurrence of cracks in the valve seat 3 and a reduction in the life of the upper electrode 24.

Further, an inlet for cooling water is provided on the side of the upper electrode 24 opposite to the contact portion with the valve seat 3, and an outlet 37a for cooling water is provided on the side of contact with the valve seat 3, respectively. Since the cooling water flows in one direction from the inflow port to the outflow port 37a to cool the upper electrode 24, there is no need for a space in which the cooling water is reciprocated up and down as in the related art. Even if the diameter of the electrode tip 36 (space in a direction substantially along the contact portion with the valve seat 3) is small, a sufficient amount of cooling water can flow smoothly without stagnation. Therefore, the upper electrode 24 can be reliably cooled by a simple method, and the softening of the upper electrode 24 can be suppressed and the life can be improved.

Further, since the brazing material layer 7 at the contact portion of the upper electrode 24 of the valve seat 3 is removed in advance before the upper electrode 24 is brought into contact with the upper electrode 24, the brazing material layer 7 is provided below the electrode chip 36 of the upper electrode 24 at the time of energization. The generation of brittle brass, which is an alloy of the Cu component of the chip 36 and the Zn component of the brazing material, can be prevented, and this also improves the life of the upper electrode 24.

In the above-described embodiment, Cu is uniformly dispersed throughout the valve seat 3. However, the proportion of Cu in the portion of the valve seat 3 opposite to the cylinder head body 2 is changed from that of the cylinder head body 2 side portion. The electric conductivity of the part opposite to the cylinder head main body 2 may be made higher than that of the cylinder head main body 2. That is,
For example, preliminarily sintered with different materials,
The sintering may be performed by bringing them into contact. By doing so, the amount of heat generated inside the valve seat 3 is kept small,
The heat value at each of the joint surfaces 2a, 3a, 3b can be adjusted to an appropriate value, and the valve seat 3 can be adjusted.
The vicinity of the first and second joint surfaces 3a, 3b can be made of a material having high strength and good wear resistance. For this reason, the first and second joint surfaces 3a, 3b of the valve seat 3
Can be more effectively prevented from being deformed due to overheating at the time of joining, and a valve contact surface portion 3c formed by shaving off a portion opposite to the cylinder head main body 2 and finally being formed
Is made of a material having high strength and good wear resistance. The high electric conductivity element dispersed in the powder material before sintering is not limited to Cu, but Ag having higher electric conductivity than Cu or an element having an electric resistivity of 3 × 10 ⁻⁸ Ω · m or less is used as the powder material. May be dispersed and sintered. In this case, the thermal conductivity of the element is desirably 2 J / cm · s · K or more.

Further, in the above-described embodiment, energization and pressurization are performed in a state where the first joint surface 3a of the valve seat 3 and the joint surface 2a of the cylinder head body 2 are brought into surface contact in advance. As shown in FIG. 2, the second joint surface 3b of the valve seat 3 and the joint surface 2a of the cylinder head body 2
May be brought into surface contact. As shown in FIGS. 25 and 26, a third joint surface 3f is formed between the first joint surface 3a and the second joint surface 3b of the valve seat 3, and the third joint surface 3f is connected to the cylinder head. The joint surface portion 2a of the body 2 may be brought into surface contact (FIG. 25), and the second joint surface portion 3b of the valve seat 3 on which the third joint surface portion 3f is formed and the joint surface portion 2a of the cylinder head body 2 are brought into contact. (FIG. 2
6). The surface contact is made in advance in such a case that the valve seat 3 is made of a sintered material obtained by sintering an Fe-based powder raw material in which a high electric conductivity element such as Cu is dispersed as in the above embodiment. The sintered material (Cu) obtained by sintering a powder material consisting only of conventionally used non-high electric conductivity elements (elements having an electric resistivity of more than 3 × 10 ⁻⁸ Ω · m) which is conventionally used (Which does not infiltrate the base material or the like). Further, a material composed of only the non-high electric conductivity element other than the sintered material may be used. Even in such a case,
Overheating of the entire valve seat 3 can be suppressed as much as possible.

Further, in the above embodiment, the upper electrode 24
The cooling water inlet is provided on the side opposite to the contact portion with the valve seat 3 and the contact portion side (electrode chip 3) with the valve seat 3
The cooling water outlet 37a is provided in 6), respectively.
The positional relationship between the inlet and the outlet 37a may be reversed. Then, as shown in FIG. 27, in order to further enhance the cooling effect of the electrode tip 37 of the upper electrode 24, an auxiliary flow different from the inflow port is provided on the side opposite to the outflow port 37a with respect to the center of the electrode tip 37. An inlet 37b may be provided. Here, in FIG. 27, reference numeral 39 denotes a cooling water supply pipe connected to the auxiliary inlet 37b by screwing. further,
As for the lower electrode 25, similarly to the upper electrode 24,
The lower electrode 25 may be cooled by flowing cooling water in one direction.

Further, the method of positioning the valve seat 3 in the substantially horizontal direction in the above embodiment is not limited to the case where the brazing material of the brazing material layer 7 is melted by resistance heat generated by energization.
As described at the end of the basic mode, the present invention can be applied to the case where the brazing material is melted by local heating such as high-frequency heating.

In the above embodiment, the case where the valve seat 3 and the cylinder head main body 2 are joined in the liquid phase diffusion state via the diffusion joining layer 5 and the molten reaction layer 6 has been described. Except that the brazing material layer 7 at the contact portion of the upper electrode 24 is removed in advance, as in the case of joining by a conventional resistance welding or solid-phase diffusion joining method, heat generation and pressurization due to energization between both metal members are performed. In any case, the same operation and effect as those of the above embodiment can be obtained as long as the bonding method is used. Regarding the point that the brazing material layer 7 is removed in advance, the valve sheet 3 is immersed in the brazing material bath 14 in advance to form the brazing material layer 7 on the surface of the valve sheet 3 via the diffusion bonding layer 5. In addition, any method may be used as long as the valve seat 3 and the cylinder head body 2 are joined by heat and pressure generated by energization between the two metal members.

[0101]

Next, a specific embodiment will be described. However, first, a basic example corresponding to the above-described basic mode will be described, and then an example corresponding to the above-described embodiment will be described.

First, as shown in FIG. 28, a test piece 61 was cast from an Al alloy casting (AC4D specified in JIS H5202) as a second metal member. Then, the test piece 61 was subjected to a T6 heat treatment.

Subsequently, as shown in Table 1, the brazing material coating method, the sheet shape, and the taper angle θ of the first joint surface portion
1 were made different to produce five types of Fe-based valve seats (Basic Examples 1 to 5).

[0104] In Table 1, "Friction" in the column of brazing material coating method refers to a method of coating by rubbing the brazing material when forming a diffusion bonding layer and a brazing material layer on the surface of the valve seat. That is. On the other hand, “ultrasonic waves” refers to a method of coating a brazing material by ultrasonic plating, as described in the first embodiment. Further, “thin” in the column of the seat shape means that the valve seat has a shape close to the final shape and is thin, as shown in FIG.
On the other hand, “thick” means that the shape is the same as that of the basic form and the thickness is large, as shown in FIG.

The valve seat used was a sintered material obtained by sintering a powder raw material in which each element shown in Table 2 (excluding Cu) was dispersed. In Table 2, the numerical values are% by weight, and TC means the total carbon amount (total amount of free carbon (graphite) and carbon of cementite). The Cu ratio of each valve seat is a value after infiltrating a Cu-based material as described later, and contains no Cu before infiltration.

Also, the brazing filler metal contains 95% by weight of Zn component, 4.95% by weight of Al component and 0.05% by weight of M
What consisted of g component (Zn-Al eutectic alloy) was used.

Further, the interior of each valve seat was infiltrated with a Cu-based material, and the surface was plated with Cu.

Each of the valve seats of Basic Examples 1 to 5 was joined to the test piece 61 by a joining apparatus in the same manner as in Basic Embodiment 1. The pressure and current value at the time of this joining were set to the values shown in Table 1. In addition, about a current value,
Since the contact resistance between the valve seat and the test piece 61 changes due to a change in the applied pressure and the like, the embedment depth of the valve seat changes, so that the embedment depth is set to be substantially the same.

For comparison, a thick-walled shape and θ1
= 0.52 rad (30 °) valve seat (C on the surface
u-plated), the applied pressure and the current value were 2
Solid phase diffusion bonding (pressure welding) was performed at 9420N (3000 kgf) and 70 kA (conventional example).

Next, the bonding strength of the valve seats of the above-mentioned basic examples 1 to 5 and the conventional example was measured. That is, as shown in FIG. 31, the test piece 61 is placed on the upper surface of the jig base 63 such that the side where the valve seat 62 is joined is on the lower side, and at this time, the valve seat 62 contacts the jig base 63. To prevent this, the jig table 63 is positioned above a through hole 63a provided substantially at the center of the jig table 63. Then, a cylindrical pressing jig 64 is inserted from above the through hole 61 a of the test piece 61 to push the valve seat 62, and a pulling load when the valve seat 62 comes off from the test piece 61 is measured. This removal load corresponds to the joining strength.

FIG. 32 shows the results of the above-mentioned pulling load measurement test. As a result, by comparing the basic example 1 and the basic example 2, the case where the diffusion bonding layer and the brazing material layer are formed on the surface portion of the valve seat by the ultrasonic plating is performed by rubbing the brazing material. It can be seen that the bonding strength is improved as compared with the method. This is because the diffusion bonding layer remained on the surface of the valve seat after the test in Basic Example 2 as described later (see FIG. 35), whereas in Basic Example 1, the brazing material layer and the diffusion bonding layer Since almost no trace was observed, it can be assumed that the diffusion bonding layer was not completely formed in Basic Example 1.

Here, a micrograph (approximately 180 times magnification) of the valve seat surface immediately after the ultrasonic plating in the above basic example 2 is shown in FIG. 33, and the joint surface between the valve seat and the test piece 61 after joining is shown in FIG. Micrograph (approximately 3 magnifications)
FIG. 34 shows a microphotograph (approximately 360 times) of the surface of the valve seat after the pulling load measurement test.
5 respectively. In FIG. 33, the upper side is a valve seat, and the lower side is formed with a brazing material layer via a thin diffusion bonding layer instead of a Cu plating layer. In addition, it turns out that the hole which infiltrated the Cu-based material exists inside the valve seat. In FIG. 34, there is no gap between the upper valve seat and the lower test piece 61, and the diffusion bonding layer and the molten reaction layer are clearly present. Further, in FIG. 35, it can be seen that a thin diffusion bonding layer remains on the surface portion (lower surface portion) of the valve seat.

By comparing the basic example 2 and the basic example 3, it can be seen that a thicker valve seat has a larger pulling load than a thinner valve seat. This is basic example 2
Can be presumed to be due to the fact that the actual pressing force acting on the joint surface has decreased due to the deformation since the corners and the like of the valve seat are deformed.

By comparing the basic examples 3 and 4, the basic example 4 in which the taper angle θ1 of the first joint surface portion is large has the oxide film destruction effect as described in the basic embodiment 1. It can be seen that the effect is excellent and the bonding strength increases.

Further, when the basic examples 4 and 5 are compared, it is found that the basic example 5 in which the pressing force is larger has a higher bonding strength. Moreover, the pressing force is 29420N (3000
It can be seen that by setting the weight to kgf), the joining strength is remarkably improved as compared with the conventional example.

FIG. 36 shows an electron micrograph (magnification: about 10,000 times) of the joint surface of the valve seat and the test piece 61 after the joining in the above basic example 5. In this photograph, the left side is a valve seat (including a portion that looks white), and the right side is a test piece 61. The gray portions between them are the diffusion bonding layer and the molten reaction layer. It can be seen that the thickness of both layers is about 1 μm. still,
When the elements in both layers were analyzed, Fe, Zn and Al were respectively detected.

In order to investigate the influence of the pressing force in more detail, the pressing force was set to 9807 N (1000 kgf) while the brazing material coating method, the sheet shape, and the taper angle θ1 of the first joint surface were the same as those in the above basic examples 4 and 5. , 147
10N (1500kgf) and 29420N (3000
kgf) and set the valve seat to the test piece 61.
And the extraction load was measured in the same manner as in the initial extraction load measurement test.

When the pressing force is 9807 N (1000 kg
The hardness of the test piece 61 after bonding was measured for the test piece f) and that for 29420N (3000 kgf). In the measurement of the hardness, the valve seat is moved from the corner between the first joint surface and the second joint surface of the valve seat (point = 0 from the joint surface in FIG. 38) toward the outer peripheral side of the test piece 61. This was performed at predetermined intervals along a direction inclined by about 0.79 rad (45 °) to the side opposite to the joined side.

FIG. 37 shows the results of the above-mentioned pulling load measurement test.
FIG. 38 shows the results of the hardness measurement test. From this, it is understood that the higher the pressing force, the higher the bonding strength, and the higher the pressing force, the higher the hardness of the test piece 61 near the bonding surface. This is because the higher the applied pressure, the lower the contact resistance and the smaller the calorific value, so that the softening of the test piece 61 is suppressed. When the softening is suppressed, the plastic flow is reliably performed and the oxide film is formed. This is because the effect of the destruction of the brazing material increases and the brazing material is reliably discharged.

Next, in order to examine the effect of the pulse current, the valve seat was joined to the test piece 61 by performing the pulse current. The large current value and the small current value of this pulse conduction were set to 70 kA and 0, respectively. The energizing time of the large current value pulse was 0.5 seconds, and the energizing time of the small current value pulse was 0.1 seconds. Furthermore, the pulse number of the large current value is 6
Pulsed. On the other hand, for comparison, continuous energization (60 k
The valve seat was joined to the test piece 61 by applying a current of A for 2 seconds). The pressure was 29420N for both
(3000 kgf).

[0120] The hardness before and after bonding at the upper and lower ends (A) and the center (B) of the valve seat before and after bonding, and the test piece 61, respectively, were bonded by pulse current application and continuous current application. In the direction inclined about 0.79 rad (45 °) from the corner between the first joint surface and the second joint surface of the valve seat toward the outer peripheral side of the test piece 61 toward the side opposite to the side where the valve seat is joined. The hardness and the punching load were measured for each predetermined distance along.

FIG. 39 shows the results of the hardness measurement test before and after the joining. As a result, in the case of joining by continuous energization, the hardness of the central portion (part B) in the vertical direction becomes particularly high after joining, whereas in the case of joining by pulse energization, burning does not occur due to slow cooling. It can be seen that the hardness hardly increased.

FIG. 40 shows the results of a hardness measurement test based on the distance from the joint surface. As a result, it can be seen that the hardness of the test piece 61 is reduced by receiving heat from the valve seat in the case of joining by pulsed electric current.

FIG. 41 shows the results of measurement of the unloading load. From the above, it is possible to reduce the temperature difference between the valve seat and the test piece 61 by radiating the heat to the test piece 61 while suppressing the increase in hardness by performing the slow cooling inside the valve seat by the pulse current, and reducing the shrinkage amount. Can be reduced, and the bonding strength can be improved.

Subsequently, in order to examine how the valve seat is embedded in the test piece 61 in the pulsed energization, the embedded amount y is determined according to the time from the start of pressurization.
(See FIG. 42). At this time, the large current value of the pulse current was set to 68 kA, and the small current value was set to 0. Also, the energizing time (H) of the large current value pulse, the energizing time (C) of the small current value pulse, and the number of large current value pulses (N) are variable, and are 0.5 seconds and 0.1 seconds, respectively, under basic conditions. And 6 pulses. Then, a test was performed by changing only one of these basic conditions (see FIG. 43 for the changed conditions).

FIG. 43 shows the results of the embedding amount measurement test. From this, it can be seen that the embedding was almost completed by the first energization of the large current value pulse, and the embedding did not progress in the energization performed later. In addition, the embedding amount hardly changes within the range of the setting conditions of this test. However, when the energizing time of the large current value pulse is as long as 1 second, the embedding amount is slightly larger than at the time of energizing the first large current value pulse than in other cases, and when the number of pulses is as large as 9 pulses, It can be seen that the test piece 61 softens from the middle and the embedding proceeds. Therefore, the condition that the valve seat can be embedded in the first energization of the large current value pulse, and the condition that the slow cooling inside the valve seat and the heat radiation to the cylinder head body can be performed in the energization of the second and subsequent large current value pulses, respectively. Just set it.

Next, the valve seat is made of a sintered forged material,
This was joined to the test piece 61 by applying a pulse current at a pressing force of 29420 N (3000 kgf). At this time, the large current value of the pulse current was set to 60 kA, and the small current value was set to 0.
Also, the energizing time of the large current value pulse, the energizing time of the small current value pulse, and the number of the large current value pulse are each 0.5 seconds,
0.1 seconds and 4 pulses. In addition, for comparison, Cu
A valve seat made of a sintered material infiltrated with a system material was similarly joined to the test piece 61. However, the large current value of the pulse current was 53 kA. The outer circumference of the test piece 61 is determined from the corner between the first joint surface and the second joint surface of the valve seat in the test piece 61 for the case where the valve seat is a sintered forged material and the case where the valve sheet is a sintered material infiltrated. About 0.79 rad (45 °) on the side opposite to the side where the valve seat is joined toward the side
The hardness was measured at a predetermined distance along the inclined direction.

FIG. 44 shows the result. From this,
It can be seen that the infiltrated sintered material has lower hardness inside the test piece 61. This is because the heat generation inside the valve seat was suppressed by the infiltration of the Cu-based material and the heat generation was effectively performed at the joint surface portion, so that the test piece 61 was softened. However, even if the valve seat is a sintered forged material, the joining is performed well. This can be seen from the micrograph (about 50 times magnification in FIG. 45, FIG.
6, the magnification is about 400 times). This is because the holes inside the valve seat are crushed by forging and have the same effect as infiltration.

Next, an example corresponding to the above embodiment will be described. First, a valve seat was manufactured by sintering an Fe-based powder material in which Cu was dispersed substantially uniformly throughout (Example 1). . For comparison, a sintered forged material (Comparative Example 1) and a sintered material obtained by sintering a powder material consisting of only a non-high-conductivity element with a Cu-based material infiltrated into it. (Comparative Examples 2 to 4) were produced. Table 3 shows the component ratios of these Examples and Comparative Examples 1 to 4. Incidentally, the Cu ratios of Comparative Examples 2 to 4 were the same as those shown in Table 2,
This is a value after infiltration of the system material, and contains no Cu before infiltration. Further, the Cu ratio in the example is approximately the same as the Cu ratio after infiltration in Comparative Examples 2 to 4.

FIG. 47 shows the shapes of the valve seats of Example 1 and Comparative Examples 1-4. Further, a valve seat made of a sintered material having the same components as in the above-mentioned Example 1 and having only a different shape was produced (Example 2). FIG. 48 shows the shape of the second embodiment. That is, the valve seat of the second embodiment has the third joint surface between the first joint surface and the second joint surface in the same manner as that shown in FIGS. 25 and 26.

On the other hand, as shown in FIG.
A test piece 71 made of the same material as that of No. 1 was produced. The test piece 71 has a chamfered portion 71b above the through hole 71a, like the test piece 61, and the chamfered portion 71b becomes a joint surface portion before joining with the valve seat. And
The taper angle α of the chamfer 71b is about 0.52 rad.
(30 °), about 0.79 rad (45 °), about 1.04
rad (60 °) and about 1.31 rad (75 °)
Type.

The thermal conductivity and density of Example 1 and Comparative Examples 1 to 4 were measured. The results are also shown in Table 3. From this, it can be seen that the density of Example 1 is lower than those of Comparative Examples 1 to 4. That is, it has holes. On the other hand, although the thermal conductivity is higher than that of Comparative Example 1, it can be seen that the thermal conductivity is lower than that of the infiltration materials of Comparative Examples 2 to 4 due to the heat insulating effect of the holes.

Further, Example 1 and Comparative Examples 1, 2, 4
For each sample, the change in hardness with temperature was examined. The result of the hardness measurement test is shown in FIG. As a result, the hardness of the valve seat of Example 1 was the same as that of the sintered forged material of Comparative Example 1 or Comparative Example 2
It can be seen that it is slightly smaller than the infiltration material of No. 4 and therefore easily deformed by the pressing force at the time of joining.

The valve seats of Example 1 and Comparative Examples 1 to 4 have a taper angle α of about 0.79 rad (45
°). That is, energization and pressurization were performed in a state where each valve seat and the test piece 71 were in line contact with each other in advance. Thereafter, the unloading load of the joined pieces was measured.

FIG. 51 shows the results of the pulling load measurement test. From this, the bonding strength of Example 1 is comparative example 2
It can be seen that, although smaller than the infiltrated material of No. 4, the same level as that of the sintered forged material of Comparative Example 1 was maintained.

Here, a micrograph (approximately 50 times magnification) of the inside of the valve seat after bonding in Example 1 is shown in FIG.
Shown in As a result, the holes remain after the joining, and the heat insulating effect can be maintained to suppress the heat shrinkage more than the infiltration material.

Subsequently, the effect of energization and pressurization in a state of surface contact in advance was examined. That is, the first embodiment
The taper angle α is about 0.52 rad (30
°). At this time, the first joint surface of the valve seat and the joint surface 71a of the test piece 71 are brought into a state in which they are brought into surface contact (contact area: 40 to ²⁰⁰ mm ² ) in advance. Further, the valve seat of Example 2 was joined to a test piece 71 having a taper angle α of about 1.04 rad (60 °). At this time, the valve seat and the joint surface portion 71a of the test piece 71 are brought into line contact in advance. Furthermore, the taper angle α of the valve seat of the second embodiment is about 1.31 rad (75 °).
Was bonded to the test piece 71. At this time, the second contact surface portion of the valve seat and the joint surface portion 71a of the test piece 71 are brought into a state of surface contact (contact area: 40 to ²⁰⁰ mm ² ) in advance.

[0138] Then, the unloading load of the joined parts is
Approximately vertical center of each valve seat after bonding (hardened layer)
The hardness of the test piece 71 and the valve from the corner of the first joint surface portion and the second joint surface portion of the valve seat (the center of the third joint surface portion in Example 2) toward the outer peripheral side of the test piece 71 About 0.79 rad on the side opposite to the side where the sheets are joined
(45 °) The hardness was measured for each predetermined distance along the inclined direction. FIG. 53 (also shows the case of the line contact of Example 1 already measured) showing the result of the pulling load measurement test, and FIG. 54 shows the result of the valve seat hardness measurement test. The results of the measurement test are shown in FIG. Thus, when current is applied and pressurized in a state where the test pieces are in line contact with each other in advance, the amount of heat generated at the joint surface becomes too large, and a part of the heat reaches the inside of the test piece 71 and
, While the remaining heat reaches the inside of the valve seat, and the hardness inside the valve seat increases due to rapid cooling caused by the stop of energization. On the other hand, when current is applied and pressurized in a state where the surfaces are brought into contact with each other in advance, the amount of heat generated at the joint surface is suppressed, and an increase in hardness can be suppressed, and
The joining strength can be improved.

