US20020050509A1 - Friction stir bonding method - Google Patents

Friction stir bonding method Download PDF

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Publication number
US20020050509A1
US20020050509A1 US09/791,830 US79183001A US2002050509A1 US 20020050509 A1 US20020050509 A1 US 20020050509A1 US 79183001 A US79183001 A US 79183001A US 2002050509 A1 US2002050509 A1 US 2002050509A1
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US
United States
Prior art keywords
diameter portion
rotary tool
friction stir
protrusion
small
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US09/791,830
Other languages
English (en)
Inventor
Masakuni Ezumi
Kazushige Fukuyori
Akihiro Satou
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hitachi Ltd
Original Assignee
Hitachi Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hitachi Ltd filed Critical Hitachi Ltd
Assigned to HITACHI, LTD. reassignment HITACHI, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: EZUMI, MASAKUNI, FUKUYORI, KAZUSHIGE, SATOU, AKIHIRO
Publication of US20020050509A1 publication Critical patent/US20020050509A1/en
Priority to US10/218,573 priority Critical patent/US7051916B2/en
Abandoned legal-status Critical Current

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Classifications

    • 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
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • 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
    • B23K33/00—Specially-profiled edge portions of workpieces for making soldering or welding connections; Filling the seams formed thereby
    • 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
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • 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
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/04—Tubular or hollow articles
    • B23K2101/045—Hollow panels

