TWI762588B - 以熱噴塗中間層電阻焊接不可焊金屬 - Google Patents
以熱噴塗中間層電阻焊接不可焊金屬 Download PDFInfo
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- TWI762588B TWI762588B TW107106193A TW107106193A TWI762588B TW I762588 B TWI762588 B TW I762588B TW 107106193 A TW107106193 A TW 107106193A TW 107106193 A TW107106193 A TW 107106193A TW I762588 B TWI762588 B TW I762588B
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- 238000003466 welding Methods 0.000 title claims description 70
- 229910052751 metal Inorganic materials 0.000 title description 20
- 239000002184 metal Substances 0.000 title description 20
- 239000011229 interlayer Substances 0.000 title description 3
- 150000002739 metals Chemical class 0.000 title description 3
- 238000000034 method Methods 0.000 claims abstract description 53
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 48
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 47
- 239000000463 material Substances 0.000 claims abstract description 38
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 26
- 239000010959 steel Substances 0.000 claims abstract description 26
- 239000000758 substrate Substances 0.000 claims abstract description 20
- 230000000930 thermomechanical effect Effects 0.000 claims abstract description 5
- 239000004411 aluminium Substances 0.000 claims description 14
- 238000000576 coating method Methods 0.000 claims description 11
- 239000010935 stainless steel Substances 0.000 claims description 9
- 229910001220 stainless steel Inorganic materials 0.000 claims description 9
- 239000011248 coating agent Substances 0.000 claims description 8
- 229910045601 alloy Inorganic materials 0.000 claims description 5
- 239000000956 alloy Substances 0.000 claims description 5
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 3
- 229910052749 magnesium Inorganic materials 0.000 claims description 3
- 239000011777 magnesium Substances 0.000 claims description 3
- 229910000838 Al alloy Inorganic materials 0.000 claims description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 2
- 229910052799 carbon Inorganic materials 0.000 claims description 2
- 238000004140 cleaning Methods 0.000 claims description 2
- 238000005488 sandblasting Methods 0.000 claims description 2
- 230000001681 protective effect Effects 0.000 claims 3
- 229910000975 Carbon steel Inorganic materials 0.000 claims 2
- 239000010962 carbon steel Substances 0.000 claims 2
- 229910000861 Mg alloy Inorganic materials 0.000 claims 1
- 238000007751 thermal spraying Methods 0.000 claims 1
- 238000005304 joining Methods 0.000 abstract description 18
- 239000010410 layer Substances 0.000 description 21
- 238000005507 spraying Methods 0.000 description 15
- 229910000679 solder Inorganic materials 0.000 description 10
- 239000007921 spray Substances 0.000 description 9
- 239000002131 composite material Substances 0.000 description 6
- 238000005260 corrosion Methods 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 238000005422 blasting Methods 0.000 description 4
- 230000007797 corrosion Effects 0.000 description 4
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- 239000011324 bead Substances 0.000 description 3
- 229910002056 binary alloy Inorganic materials 0.000 description 3
- 229910015372 FeAl Inorganic materials 0.000 description 2
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 230000006698 induction Effects 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 238000005476 soldering Methods 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- 239000011800 void material Substances 0.000 description 2
- 229910052725 zinc Inorganic materials 0.000 description 2
- 239000011701 zinc Substances 0.000 description 2
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- 229910000760 Hardened steel Inorganic materials 0.000 description 1
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical compound [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 229910000423 chromium oxide Inorganic materials 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 239000010431 corundum Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000005238 degreasing Methods 0.000 description 1
- 238000012938 design process Methods 0.000 description 1
- 238000010283 detonation spraying Methods 0.000 description 1
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- 238000010894 electron beam technology Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000010285 flame spraying Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
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- 239000003102 growth factor Substances 0.000 description 1
- 230000001939 inductive effect Effects 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000005272 metallurgy Methods 0.000 description 1
- QMQXDJATSGGYDR-UHFFFAOYSA-N methylidyneiron Chemical compound [C].[Fe] QMQXDJATSGGYDR-UHFFFAOYSA-N 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000002161 passivation Methods 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 238000007750 plasma spraying Methods 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
- B23K3/04—Heating appliances
- B23K3/047—Heating appliances electric
- B23K3/0478—Heating appliances electric comprising means for controlling or selecting the temperature or power
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/06—Resistance welding; Severing by resistance heating using roller electrodes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/10—Spot welding; Stitch welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/10—Spot welding; Stitch welding
- B23K11/11—Spot welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/14—Projection welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/16—Resistance welding; Severing by resistance heating taking account of the properties of the material to be welded
- B23K11/163—Welding of coated materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/16—Resistance welding; Severing by resistance heating taking account of the properties of the material to be welded
- B23K11/20—Resistance welding; Severing by resistance heating taking account of the properties of the material to be welded of different metals
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- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/20—Bonding
- B23K26/32—Bonding taking account of the properties of the material involved
- B23K26/323—Bonding taking account of the properties of the material involved involving parts made of dissimilar metallic material
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- B23K9/00—Arc welding or cutting
- B23K9/23—Arc welding or cutting taking account of the properties of the materials to be welded
- B23K9/232—Arc welding or cutting taking account of the properties of the materials to be welded of different metals
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
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- B32B15/00—Layered products comprising a layer of metal
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- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
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- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
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- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
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- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
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- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
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- B23K2103/00—Materials to be soldered, welded or cut
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Abstract
本發明係關於一種利用熱結合製程以搭接組態結合至少兩種彼此不可直接焊接之材料的方法，其中使用由第一步驟及第二步驟所組成的兩步驟順序，第一步驟係將熱機械或機械表面保護層施加於(不鏽)鋼基板(1)之表面上，及在第二步驟中，使用熱結合製程來焊接噴塗層(2)與外加鋁片材(3)，且於整個材料組態中不具有脆性金屬間相。
Description
本發明係關於藉由在(不鏽)鋼之表面上施加一具有明確厚度、表面粗糙度及過渡電阻的鋁熱噴塗層，而使不可焊的金屬組合如鋁對(不鏽)鋼變得可電阻焊接。隨後在第二步驟中，接著進行電阻(點)焊接製程。所使用之焊接參數必需以僅鋁對鋁接觸區域熔融，且在鋁層與(不鏽)鋼之間不具有脆性金屬間相的方式來選擇。
電阻焊接係金屬製造工業中之其中一種最常用的焊接程序。可例如藉由點焊(spot welding)、輥縫焊接(roller seam welding)、突點焊接(Projection welding)或點焊黏結(weldbonding)來進行電阻焊接，以獲得經焊接的白色家電、燃料槽、汽車、鐵路或卡車之車體構造。但有許多材料(諸如熱成形麻田散鐵不鏽鋼或二及三接點材料組合)不具有用於電阻焊接製程的可焊接性。針對該等材料，存在若干於材料上產生機械焊料或硬焊沉積物的概念。然而，該等機械焊料或硬焊沉積物需要變形及/或切割材料以在材料與機械焊料或硬焊沉積物之間獲得良好黏結或形成閉合。當材料進一步藉由傳統電阻焊接製程處理時，焊接點通常最終具有冷裂脆性斷裂行為及因此具有低強度水平以及低電力傳遞。
整個汽車車體工程工業希望以多材料設計利用不同接頭使用不同金屬如(不鏽)鋼及鋁。當前最新技術沒有可利用的熱焊接方法，而僅可使用黏結及機械結合。利用習知的焊接方法，會在鋁與(不鏽)鋼之間產生脆性金屬間相。藉由本發明，可使用廉價且循環時間快速的電阻點焊。此外，(接觸)抗腐蝕性會提高。藉由本發明，可針對不同組合達成如類似鋁接頭的結合力。
EP專利申請案2679328 A1係關於一種藉由電阻焊接來結合第一結合伴體與第二結合伴體的方法，及在兩結合伴體之間的程序新型永久連接。目標係要提供一種使用結合輔助件及焊接製程結合第一結合伴體與第二結合伴體的替代方式，特定言之提供一種添加待結合之不同部件，特定言之不同結合伴體(其中至少一者包含氧化物層)的方式。
DE專利申請案102016106756係關於一種用於腐蝕保護之熱噴塗，例如鋁熱噴塗。在一具體例中，提供一種抗腐蝕總成，其包括：與第二金屬組件組裝之第一金屬部件，介於第一與第二組件之間的接頭，及覆蓋至少一部分接頭的腐蝕保護層，其中該腐蝕保護層係鋁或鋅。
DE專利申請案102014011599係關於一種用來結合至少兩組件之方法，其中可以製程及製造技術簡單的方式實現兩組件的可靠連接。焊塊自結合輔助元件與第二組件(鋼)之內部之間居中形成。此容許減小偏心材料鎖定連接、以及不良透鏡形成、結合輔助元件傾斜、孔隙及空隙形成及各向同性強度性質的缺點。在材料增厚上方之圓頂的直徑可小於元件頭部直徑且僅將尺寸定得夠大使得仍獲得兩組件間之可容許間隙。
EP專利申請案1582283係關於一種用於點焊兩個最終於電泳浴中底塗或塗漆之硬鋼片材部件之製程，其包括將較佳為諸如低碳鐵之易焊金屬的小片狀物設置於片材間的焊接點處。用於點焊由高強度鋼製成之兩片狀金屬部件的方法隨後藉由電泳浴塗漆或待塗漆。
DE專利申請案10251414係關於一種藉由電阻或感應加熱組件(特定言之由金屬性材料製成之片狀金屬部件)的點焊或焊接方法，以及一種用來實施結合輔助構件之特定方法。使用電阻或感應加熱進行點焊或焊接的製程包括確定藉由電流強度之受控變化引入之熱及取決於插入於待焊接或軟焊之組件間之接頭輔助元件之選定橫截面輪廓的結合力。
DE專利申請案102004025493及102004025492係關於一種用來結合組件之方法、一種結合元件及一種用於結合組件之組件。使兩個或更多個結合部件(特定言之金屬片材及/或塑膠片材)藉由結合元件結合在一起。當結合元件時，其可充作鉚釘或螺釘。待結合之組件具有開口，特定言之具有結合元件可插入其中的鑽孔。將部件彼此定位然後藉由焊接結合元件來結合。有利地可使用習知之焊槍作為習知之焊接，但軟焊(soldering)所需之熱輸入顯著地低於焊接。
DE專利申請案102012013325係關於較容易製造之三個或更多個組件之複合物，特定言之透過在最終製造整個複合組件之前將兩個或更多個組件簡單地預固定至部分複合物。一種組裝不同材料之組件的方法。一種以第一組件用來實現第二組件及第三組件之經改良的複合組件，提供輔助黏結構件，藉由結合輔助件製造 兩組件中之一者之部分複合物，其中：藉由結合助件穿透其中兩個組件，並於該兩個組件與結合工具之間產生正面及/或非正面連接，及藉由壓力焊接將穿透結合輔助件之部分複合物結合至剩餘的一個組件。
DE專利申請案102012013589係關於用於電阻器元件焊接以結合多於兩個由扁平材料所形成之組件的自衝孔緊固元件。所述類型之自刺穿緊固元件適用於結合多於兩個組件，其中此等組件中之至少一個亦可由非塑性可變形材料形成。
WO專利申請案2010022709係關於一種如此提供之至少在由鋼(特定言之熱成形高強度鋼)與至少一個來自鋁材料之片狀金屬組件之間產生接頭連接之方法，其中首先藉由電弧或雷射製程沉積焊料以確保固定對其中一個金屬組件之安全輸送，然後藉由在接頭區域中施加電流及施加金屬組件壓縮壓力或藉由感應加熱來加熱而安置於經設置之焊料沉積物上之片狀金屬部件與金屬組件之間，以致在由鋼製成之片狀金屬部件與焊料之間沉積焊料並在來自鋁材料之片狀金屬組件與焊料沉積物之間形成焊接或軟焊。
US專利申請案5273204係關於一種方法，其中使用對接組態來將焊接縫熱噴塗成v形對接。熱噴塗材料同時位在焊接縫上。
US專利申請案20100089977A1描述一種摩擦攪拌焊接製程，其中將粉末鬆散地施加於兩金屬之間以產生特殊的冶金學並(例如)硬化鋁合金。
當前最新技術不存在任何用來結合不同金屬組合(如鋁對(不鏽)鋼)之焊接方法，而僅可利用黏結或機械結合(兩者皆具有較低的電力傳遞)。在習知的(電阻)焊接中，焊接接觸區域在高於350℃之溫度範圍中熔融，從而產生FeAl3及Fe2Al5之脆性金屬間相。
在提高車體工程之多材料設計過程中，製造工業同時使用鋁及(不鏽)鋼。電阻點焊係於車體工程中主要使用的結合方法。
本發明的概念係要藉由在(不鏽)鋼之表面上施加一具有明確厚度、表面粗糙度及過渡電阻的鋁熱噴塗層來使不可焊的金屬組合如鋁對(不鏽)鋼或一般的不可焊材料如熱成形麻田散鐵不鏽鋼變得可電阻焊接。隨後在第二步驟中，接著進行電阻(點)焊接製程。所使用之焊接參數必需以僅鋁對鋁接觸區域熔融，且在鋁層與(不鏽)鋼之間不具有脆性金屬間相的方式來選擇。
用於相成長的公式可以拋物線成長曲線來表示：Xm 2=k．t，其中Xm=平均穿透深度=金屬間相厚度，k=成長係數，文獻值：8.46．10-15m2/s(於873K下)
t=焊接時間。
拋物線成長曲線公式提供關於典型點焊之層厚度的資訊，其意謂強度與鋁基礎材料相比減小超過50%。
點焊的典型層厚度係大於或等於15μm。其意謂與鋁基礎材料(280N/mm2)相比強度減小超過50%。因此，本發明必需避免在焊接期間的任何金屬間相成長。
關於本發明之熱機械塗布方法可由火焰噴塗、電弧噴塗、電漿噴塗、雷射噴塗、冷氣體噴塗、爆震噴塗、高速氧燃料噴
塗或熔池噴塗組成。
在噴塗製程中，材料或噴塗消耗物係作為線、桿、棒、索、粉末或作為熔池供應。
在沒有本發明方法所使用之熱噴塗層之情況下不可直接焊在一起的材料可為例如鋼如未合金化、低合金化或不鏽鋼、鋁、鋁基合金、鎂或鎂基合金。
熱噴塗層係根據本發明藉由電弧、雷射束、電子束、嵌柱或電漿焊接，較佳利用電阻焊接製程如電阻點焊、點焊黏結、電阻輥縫焊接或突點焊接，進行與外加片材的焊接。自然地，可於根據本發明之焊接製程中使用其他焊接方法。
熱噴塗層厚度對由點焊所達成之直徑的比係小於/低於或等於0.25。
包括基板、熱噴塗層、外加片材之總片材厚度係介於1.5mm至6.0mm之間，同時介於熱噴塗層與基礎材料間之過渡區係低於350℃。於運輸應用中用於薄座椅結構部件之一典型的厚度組合可係：T[mm]=t基礎+t噴塗層+t外加片材=0.5mm+0.25mm+0.75mm=1.5mm
可針對客車之碰撞相關結構部件(如電動車之b-柱或電池殼之連接性)製作厚度設計的另一實例：T[mm]=t基礎+t噴塗層+t外加片材=1.7mm+1.5mm+2.8mm=6.0mm
其中T係t基礎+t噴塗層+t外加片材加總之總片材厚度[mm]，t基礎係基礎材料(在以上實例中為(不鏽)鋼)之片材厚度[mm]，t噴塗層係熱噴塗層(在以上實例中利用電弧噴塗製程製造，其中使用AlMg3之線)之厚度[mm]。至少t外加片材係施加在熱機械塗布層上之片材的厚度[mm]，其在以上實例中係EN AW-6081合金之鋁片材。
待熱噴塗之基板可由鋼材料，較佳具有熱浸及電解鍍鋅表面塗層的未合金化或低合金化鋼所組成。更佳地，其係具有氧化鉻鈍化層之不鏽鋼。另外，適用於本發明方法中之材料亦可係具有包括鋁-矽或鋅塗層之對比面(scaled surface)或表面保護層的熱成形或模壓淬火鋼(press-hardened steel)。
該方法尤其適用於脆性材料如具有超過800MPa之抗拉強度的高強度鋼。此外，待熱噴塗之基板可係具有高於0.65%之碳當量(CEV)的未合金化或低合金化鋼，其中CEV係使用下式來計算(元素含量以重量%計)CEV=C+Mn/6+(Cu+Ni)/15+(Cr+Mo+V)/5。
此外，基板表面可根據本發明來處理，藉由清潔或脫脂、及噴砂或珠擊來預處理。在該情況中，用於噴砂或珠擊之噴砂磨料亦可由剛玉、鋼線、碳化矽、及硬鑄沙礫或玻璃珠組成。
本發明展現彼等不同焊接的高電力傳遞。斷裂行為可集中於外加片材區域。因此，本發明可相對於當前最新技術中之其中一種材料的相似焊接，相較於相同厚度組合達成較高或相等的電力傳遞。
待用於本發明方法中之較佳的電阻焊接製程步驟可藉由不同種類的電阻焊接(諸如點焊、輥縫焊接、突點焊接或點焊黏結)來實施。
1:基板材料
2:熱噴塗中間層
3:外加鋁；鋁片材
4:點焊區域
本發明參照圖式更詳細地說明於下，其中圖1繪示如於本發明之先前技術中所述之介於鋁與鋼間之相的二元系統Fe/Al金屬間成長。
圖2繪示如於本發明之先前技術中所述之金屬間層厚度與所得強度值的關係。
圖3繪示本發明之熱噴塗層與(不鏽)鋼基板之一較佳具體例的示意性側視圖，且其顯示噴塗鋁層至基礎材料/基板之第一步驟。
圖4繪示本發明之電阻點焊熱噴塗鋁層與鋁扁平片材之另一較佳具體例的示意性側視圖，其中展示具有另一鋁扁平片材之焊接熱噴塗層/不鏽鋼。
一種實例係在不鏽鋼表面之頂部上產生鋁熱噴塗層，其使用層的擴散、黏附、機械互鎖效應、化學結合，且其中不鏽鋼上的層係由鋁基合金組成，且該組合係藉由電阻焊接進行與外加鋁片材的焊接以避免金屬間脆性相。
圖1中說明二元系統的理論背景，其僅適用於無限長的冷卻速率，因此電阻點焊具有
1,500K/s冷卻速率與脆性金屬間相：FeAl3及Fe2Al5。Fe/Al之二元系統*以溫度範圍表示。
*來源係來自Guimaraens,E.,university of Bayreuth,2005。
圖2中說明相成長的理論背景，其以拋物線成長曲線表示。呈現金屬間層厚度與抗拉強度的關係。結果，典型點焊的層厚度係大於或等於15μm。曲線顯示與鋁基礎材料(280N/mm2)相比，強度減小超過50%。由於該現象，因此在本發明中，與此相關之方法必需避免焊接期間之金屬間相的任何成長。
圖3中繪示本發明之較佳具體例之側視圖的示意圖。利用熱噴塗中間層(2)製造的熱機械或機械Al合金化表面塗層位於不可彼此直接焊接之基板材料(1)如不鏽鋼的頂部。
圖4中繪示本發明之較佳具體例之側視圖的示意圖，其中使用在基板(1)上之熱噴塗塗層(2)與外加鋁(3)片材之間的習知電阻焊接製程來結合材料組合。在基板(1)、熱噴塗中間層(2)與鋁片材(3)之間存在點焊區域(4)。在基板(1)與熱噴塗塗層間之接觸區域中的溫度低於攝氏350度。
1‧‧‧基板材料
2‧‧‧熱噴塗中間層
Claims (10)
- 一種利用熱結合製程以搭接組態結合至少兩種彼此不可直接焊接之材料的方法，其特徵在於使用由第一步驟及第二步驟所組成的兩步驟順序，第一步驟係藉由熱噴塗將表面保護鋁層施加於鋼基板(1)之表面上，及在第二步驟中，使用焊接製程來將該表面保護鋁層(2)焊接至外加片材(3)，其為鋁、鋁合金、鎂或鎂合金片材，且於整個材料組態中不具有脆性金屬間相，該表面保護鋁層(2)厚度對由點焊(4)所達成之直徑的比係小於或等於0.25，以及在該基板(1)與該表面保護鋁層間之接觸區域中的溫度係低於350℃。
- 如請求項1之方法，其中，該表面保護鋁層係藉由熱機械塗布方法實施。
- 如請求項1或2之方法，其中，該表面保護鋁層(2)係鋁、鋁基合金或鋁與碳化物之組合。
- 如請求項1或2之方法，其中，該表面保護鋁層(2)係藉由選自由點焊黏結(weldbonding)、點焊(spot welding)、突點焊接(projection welding)或輥縫焊接(roller seam welding)組成之群的電阻焊接方法而與該外加片材(3)焊接。
- 如請求項1或2之方法，其中，包括基板(1)、表面保護鋁層(2)及外加片材(3)之總片材厚度係自1.5mm至6.0mm。
- 如請求項1或2之方法，其中，該表面保護鋁層(2)之厚度係自0.25mm至1.5mm。
- 如請求項1或2之方法，其中，待熱噴塗之該基板(1)係具有高於0.65%之碳當量(CEV)的碳鋼，其中CEV係使用下式來計算(元素含量以重量%計)CEV=C+Mn/6+(Cu+Ni)/15+(Cr+Mo+ V)/5。
- 如請求項1或2之方法，其中，待熱噴塗之該基板(1)係具有鍍鋅表面塗層的碳鋼。
- 如請求項1或2之方法，其中，待熱噴塗之該基板(1)係不鏽鋼。
- 如請求項1或2之方法，其中，該基板(1)表面係藉由清潔及噴砂來預處理。
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2018
- 2018-02-16 AU AU2018223090A patent/AU2018223090A1/en not_active Abandoned
- 2018-02-16 US US16/487,930 patent/US11548087B2/en active Active
- 2018-02-16 KR KR1020197026381A patent/KR102436341B1/ko active IP Right Grant
- 2018-02-16 CN CN201880012634.5A patent/CN110312589B/zh active Active
- 2018-02-16 BR BR112019017427A patent/BR112019017427A2/pt not_active Application Discontinuation
- 2018-02-16 CA CA3053613A patent/CA3053613A1/en active Pending
- 2018-02-16 JP JP2019546234A patent/JP7261167B2/ja active Active
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- 2018-02-16 SG SG11201907514XA patent/SG11201907514XA/en unknown
- 2018-02-16 WO PCT/EP2018/053892 patent/WO2018153785A1/en active Application Filing
- 2018-02-16 MX MX2019010071A patent/MX2019010071A/es unknown
- 2018-02-23 TW TW107106193A patent/TWI762588B/zh active
- 2018-12-14 TW TW107145270A patent/TWI783095B/zh active
- 2018-12-19 WO PCT/EP2018/000565 patent/WO2019149336A1/en active Application Filing
- 2018-12-19 CN CN201880077294.4A patent/CN111432971A/zh active Pending
- 2018-12-19 US US16/955,865 patent/US11524351B2/en active Active
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- 2024-02-28 AU AU2024201319A patent/AU2024201319A1/en active Pending
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| Publication number | Publication date |
|---|---|
| EP3366406A1 (en) | 2018-08-29 |
| TW201838493A (zh) | 2018-10-16 |
| JP2020508877A (ja) | 2020-03-26 |
| CN111432971A (zh) | 2020-07-17 |
| TWI783095B (zh) | 2022-11-11 |
| KR20190122219A (ko) | 2019-10-29 |
| US11524351B2 (en) | 2022-12-13 |
| WO2019149336A1 (en) | 2019-08-08 |
| JP7261167B2 (ja) | 2023-04-19 |
| TW201938390A (zh) | 2019-10-01 |
| EP3369516A1 (en) | 2018-09-05 |
| AU2024201319A1 (en) | 2024-03-21 |
| CN110312589B (zh) | 2022-12-16 |
| BR112019017427A2 (pt) | 2020-04-07 |
| AU2018223090A1 (en) | 2019-09-05 |
| CA3053613A1 (en) | 2018-08-30 |
| US11548087B2 (en) | 2023-01-10 |
| CN110312589A (zh) | 2019-10-08 |
| SG10202108993YA (en) | 2021-09-29 |
| KR102436341B1 (ko) | 2022-08-25 |
| MX2019010071A (es) | 2019-10-15 |
| WO2018153785A1 (en) | 2018-08-30 |
| RU2019126649A3 (zh) | 2021-04-07 |
| US20210069819A1 (en) | 2021-03-11 |
| EP3369516B1 (en) | 2023-10-18 |
| SG11201907514XA (en) | 2019-09-27 |
| US20190381592A1 (en) | 2019-12-19 |
| RU2019126649A (ru) | 2021-03-24 |
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