Here, in order to examine how the valve seat is deformed after bonding in the case of surface contact in Example 2 above, the bonded product was cut vertically and the cross section was observed with a microscope. did. The micrograph is shown in FIG.
6 is shown. For comparison, FIG. 57 shows a cross-sectional micrograph after bonding in the case of line contact in Example 2 above. Furthermore, it does not have the chamfered portion 71b (the through-hole 71
A micrograph of a cross-section after bonding is obtained when the valve seat of Example 2 is bonded to a test piece 71 (a extends to the upper surface with the same diameter) (that is, in this case, a line contact is also made in advance). As shown in FIG. The magnification of each of these photographs is 10 times. From this, the third joint surface portion of the valve seat is largely deformed inward when it is brought into line contact in advance, whereas the amount of heat generated at the joint surface portion is suppressed when it comes into surface contact in advance, It can be seen that there is almost no deformation at the joint surface of the valve seat, even though it is easier to deform than the infiltration material. From these photographs, it can be seen that the inner peripheral surface of each valve seat is greatly deformed inward. However, since the valve seat was positioned as in the above embodiment, the positioning could be performed well without causing cracks in the valve seat or damaging the upper electrode.

[0140]

As described above, according to the first or ninth aspect of the present invention, the first metal member and the second metal member are
As a joining method of joining the two metal members using heat and pressure caused by energization between the two metal members using an electrode, a contact portion side of the electrode with the first metal member or the second metal member and a side opposite to the contact portion An inlet for a cooling medium for cooling the inside of the electrode is provided on one side, and an outlet for the cooling medium is provided on the other side, and current is supplied while flowing the cooling medium in one direction from the inlet to the outlet. By doing so, the life of the electrode can be improved by a simple method.

According to the second or tenth aspect of the present invention, the first metal member and the second metal member are previously provided on the joint surface of the first metal member.
The brazing material layer is formed via a diffusion layer of a brazing material having a lower melting point than that of the metal member and having a eutectic composition with the second metal member and the first metal member, and A diffusion layer of the brazing material and the second metal member is formed by heating and pressing the metal member and the second metal member to a temperature equal to or higher than the melting point of the brazing material due to energization between the two metal members. By joining the molten brazing material in the liquid phase diffusion state through the two diffusion layers while discharging the molten brazing material from between the joining surfaces of the two metal members, the joining strength of the two metal members is reliably improved. be able to.

According to the third aspect of the present invention, the first metal member is made of an Fe-based material, and the second metal member is made of an Al-based material.
By using a Zn-based material as the brazing material, an optimum combination of materials can be obtained for the joining method according to the second aspect of the present invention.

According to the fourth aspect of the present invention, the surface of the first metal member in the brazing material bath is coated with the brazing material by applying ultrasonic vibration, so that the first metal member and the brazing material layer are coated. By forming the diffusion layer between the brazing material and the first metal member, it is possible to reliably form the diffusion layer between the brazing material and the first metal member by a simple method.

According to the fifth aspect of the present invention, the first metal member is made of a sintered material, and the high electric conductivity material is infiltrated and infiltrated into the inside of the first metal member, so that the joining strength is reduced. The electrode life can be effectively improved, and the life of the electrode can be further improved.

According to the sixth aspect of the present invention, the first metal member is a sintered material obtained by sintering a powder material in which a high electric conductivity element is dispersed. In addition to the effect, it is possible to reduce the manufacturing cost and to improve the wear resistance of the first metal member when used at a high temperature.

According to the seventh aspect of the present invention, since the high electric conductivity element is Cu, the resistance value inside the first metal member can be effectively reduced at low cost.

According to the eighth or eleventh aspect of the present invention, the first metal member and the second metal member are joined by plastically flowing the joint surface of the second metal member. The joint strength of the members can be further improved.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a main part of an engine cylinder head as a joining metal member manufactured by a joining device according to a first embodiment of the present invention.

FIG. 2 is a cross-sectional view schematically illustrating a joined state of a valve seat and a cylinder head main body.

FIG. 3 is a sectional view showing a shape of a valve seat before joining.

FIG. 4 is an explanatory view showing a procedure for joining a valve seat to a cylinder head body.

FIG. 5 is an explanatory view schematically showing a joining process of a valve seat and a cylinder head main body.

FIG. 6 is an explanatory diagram showing a state in which a brazing material is coated by applying ultrasonic vibration to a surface portion of a valve seat in a brazing material bath.

FIG. 7 is a side view showing the joining device.

8 (a) is a view in the direction of arrow VIII in FIG. 7, and FIG. 8 (b)
Is a bottom view of the upper electrode.

FIG. 9 is a timing chart showing a control method of pressurization and energization.

FIG. 10 is a diagram corresponding to FIG. 9 showing another example of the pressurization control method.

FIG. 11 is a phase diagram of an Al—Zn alloy.

FIG. 12 is a diagram corresponding to FIG. 9, showing a basic mode 2.

FIG. 13 is a graph showing a temperature change inside a valve seat due to pulsed current.

FIG. 14 is a diagram corresponding to FIG. 9 showing another example of the energization control method.

FIG. 15 is a cross-sectional view showing a state in which cooling water is sprayed on the inner peripheral surface of the valve seat.

FIG. 16 is a diagram corresponding to FIG. 9, showing a basic mode 3.

FIG. 17 is a diagram corresponding to FIG. 9, illustrating another example of the energization control method.

FIG. 18 is a cross-sectional view showing a state in which the valve seat is also pressed in the diameter reducing direction to suppress the thermal expansion thereof.

FIG. 19 is a view corresponding to FIG. 3, showing another example of the shape of the valve seat.

FIG. 20 is a cross-sectional view of a main part showing a state where the valve seat and the cylinder head main body are joined by the joining device according to the fourth embodiment.

FIG. 21 is a cross-sectional view showing an engine piston as a bonded metal member according to the fifth embodiment.

FIG. 22 is a cross-sectional view illustrating a main part of a cylinder block of an engine as a joining metal member according to a sixth embodiment.

FIG. 23 is a cross-sectional view of main parts showing a state where the valve seat and the cylinder head main body are joined in the embodiment.

FIG. 24 is a view showing a state where the second joint surface of the valve seat and the joint surface of the cylinder head main body are in surface contact with each other.
FIG.

FIG. 25 is a view showing a state where the third joint surface of the valve seat is brought into surface contact with the joint surface of the cylinder head body.
FIG.

FIG. 26 illustrates a second example of the valve seat having the third joint surface formed thereon.
FIG. 24 is a diagram corresponding to FIG. 23, showing a state in which the joint surface and the joint surface of the cylinder head body are in surface contact.

FIG. 27 is a diagram corresponding to FIG. 23, illustrating another method of cooling the upper electrode.

FIG. 28 is a cross-sectional view showing a test piece used for bonding in the basic example.

FIG. 29 is a sectional view showing a thin valve seat.

FIG. 30 is a sectional view showing a thick valve seat.

FIG. 31 is a schematic cross-sectional view showing the procedure of a pulling load measurement test.

FIG. 32 is a graph showing the results of a punching load measurement test on the valve seats of the basic examples 1 to 5 and the conventional example.

FIG. 33 is a micrograph showing the state of the valve seat surface immediately after ultrasonic plating.

FIG. 34 is a micrograph showing a joint state of a valve seat and a test piece in Basic Example 2.

FIG. 35 is a photomicrograph showing the state of the surface of the valve seat after the pulling load measurement test.

FIG. 36 is a micrograph showing a joint state of a valve seat and a test piece in Basic Example 5.

FIG. 37 is a graph showing a relationship between a pressing force at the time of joining and a removal load.

FIG. 38 is a graph showing a change in hardness depending on a distance of a test piece from a bonding surface portion.

FIG. 39 is a graph showing changes in hardness before and after joining of a valve seat in continuous energization and pulse energization.

FIG. 40 is a graph showing a change in hardness depending on a distance from a joint surface of a test piece in continuous energization and pulse energization.

FIG. 41 is a graph showing the results of an extraction load measurement test in continuous energization and pulse energization.

FIG. 42 is an explanatory diagram showing an embedded amount y in an embedded amount measurement test.

FIG. 43 is a graph showing the relationship between the time from the start of pressurization and the embedding amount y.

FIG. 44 is a graph showing a change in hardness depending on a distance from a joint surface of a test piece in a case where a valve seat is a sintered forged material and in a case where a valve seat is a sintered material infiltrated.

FIG. 45 is a micrograph showing a joint state between a valve seat made of a sintered forged material and a test piece.

FIG. 46 is a micrograph showing a further enlarged view of a joint state between a valve seat made of a sintered forged material and a test piece.

FIG. 47 is a sectional view showing the valve seat of the first embodiment.

FIG. 48 is a cross-sectional view illustrating a valve seat according to a second embodiment.

FIG. 49 is a cross-sectional view of a main part showing a main part of a test piece used for bonding in an example.

FIG. 50 is a graph showing the relationship between temperature and hardness in the valve seats of Example 1 and Comparative Examples 1, 2, and 4.

FIG. 51 is a graph showing the results of a punching load measurement test on the valve seats of Example 1 and Comparative Examples 1 to 4.

FIG. 52 is a photomicrograph showing the internal state of the bonded valve seat in Example 1.

FIG. 53 is a graph showing the results of a punching load measurement test when a line contact or a surface contact is made in advance in Examples 1 and 2.

FIG. 54 is a graph showing the results of a valve seat hardness measurement test in Examples 1 and 2 when a line contact or a surface contact was made in advance.

FIG. 55 is a graph showing a change in hardness according to a distance from a joint surface portion of a test piece when line contact or surface contact is made in advance in Examples 1 and 2.

FIG. 56 is a photomicrograph showing a joint state in a case where the valve seat of Example 2 was brought into surface contact with a test piece in advance and joined.

FIG. 57 is a micrograph showing a joining state when the valve sheet of Example 2 is joined to a test piece by previously making line contact.

FIG. 58 is a photomicrograph showing a joint state when the valve seat of Example 2 was joined to a test piece having no chamfered part by line contact in advance.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Cylinder head 2 Cylinder head main body (2nd metal member) 2a Joining surface 3 Valve seat (1st metal member) 3a 1st joining surface 3b 2nd joining surface 3f 3rd joining surface 5 Diffusion joining layer (with brazing material) 6 Diffusion layer with valve seat 6 Melting reaction layer (diffusion layer between brazing material and cylinder head body) 7 Brazing material layer 14 Brazing material bath 24 Upper electrode 25 Lower electrode 37 Cooling passage 37a Outlet 37b Auxiliary inlet

[Table 1]

[Table 2]

[Table 3]

────────────────────────────────────────────────── ─── front page continued (51) Int.Cl. ⁶ identifications FI B23K 20/00 310 B23K 20/00 310L F01L 3/22 F01L 3/22 B F02F 1/24 F02F 1/24 S // B23K 103 : 20

Claims (11)

[Claims] 1. A first metal member and a second metal member,
A bonding method for bonding by heating and pressurization caused by energization between the two metal members using an electrode, comprising: a contact portion of the electrode with a first metal member or a second metal member; An inlet for a cooling medium that cools the inside of the electrode is provided on one of the opposite sides, and an outlet for the cooling medium is provided on the other side, and the cooling medium is unidirectionally supplied from the inlet of the electrode to the outlet. A method for joining metal members, wherein current is supplied while flowing through a metal member. 2. The method for joining metal members according to claim 1, wherein the second metal member has a lower melting point than the first metal member and the second metal member on the joint surface of the first metal member in advance. The brazing material layer is formed through a diffusion layer of a brazing material having a eutectic composition with the member and the first metal member, and the first metal member and the second metal member are separated from each other. By the heating and pressurization to a temperature equal to or higher than the melting point of the brazing material due to energization between the metal members, a diffusion layer of the brazing material and the second metal member is formed and the molten brazing material is joined to the joining surface of the two metal members. A method for joining metal members, wherein the joining is performed in a liquid phase diffusion state via the two diffusion layers while discharging from the space. 3. The method according to claim 2, wherein the first metal member is made of an Fe-based material, the second metal member is made of an Al-based material, and the brazing material is a Zn-based material. A method for joining metal members, comprising: 4. The method according to claim 2, wherein the first metal member in the brazing material bath is coated with a brazing material by applying ultrasonic vibration to the first metal member. A method for joining metal members, wherein a brazing material layer and a diffusion layer of the brazing material and the first metal member are formed on the metal member. 5. The method for joining metal members according to claim 1, wherein the first metal member is a sintered material, and a high electrical conductivity is previously provided inside the first metal member. A method for joining metal members, comprising infiltrating a material. 6. The method for joining metal members according to claim 1, wherein the first metal member is a sintered material obtained by sintering a powder material in which a high electric conductivity element is dispersed. A method for joining metal members, characterized in that: 7. The method for joining metal members according to claim 6, wherein the high electric conductivity element is Cu. 8. The joining method of a metal member according to claim 1, wherein the joining of the first metal member and the second metal member is performed by plastically flowing the joining surface of the second metal member. A joining method of a metal member. 9. A metal member having an electrode, wherein the first metal member and the second metal member are joined by heat and pressure generated by energization between the two metal members using the electrode. A joining apparatus, wherein an inlet of a cooling medium for cooling the inside of the electrode is provided on one of a contact portion side of the electrode and a side opposite to the contact portion with the first metal member or the second metal member. An outlet for the cooling medium is provided on the other side, and the metal member is characterized in that it is configured to conduct electricity while flowing the cooling medium in one direction from the inlet of the electrode to the outlet. Joining equipment. 10. The joining device for a metal member according to claim 9, wherein the joining surface has a melting point lower than that of the first and second metal members and a eutectic composition with the second metal member. The first metal member on which the brazing material layer is formed via a diffusion layer with the first metal member and the second metal member are heated to a temperature equal to or higher than the melting point of the brazing material between the two metal members. Forming a diffusion layer of the brazing material and the second metal member by heating and pressurizing, and discharging the molten brazing material from between the joining surfaces of the two metal members, and forming a liquid phase diffusion state through the two diffusion layers. A joining device for a metal member, characterized in that the joining device is configured to be joined with a metal member. 11. The metal member joining apparatus according to claim 9, wherein the first metal member and the second metal member are joined by plastically flowing a joining surface portion of the second metal member. An apparatus for joining metal members, comprising: