MXPA99006420A

MXPA99006420A - Tailored blank

Info

Publication number: MXPA99006420A
Application number: MXPA/A/1999/006420A
Authority: MX
Inventors: Duley Walter; Ogmen Melih; Hughes David
Original assignee: Powerlasers Ltd
Priority date: 1997-01-14
Filing date: 1999-07-08
Publication date: 2000-06-01

Abstract

A tailored blank is provided by welding a pair of constituent parts (10, 20) to one another in juxtaposition. The parts (10, 20) are laser welded (34, 36, 38) together to form a unitary blank (42) that is subsequently formed into a shaped finished component.

Description

UNREASONED ADAPTED METAL PIECES The present invention relates to a method for forming unprocessed, metal parts used to produce metal-shaped components.

Metal sheet components of complex shapes are typically produced with flat metal pieces that are formed in the final form through a series of forming or marking operations. Where relatively complex products will be produced, it is usual to build the component by overcoming several elements, each of which is marked on a metal part. The need to use multiple components may result from the complexity of the final product or may result from the different characteristics of the material required in different component areas. For example, if the component is a car door-shaped structure, most door-shaped structures can be formed from a sheet of metal Ref. 30695 relatively thin but the mounting points for the door hinges require extra resistance. The use of multiple elements to produce the final compound increases the complexity of manufacturing.

To mitigate this complexity, it has been proposed to produce a metal part without adapted transformation where appropriate sheets of material are connected end to end by means of a laser welding process to produce a metal part without unitary transformation: When formed, the metal part without processing produces a component that differs from the characteristics of the material along the structure. This process allows the optimal use of the material but at the same time minimizes the subsequent assembly of multiple elements in the final product.

The production of a metal part without adapted treatment -requires the metal pieces in laminar form cut with precision so that the laser welding can develop efficiently and retain an adequate welding quality. This requires precision cutting of the constituent components and in pending Application No. 9'624039.5 recorded on November 19, 1996 and 9624652.5 registered on November 27, 1996 and an application entitled "Overlampping Join for Laser Welding of Metals Including Tubes" registered on January 8, 1997, different methods are described to mitigate the difficulties encountered to obtain the required precision for the constituent parts. However, in certain circumstances, it is desirable to produce a composite formed with a final surface of very high quality so that the subsequent process such as painting can be performed with a minimum of restoration of the surface after welding. Laser welding generally offers a relatively high quality welding surface and the process contemplated in the aforementioned applications also facilitates the production of a smoothly cut surface, however there is a need for a metal part without adapted transformation that can be used directly to produce a final surface.

Therefore, it is an object of the present invention to obviate or mitigate the above disadvantage.

In general terms, the present invention provides an adapted metal part having a pair of laminar constituent parts each of which has a pair of opposingly directed upper surfaces. A top surface of one of the components is placed on the upper surface of the other component and the pieces are welded to another to produce a unchanged metal piece. The metal part without transformation can then subsequently be formed into a component with different material characteristics.

Preferably, the welding of the constituent parts is carried out by laser welding and as another preference, the laser welding does not penetrate towards the other upper surface of the other constituent part.The embodiments of the invention will now be described only as a means of example, with reference to the accompanying drawings in which: Figure 1 is a sectional view of a pair of constituent parts before processing; Figure 2 is a sectional view of a pair of constituent parts after processing; Figure 3 is a high perspective view of the components after processing; Figure 4 is a schematic representation of a part formed by the components of Figure 3; Figure 5 is an alternative embodiment of the "adapted unprocessed metal part; Figure 6 is another embodiment of the adapted unprocessed metal part; Figure 7 is a sectional view of an arrangement of the alternative processing of the adapted unprocessed metal part; Figure 8 is a sectional view showing the processing of tubular components; Figure 9 is a perspective view of a finished component formed by an unprocessed metal part of Figure 8; Figure 10 is a side view of another embodiment of the unprocessed metal part similar to Figure 9; Figure 11 is a side view of another embodiment similar to Figure 10; Figure 12 is a section of an alternative arrangement of the metal part without processing incorporating a supplementary component; Figure 13 is a flat view of a metal part without processing used in the formation of an automotive component; "Figure 14 is a section on line 14-14 of Figure 13; Figure 15 is a section similar to Figure 14 showing a subsequent stage forming; Figure 16 is a sectional view of the finished component; Figure 17 is a flow diagram showing the sequence of steps developed in Figures 13-16; Figure 18 is an elevated view of the • components of another embodiment of the metal part without processing; Figure 19 is a side view of the metal part without coupled processing of Figure 18; Figure 20 is a top view of Figure 19; Figure 21 is a sectional view of another embodiment of the unprocessed metal part shown in Figure 19; Y Figure 22 _ is a series of schematic representations of the unprocessed metal parts formed using the modalities of Figures 18-21.

Referring to Figure 1, a pair of constituent parts 10, 20 which may have different characteristics - in this case different thickness - each is flat and are formed by weldable metal sheets. As such, each has a pair of oppositely directed upper surfaces 12, 14 and 22, 24 interconnected at the periphery of the ends 16, 26 respectively.

The constituent parts 10, 20 are placed in juxtaposition with an upper surface 14 of the underlying constituent part 10 and abuts one of the upper surfaces 22 of the constituent part 20. The constituent part 10, which is smaller in area than the the constituent part 20 is positioned within the periphery of the piece 20 such that after forming, an increased thickness of material will be available in the desired region of the final component.

The constituent parts 10, 20 are secured in abutting relation by clips 32 suitably including magnetic clips if the same components are magnetic. A laser 34 directs a ray 36 on the exposed upper surface 12 of the constituent part 10 and produces local melting of the constituent part 10 and the upper surface 22. The ray 36 is controlled so that partial penetration of the component is obtained 20 but the liquid region 38 does not exceed the lower surface 24. The irradiated area can be protected with an inert gas in an appropriate conventional manner.

"The beam 36 is set in motion relative to the constituent parts 10, 12 along" a predetermined path so that the beam 36 moves, the constituent part 10 and part of the constituent part 20 are locally fused in the region indicated by the number 38. The continuous movement of the beam 36 allows the region 38 of the constituent parts 10, 20 to solidify after the lightning step and join one another as indicated by the weld 40.

As indicated in Figure 3, the beam 36 is again placed laterally to provide welding at the spaced locations and by this securing a constituent part 10 to the other constituent part 20. Alternatively, multiple beams can be used to produce welds simultaneous.

After welding the constituent parts 10, 20 provide a unitary unprocessed metal part 42 to which it can subsequently subsequently be formed into a component of "required shape as shown schematically in Figure 4. A pair of complementary dies 44, 46 they are coupled to the opposite surfaces 12, 24 of the unprocessed metal part 42- to form it in a shape defined by the dies, the components 10, 20 each being shaped into a finished component of the desired shape.

By controlling the beam 36 such that it only melts part of the path through the constituent part 20, the upper surface 24 is not adversely affected by the welding process and therefore presents a continuous smooth surface that may not require further processing before the termination. At the same time, the unprocessed metal part provides the variation of the characteristics of the material in the finished component. It will be appreciated that complete penetration of the constituent part 20 can be allowed where the final surface finish is not significant.

In the tests performed with the composite raw metal part 42 shown in FIG. 3, the following parameters were used: Relative speed _ 6.2 meters per minute between the laser beam and the constituent part Energy of the laser beam 6 kilowatts using a continuous laser of C02 Laser beam mode: TEM0? Lightning diameter .0.028 inch laser: Protection gas: Top helium, • Bottom argon Thickness of the piece tx = 0.034 inches constituent 20: Thickness of the piece t2 = 0.074 inches constituent 10: Material of the Galvaneal part (constituent steel: tempered galvanized hot rolled) Naturally, the constituent parts can be similar to one another having the same thickness and composition or can be selected with different characteristics, such as thickness, composition, coating or the like. By selecting the constituent part with appropriate characteristics, the unit unprocessed metal part 42 is formed with a uniform surface but with local reinforcements to provide the variation of characteristics in the formed component. In a particularly beneficial embodiment, the constituent part 20 is coated with zinc and the constituent part 10 is cold rolled steel. The surface 24 of the part 20 of this form is not affected by the welding by providing a continuous coated surface with zinc that can be used as an exterior paint surface and / or as a corrosion resistance.

Alternative arrays of constituent parts and welds can be used to produce the adapted unprocessed metal part that is required. For example, as shown in Figure 5, the constituent part 10a is secured to the constituent part 12a through the intersecting lines of the indicated welds 40a so that the constituent part 10a is secured above its total periphery of the constituent pj ^ ez 12.

As shown in Figure 6, the constituent part 10b does not need to be rectangular or a regular shape, and the laser beam 36b can move along the path by forming the periphery of the constituent part 10b to secure it to a constituent part of the component. different form 20b.

The above embodiments contemplate the welding of the constituent part in a space spaced from the periphery of the constituent part 10a. However, as indicated in Figure 7, the constituent part 10c can be welded to the constituent part 12c by following the edge of the constituent part and providing a flange by the weld 40c along the periphery of the constituent part 10c . Again, where the upper surface 24c is used as a finishing surface, the beam 36c controls the limit penetration through the constituent part 20c.

The above embodiments show the formation of adapted unprocessed metal pieces of generally flat constituent parts. However, as indicated in Figures 8-11, tubular constituent parts 10D, 20d can be used to provide local reinforcement in the walls of an unprocessed tubular metal part. As seen in Figure 8, the constituent part 11D is tubular and is located within the tubular component 20d. The laser beam 36d strikes the radially directed outer upper surface 12d and penetrates the adjoining upper surfaces 14d, 22d to weld the two surfaces. The tubular component 20d can be rolled around its longitudinal axis relative to the beam 36d to produce a circumferential weld.

The constituent parts lOd, 20d may be connected at longitudinally spaced locations to connect the constituent parts as required for the subsequent formation.

This arrangement is particularly useful where the uncut tubular metal part 42d is used in a hydroforming operation where high pressure fluid is used to expand an unprocessed tubular metal part 42d into a die cavity. An example is shown in Figure ^ 9 where a radial expansion of the unprocessed tubular metal part 42d produces a bulb-shaped component with varying wall thickness. The local reinforcement provided by the piece 20d makes it possible to vary the characteristics obtained along the length of the finished component.

As shown in Figure 10, the constituent part 20e can externally provide the lOe tube and several longitudinally spaced locations. This facilitates the placement of the pieces 20e and allows the adaptation of the unprocessed tubular metal part 42e. When used in the chassis of vehicles, the variation of the wall thickness provided by the constituent parts 10e, 20e allows a progressive resistance to crushing obtained by the finished component. Similarly, as illustrated in Figure 11, multiple constituent parts can be stacked on top of another to provide another variation in wall thickness. Of course, a similar stack can be made with flat components illustrated in Figures 1-7.

Lamination of the metal part adapted without "processing" 42 also allows supplementary materials to be incorporated in the unprocessed metal part 42. As shown in Figure 12, the characteristics of sound transmission can be modified by incorporating a non-metallic layer 48, such as plastic or paper, between the constituent parts lOg, 20g Typically, the intermediate layer 48 can be 0.004 inches thick and remain within the smallest constituent part lOg to separate the upper surfaces 14g, 22g and provide a margin peripheral 50 where contact between the surfaces 14g, 22g is not inhibited The constituent parts may be welded together around the peripheral margin 50 to inhibit moisture ingress or intermittent welding to retain the layer 48. The adapted unprocessed metal part 42g can then be formed in the required form in a press with the intermediate layer 48 retained in situ during the training Shown in Figures 13-16 is another example of "a component formed from an adapted unprocessed metal part where the formation of a stacked projection for use in a body of a vehicle using the process steps shown in FIG. Figure 17. A stacked projection is used to support the suspension components in a vehicle and it is subjected to severe local shear loads, however the stacked projection is usually lengthened to accommodate the vertical displacement of the suspension components and thus both have a significant wall area.

An unprocessed metal part 42h is formed from a constituent part 20h and a pair of constituent parts lOh. The second constituent part 20h is formed from a flat sheet of cold-rolled steel with a pair of D-shaped incisions 52 located in local depressions 53. - The incisions 52 and the depressions 53 are provided in a preforming step at mark the sheet of the material in a conventional manner.

"The first constituent parts 10 are cut from the laminate stack that is thinner and of greater strength than they serve as a mounting point and are located over the incisions 52. The lOh pieces overlap the ends of the incisions 52 within the depression to provide a peripheral margin 54 of the juxtaposed pieces The depth of the depressions corresponds to the thickness of the pieces lOh so that the upper surfaces 24h and 14h are coplanar.Thus a flat surface is provided to facilitate the subsequent forming operations.

The constituent parts 10, 20h are then welded with the laser to one another in a range 5-4 with a continuous weld 40h as indicated above.

The resulting unprocessed metal part 42h contains two individual unprocessed metal pieces to form the stacked projection and thus they are spaced along a line of symmetry 56 in the individual unprocessed metal parts. Each individual unprocessed metal part is then formed in a press in a stacked projection as shown in Figure 16 with walls of relatively thin material but with mounting plates provided with a double thickness by the constituent part lOh.

The techniques described above can also be used to provide an unprocessed metal part incorporating unwelded components, or components that are not compatible to weld together. For example, tempered steel and aluminum can each be welded, but when they are welded together, brittle, intermetallic compounds are formed.

An arrangement is shown in Figures 18-20 where a pair of constituent parts lOj, 20j are interconnected by solders 40j and mechanically connected to an additional component 60. Component 60 is a plastic material and has a series of rectangular depressions 62 along the marginal edges 64. An undercut 66 is formed at the end of the constituent part lOj with a lower part of the surface 68 spaced from the upper surface 24j by the thickness of the additional component 60. The projections 70 depend on the bottom surface 68 and not complementary to the depressions 62 so that it fits snugly within them.

The constituent parts lOj, 20j are placed in juxtaposition with the component 60 placed therebetween. The projections 70 are coupled to the depressions 62 so that the component 60 is mechanically clamped to the part 10. The parts 10j, 20j are then welded at 40j to connect them and secure the component 60. The resulting unprocessed metal part it can be shaped with the mechanical connection that retains the integrity of the lOj parts and the component 60. It will be appreciated that the component 60 can be a plastic composite, glass or other material that can not be welded normally or could be a metallic material dissimilar such as aluminum.

As an alternative to the rectangular depressions 62, the spherical recesses of the parts can be used as shown in Figure 21. In this embodiment, the dimples or "dimples" 72 are formed in each of the parts 10k, 20k and the component. 60k by means of a spherical punch of the part and the parts lOk, 20k are welded together to form an integral unprocessed metal part 42k.

The mechanical interconnection of the component 60 and "the pieces 10, 20 can be used in different ways as shown in Figure 22. The component 60 can be used to cover an opening in the piece 20 as shown in Figure 22a, or it can form a liner on a portion of the piece 20 as shown in Figure 22b.

The component 60 may be circular as illustrated in Figure 22c or it may be formed with a peripheral assembly so that a glued surface is provided as shown in Figure 22d.

In some circumstances, a positive mechanical connection is not necessary in which case a friction location is obtained by bending one or both constituent parts as shown in Figures 22e-22h. In these arrangements, the component 60 is mechanically trapped by the constituent parts to allow the subsequent forming operations.

It will be seen that the preparation of an unprocessed metal part adapted with the juxtaposed constituent parts allows the unprocessed metal part to be formed with different characteristics of the material without the preparation of precision ends of the parts.

Other typical applications where the above embodiments find utility are the provision of a reinforcement section within a vehicle door liner to receive a tight fitting assembly or mounting pads to secure the seat belts on a floor plate of a vehicle.

Although laser welding is preferred, alternative welding techniques such as MASH welding can be used which allows the unprocessed metal part to be assembled and subsequently shaped. Welding patterns will be selected to meet the requirements of the forming process, which include the tension properties of the unprocessed metal part and the subsequent use of the components.

By securing the constituent parts in an unprocessed metal part before it is formed, the need to precisely fix the parts to be welded into an unprocessed metal part is mitigated. However, because the required material characteristics can be obtained with the unprocessed metal part, the need for additional welding of the components after the forming process is avoided. It is particularly significant that accurate fixing of complex shapes after training is difficult and time consuming. A uniform closed surface can also be obtained without depending on the integrity of the weld.

In each of the above embodiments, continuous welding between the constituent parts has been illustrated. Wherever the structural requirements allow, it is of course possible to provide the weld located in discrete places on the constituent parts so that the constituent parts remain together during the forming process but continuous welding is not necessary.

It is noted that in relation to this date, the best method known by the applicant to carry out the aforementioned invention, is one that "is clear from the present invention.

"Having described the invention as above, property is claimed as contained in the following.

Claims

CLAIMS.

1. An adapted unprocessed metal part to subsequently shape it into a final component, characterized in that the unprocessed metal part has a pair of metal constituent parts, each having a pair of opposed upper surfaces directed with an upper surface of a co-constituent part juxtaposed with a main surface of another constituent part, one of the constituent parts has a peripheral edge within the upper surface of the other and the constituent parts are welded together by a solder joint formed by laser welding extending around the edge peripheral to provide a unprocessed piece of metal.

2. An unprocessed adapted metallic part according to claim 1, characterized in that another upper surface of one of the constituent parts provides a surface directed externally in a continuous manner towards said unprocessed metal part.

3. An unprocessed adapted metal part according to claim 1, characterized in that the solder connection by laser partially penetrates the other component and ends before the other upper surface of the other constituent.

4. An unprocessed adapted metallic part according to claim 1 or 3, characterized in that an opening is provided in one of the constituent parts and the other constituent part extends over the opening.

5. An adapted unprocessed metal part to subsequently shape it into a final component, characterized in that the unprocessed metal part has a pair of metal constituent parts, each having a pair of oppositely directed upper surfaces with an upper surface of a constituent part juxtaposed with a main surface of another constituent part, and having a peripheral edge within the upper surface of the other constituent part, an intermediate layer interposed between the main surfaces of the constituent parts and which is located within the peripheral edge to provide a margin peripheral, the constituent parts are secured to each other by a laser welding in the "peripheral margin to retain the intermediate layer in situ during the formation.

6. An unprocessed adapted metallic part according to claim 5, characterized in that the constituent parts are welded together.

7. An adapted unprocessed metal part according to claim 5 or 6, characterized in that the intermediate layer is not a metal.

8. A method of forming a finished component from constituent parts of an unprocessed metal part, characterized in that the method comprises the steps of forming one of the constituent parts with a peripheral edge located within the upper surface of another of the constituent parts , the opposingly directed juxtaposed upper surfaces of the constituent parts, directing a laser beam to the peripheral edge to melt the adjacent portions of the upper surface of the other portion to weld with the laser the constituent parts to each other to provide a metal part unprocessed unprocessed to provide a finished shaped component.

9. A method according to the claim 8, characterized in that it includes the step of forming an opening in one of the constituent parts above, to the juxtaposition of the pieces.

10. A method according to the claim 9, characterized in that another of the constituent parts is placed to cover the opening before the application of the welding.

11. A method according to claim 10, characterized in that the localized depression is formed in one of the constituent parts; to receive the other of the constituent parts.

12. A method according to any of claims 8 or 11, characterized in that the laser welding partially penetrates the other constituent part to finish before the other upper surface of the other constituent part.

13. A method for forming a tubular component from a pair of tubular constituent parts, characterized in that it comprises the steps of assembling the tubular pieces by locating an intermediate at the ends of the others to provide a local reinforcement, securing the pieces to each other by Laser welding, placing the interconnected parts in a die and expanding the tubular parts by the application of pressurized fluid to provide the finished shape of the tubular component.

14. A method according to claim 13, characterized in that the local reinforcement is placed externally.

15. A method according to claim 13, characterized in that the local reinforcement is placed internally.

16. A method according to claim 13, characterized in that it includes the step of placing a plurality of intermediate constituent parts at the ends of the other constituent parts to provide spaced local reinforcements.