Definitions

  • the present invention relates to a friction stir bonding method, and is especially preferable for application to bonding hollow members.
  • a friction stir bonding method is a method for bonding members by inserting a round shaft (called a rotary tool) to a joint portion and moving the tool along the joint line, thereby heating, mobilizing and plasticising the joint portion in order to perform solid-phase bonding of the members.
  • the rotary tool comprises a large-diameter portion and a small-diameter portion.
  • the small-diameter portion is to be inserted to the members to be bonded, and the end surface of the large-diameter portion contacts the members.
  • the small-diameter portion is equipped with a screw.
  • a convex portion is formed to the area where the rotary tool is to be inserted between the two members to be bonded, and the metal material forming the convex portion is mobilized to fill the gap between the two members.
  • the large-diameter portion of the rotary tool is arranged to fit within the convex portion.
  • Friction stir bonding is carried out by inserting a rotary tool to the members to be bonded, thereby plasticising and mobilizing the metal material thereof. If the thickness of the material from the tip portion of the small-diameter portion of the inserted rotary tool to the back surface of the bonded member (opposite to the large-diameter portion) is small, the mobilized metal may flow out to the back surface thereof. Even if the material does not flow out, the member will be expanded outwardly. Such phenomenon is also included in the meaning of the term “flow-out” used hereinafter in the specification. Because of this flow-out, the thickness of the protrusion compensating for the flow-out metal material must be increased. The flow-out also causes holes to be generated to the joint portion. In an attempt to prevent the flow-out, the thickness of the member is increased so that the distance from the tip of the small-diameter portion to the back surface of the member is increased. However, this increases both the weight of the member and the manufacturing cost thereof.
  • the object of the present invention is to provide a friction stir bonding method enabling a lightweight bond having good characteristics.
  • the friction stir bonding method according to the present invention characterizes in positioning the portion of the member having greater thickness, from the tip of the small-diameter portion to the back surface of the member, where the mobilized metal has the greatest pressure.
  • FIG. 1 is a vertical cross-sectional view showing the joint portion according to one embodiment of the present invention
  • FIG. 2 is a plan view of FIG. 1;
  • FIG. 3 is a vertical cross-sectional view showing one pair of hollow members according to one embodiment of the present invention.
  • FIG. 4 is a perspective view showing the body of the railroad car.
  • FIG. 5 is a vertical cross-sectional view showing the joint portion according to another embodiment of the present invention.
  • a body 500 of a railroad car comprises a side structure 501 constituting the side surfaces, a roof structure 502 constituting the roof, an underframe 503 constituting the floor, and an end structure 504 constituting the longitudinal edge portions of the car.
  • the side structure 501 , the roof structure 502 and the underframe 504 are each formed by bonding plural extruded members 10 , 20 .
  • the longitudinal direction (the extruded direction) of the extruded members 10 , 20 are arranged to the longitudinal direction of the car body 500 .
  • the extruded members 10 , 20 are hollow members made of aluminum alloy.
  • the hollow member 10 ( 20 ) comprises two substantially parallel face plates 11 ( 21 ), 12 ( 22 ), and a plural number of connecting plates 13 ( 23 ) connecting the two face plates.
  • the connecting plates 13 ( 23 ) are each tilted against the face plates 11 ( 21 ) and 12 ( 22 ).
  • the face plates 11 ( 21 ), 12 ( 22 ) and the connecting plates 13 ( 23 ) constitute a truss.
  • a connecting plate 14 ( 24 ) formed to the end portion of the hollow member 10 ( 20 ) in the width direction is orthogonal to the face plates 11 , 12 ( 21 , 22 ).
  • the outer surface of the joint between the connecting plate 14 and the face plate 11 ( 12 ) is a convex portion for receiving the face plate 21 ( 22 ) of the hollow member 20 .
  • the end portion of the hollow member 10 is stacked on the face plates 21 , 22 of the hollow member 20 .
  • the ends of the face plates 11 , 12 are each provided with a protrusion 15 for supporting the face plate 21 or 22 .
  • the protrusion 15 is protruded from the connecting plate 14 .
  • the protrusion 15 is connected to the concave portion.
  • the end of the face plates 11 , 12 ( 21 , 22 ) are each provided with a convex portion 17 ( 27 ) extending outward from the outer surface of the hollow members 10 , 20 (protruded outward in the direction of thickness).
  • the end surface of the face plates 11 , 21 ( 21 , 22 ) and the convex portion 17 ( 27 ) is formed along the direction of thickness of the hollow member 10 ( 20 ).
  • the end surface of the face plates 11 , 21 and the convex portion 17 (in other words, the convex portion close to the face plates 11 , 12 ) is positioned near the center of thickness of the connecting plate 14 .
  • the end surface of the face plate 11 ( 12 ) and the convex portion 17 of the hollow member 10 is abutted against the end surface of the face plate 21 ( 22 ) and the convex portion 27 of the hollow member 20 .
  • the face plate 11 ( 12 ) and the face plate 21 ( 22 ) are positioned along the same face, and the protruded margin of the convex portions 17 and 27 are equal.
  • the width of the two convex portions 17 , 27 are equal.
  • the width of the two convex portions is greater than the diameter of the large-diameter portion 51 of the rotary tool 50 .
  • the metal forming the convex portions 17 , 27 is used as the source material for filling the gap of the abutted portions.
  • Reference number 101 refers to a groove to which the convex portions 17 , 27 formed to the lower surface is inserted.
  • the rotary tool 50 comprises a large-diameter portion 51 and a small-diameter portion 52 mounted on the end of the large-diameter portion 51 .
  • the small-diameter portion 52 is equipped with a screw. Upon bonding, the rotary tool 50 is inserted to the abutted portions.
  • the bottom area of the large-diameter portion 51 is positioned within the convex portions 17 , 27 .
  • the small-diameter portion 52 is inserted to the abutted portions between the face plates 11 and 21 .
  • the lower end of the small-diameter portion 52 is somewhat inserted to the protrusion 15 . While rotating the rotary tool 50 , the tool is moved along the joint line of the abutted portions.
  • FIG. 2 which is a plan view of FIG. 1
  • arrow A shows the direction of movement of the rotary tool 50
  • arrow B shows the direction of rotation of the rotary tool 50
  • the screw of the small-diameter portion 52 is a left-hand screw.
  • the rotational direction of the rotary tool 50 is rightward (clockwise).
  • the protrusion 15 is positioned to the right from the center of axis of the rotary tool 50 , as shown in FIG. 1.
  • the pressure provided to the metal material of the joint portion mobilized by the rotary tool 50 is greater in the right side of the axial center of the rotary tool 50 than the left side thereof in the direction of movement of the rotary tool 50 .
  • the right-hand rotation of the rotary tool 50 is considered to cause this phenomenon, the rotation pushing the material existing in front of the rotary tool 50 that has not yet been bonded toward the right side of the tool.
  • a hollow area 10 b , 10 a exists on the left and right sides of the connecting plate 14 .
  • the distance from the tip of the small-diameter portion 15 inserted to the joint portion to the left and right hollow areas 10 b , 10 a is set so that the distance from the tip to the protrusion 15 existing in the right side is greater than to the left side. Since the protrusion 15 must support the face plate 21 , the thickness of the protrusion is relatively thick. Therefore, the thickness of the area of the member receiving higher pressure is designed thicker. The mobilized metal will not flow out into the hollow area 10 a because of this thickness of the protrusion 15 , and therefore, no hole will be generated within the joint portion.
  • the pressure provided to the left side of the rotary tool 50 is relatively low compared to the right side thereof. The reason for this is considered to be because no unbonded metal exists behind the rotary tool 50 .
  • the thickness of the member measured from the tip of the small-diameter portion 52 to the hollow portion 10 b of the left side of the connecting plate 13 can be reduced. This enables to lighten the weight of the hollow member 10 .
  • the “thickness of the member beginning from the tip of the inserted small-diameter portion 52 to the hollow portions 10 b or 10 a ” will now be explained with reference to FIG. 1.
  • the thickness of the metal needed in order to prevent the flow-out of metal at the side receiving higher pressure is set as R.
  • Thickness R is necessary t the right side of the axial center of the small-diameter portion 52 measured from the tip of the portion 52 .
  • the member on the right of the small-diameter portion 52 must have a thickness of radius R centering at the right-end corner of portion 52 .
  • thickness of the member beginning from the tip of the inserted small-diameter portion 52 to the hollow portion lob refers to the thickness in the horizontal direction as well.
  • the thickness of the member to the left of the axial center of the small-diameter portion 52 is smaller than thickness R.
  • the stacked surface near the joint portion may be knuckled toward the large-diameter portion 51 of the rotary tool 50 , generating a notch.
  • the stacked area is positioned to the right side thereof, the stacked area exists where the pressure is high, and therefore reduces the possibility of generating a notch.
  • the area having a greater thickness measured from the tip of the small-diameter portion 52 to the surface of the member opposite the large-diameter portion 51 should be placed where the pressure is higher.
  • the high-pressure region exists at the right side of the rotary tool 50 when observing the tool from behind the direction of movement, if the direction of rotation of the rotary tool 50 is right-hand rotation when observing the tool from the large-diameter portion 41 .
  • the screw of the small-diameter portion 52 is a right-hand screw, and if the direction of rotation of the rotary tool 50 is left-handed (counterclockwise), the hollow members 10 and 20 should be oppositely assembled, so that the protrusion 15 is positioned to the left of the axial center of the rotary tool 50 .
  • FIG. 5 shows the present bonding method applied to bond non-hollow members.
  • the face plates 12 , 22 and connecting plates 14 , 24 are removed from the hollow members 10 and 20 of FIG. 2.
  • the back surface of the joint portion is mounted on a flat base 105 .

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
US09/791,830 2000-10-27 2001-02-26 Friction stir bonding method Abandoned US20020050509A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US10/218,573 US7051916B2 (en) 2000-10-27 2002-08-15 Friction stir welding method

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2000-328080 2000-10-27
JP2000328080A JP3538378B2 (ja) 2000-10-27 2000-10-27 摩擦攪拌接合方法

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US10/218,573 Continuation US7051916B2 (en) 2000-10-27 2002-08-15 Friction stir welding method

Publications (1)

Publication Number Publication Date
US20020050509A1 true US20020050509A1 (en) 2002-05-02

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ID=18804990

Family Applications (2)

Application Number Title Priority Date Filing Date
US09/791,830 Abandoned US20020050509A1 (en) 2000-10-27 2001-02-26 Friction stir bonding method
US10/218,573 Expired - Fee Related US7051916B2 (en) 2000-10-27 2002-08-15 Friction stir welding method

Family Applications After (1)

Application Number Title Priority Date Filing Date
US10/218,573 Expired - Fee Related US7051916B2 (en) 2000-10-27 2002-08-15 Friction stir welding method

Country Status (7)

Country Link
US (2) US20020050509A1 (ja)
EP (1) EP1201348A3 (ja)
JP (1) JP3538378B2 (ja)
KR (1) KR20020033015A (ja)
CN (1) CN1350902A (ja)
AU (1) AU777236B2 (ja)
TW (1) TW495407B (ja)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10241028B3 (de) * 2002-09-05 2004-07-29 Erbslöh Ag Verfahren zur Herstellung von bogenförmigen (gerundeten) Strukturbauteilen aus einem Strangpreßprofil
JP6611544B2 (ja) * 2015-10-05 2019-11-27 Ｋｙｂ−Ｙｓ株式会社 接合体、流体圧シリンダ、及び接合体の製造方法
KR101687250B1 (ko) * 2015-11-04 2016-12-16 대우조선해양 주식회사 마찰교반용접 방법

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2660738B1 (fr) 1990-04-05 1994-10-28 Cma Installation permettant de realiser la refrigeration (ou rechauffement) rapide de produits emballes, notamment de bouteilles.
GB9125978D0 (en) 1991-12-06 1992-02-05 Welding Inst Hot shear butt welding
US5794835A (en) 1996-05-31 1998-08-18 The Boeing Company Friction stir welding
US6325273B1 (en) 1996-12-06 2001-12-04 The Lead Sheet Association Friction welding apparatus and method
JP3070735B2 (ja) * 1997-07-23 2000-07-31 株式会社日立製作所 摩擦攪拌接合方法
JP3589863B2 (ja) * 1997-07-23 2004-11-17 株式会社日立製作所 構造体および摩擦攪拌接合方法
JP4014258B2 (ja) * 1997-09-18 2007-11-28 昭和電工株式会社 金属製パイプ及びその製造方法
US6029879A (en) 1997-09-23 2000-02-29 Cocks; Elijah E. Enantiomorphic friction-stir welding probe
US6051325A (en) * 1997-12-23 2000-04-18 Mcdonnell Douglas Corporation Joining of machined sandwich assemblies by friction stir welding
US6230957B1 (en) 1998-03-06 2001-05-15 Lockheed Martin Corporation Method of using friction stir welding to repair weld defects and to help avoid weld defects in intersecting welds
JPH11267859A (ja) * 1998-03-17 1999-10-05 Sumitomo Light Metal Ind Ltd 接合用加工材とその接合方法及び接合された加工パネル
JPH11291067A (ja) * 1998-04-09 1999-10-26 Hitachi Ltd 摩擦接合方法
JP3974708B2 (ja) * 1998-05-20 2007-09-12 昭和電工株式会社 突合せ継手構造
JP3420502B2 (ja) * 1998-06-16 2003-06-23 株式会社日立製作所 構造体
JP3329738B2 (ja) * 1998-08-03 2002-09-30 住友軽金属工業株式会社 押出形材接合方法
JP2000061662A (ja) * 1998-08-24 2000-02-29 Hitachi Ltd 摩擦攪拌接合方法
AU733140B2 (en) 1998-09-29 2001-05-10 Hitachi Limited A friction stir welding method
JP3732668B2 (ja) * 1999-02-16 2006-01-05 株式会社日立製作所 摩擦撹拌接合方法
JP2000343245A (ja) 1999-05-31 2000-12-12 Hitachi Ltd 構造体の製作方法
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JP3452018B2 (ja) * 2000-03-24 2003-09-29 日本軽金属株式会社 接合方法及び接合ツール
JP3575749B2 (ja) * 2000-11-17 2004-10-13 株式会社日立製作所 摩擦攪拌接合方法
JP3818084B2 (ja) * 2000-12-22 2006-09-06 日立電線株式会社 冷却板とその製造方法及びスパッタリングターゲットとその製造方法

Also Published As

Publication number Publication date
US20020190102A1 (en) 2002-12-19
EP1201348A2 (en) 2002-05-02
JP3538378B2 (ja) 2004-06-14
US7051916B2 (en) 2006-05-30
EP1201348A3 (en) 2004-01-02
CN1350902A (zh) 2002-05-29
AU777236B2 (en) 2004-10-07
TW495407B (en) 2002-07-21
KR20020033015A (ko) 2002-05-04
JP2002137068A (ja) 2002-05-14
AU2310201A (en) 2002-05-02

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Legal Events

Date Code Title Description
AS Assignment

Owner name: HITACHI, LTD., JAPAN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:EZUMI, MASAKUNI;FUKUYORI, KAZUSHIGE;SATOU, AKIHIRO;REEL/FRAME:011567/0336

Effective date: 20010119

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION