US3857163A - Forming pressure-welded joints - Google Patents

Forming pressure-welded joints Download PDF

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Publication number
US3857163A
US3857163A US00314666A US31466672A US3857163A US 3857163 A US3857163 A US 3857163A US 00314666 A US00314666 A US 00314666A US 31466672 A US31466672 A US 31466672A US 3857163 A US3857163 A US 3857163A
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US
United States
Prior art keywords
aluminium
die
steel
slug
wedge
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.)
Expired - Lifetime
Application number
US00314666A
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English (en)
Inventor
J Hirschfield
J Lablans
W Shankland
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.)
Alcan Research and Development Ltd
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Alcan Research and Development Ltd
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Publication date
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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
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/02—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of a press ; Diffusion bonding
    • 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
    • B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
    • B23K20/227—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded with ferrous layer
    • B23K20/2275—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded with ferrous layer the other layer being aluminium

Definitions

  • a method of forming a welded joint between aluminium and steel without the formation of intermetallics at the aluminium/steel interface is achieved by driving a wedge shaped steel member into a heated aluminium slug located in a restraining die.
  • the driving is performed under such conditions that the aluminium/- steel interface is maintained substantially free from extraneous matter so that the aluminium and steel become welded to one another (without fusion of aluminium) under the high pressure resulting from the extrusion of the aluminium into the space between the die wall and the shank of the steel member during the driving of the steel member into the slug.
  • the temperature of the slug is preferably in the range of 400 to 550C and the wedge member is driven quickly (i.e., within 10 seconds) to prevent it from becoming heated and acquiring a surface oxide film.
  • the present invention relates to a method of forming a welded joint between aluminium and steel, the joint being suitable for the transmission of a heavy electric current and having a high mechanical strength.
  • a typical application of the method of the invention is to the formation of joints between aluminium and steel in cathode riser connections and anode rod connections for electrolytic reduction cells for the production of aluminium.
  • the method of the present invention is also suitable for the formation of structural joints of high strength between aluminium and steel.
  • the present invention may be employed to form a composite member for connecting an aluminium vessel to a steel support structure.
  • the present invention provides a method of making a welded joint between aluminium and steel, which comprises placing a heated aluminium slug in a restraining die and pressing a steel member formed into the slug in such a manner that virgin aluminium and clean steel are brought into intimate contact under conditions of high pressure at the aluminium steel interface as the aluminium extrudes outwardly around the shank portion of the steel member and no substantial quanitty of extraneous material is drawn into the aluminium slug by the said member.
  • the temperature of the aluminium slug is preferably in the range of 400 550C., most preferably in the range of 475 525C, which allows the steel member to penetrate into the aluminium without excessive pressure.
  • the pressure applied should be sufficient to allow the steel member to be driven into the aluminium rapidly if the aluminium is heated to a temperature of the order above indicated.
  • the initially unheated steel member typically 1 inch thick
  • This pressure is dependent on four parameters: (1) the temperature of the aluminium slug (2) the angles on the wedge, on the shank, and on the die wall (3) the die cavity width (the difference between the die cavity width and the shank thickness) and (4) the friction between the die wall and the extruding aluminium.
  • the steel has a wedge-shaped edge portion, having an edge with an apex angle of say 30, although somewhat greater or lesser apex angles may be employed, and a shank portion.
  • the end faces of the steel member are also preferably somewhat convergent to assist in tne entry of the steel into the aluminium slug.
  • the shape of the shank of the steel member and the corresponding part of the die side are preferably arranged so that there is a small amount of choke between the die side and the shank, so that the aluminium which is caused to flow between the die sides and the shank is extruded into a tapering space.
  • the extrusion of the metal into a tapering space assists in the development of the high pressure at the steel/aluminium interface required to secure pressure welding without fusion of the aluminium.
  • the space between the shank of the wedge member and the die wall is small, such as one-fourth inch or less, it is possible to develop sufficient pressure between the aluminium and the steel wedge member, even though the faces of the shank are parallel to the die sides, provided there is sufficient friction between the extruding aluminium and the die wall.
  • the provision of a taper between the die sides and the shank of the steel member may be achieved by providing parallel opposed faces on the die sides in the relevant area in conjunction with steel members having slightly tapering shanks.
  • the shanks of the steel members be parallel-sided and the die sides provided with a small amount of reverse taper, preferably from 1 to 5, most preferably about 3. It is even possible for a small amount of reverse taper to be provided on the shanks, providing that this is less than the reverse taper on the die side.
  • the included angle between the side faces of the shank is preferably in the range of 1 5, most preferably about 3.
  • the die cavity is preferably tapered in cross section, although this is not essential to the present invention.
  • the closed end of the die is preferably provided with a longitudinal groove conforming to a suitable edge preparation, for example having an apex angle of for subsequent welding of the aluminium to another aluminium component such as a bus bar.
  • the aluminium slug is shaped to have a cross section which conforms to that of the die cavity and for this purpose is preferably cut from an appropriate extruded section or is in the form of a casting.
  • the upper end of the slug is preferably formed with a shoulder at each side so that the top /2 1 inch of the slug is held away from contact with the walls of the die during initial penetration of the steel member.
  • a lubricant or parting compound between the die wall and the slug is necessary to enable the final welded assembly to be withdrawn from the die and to permit flow of aluminium against the wall of the die.
  • the provision of an initial spacing between the top end of the slug and the die wall avoids excessive drawin of parting lubricant by the steel which would prevent welding wherever it intervened between the aluminium and the steel. Without this precaution there is a tendency for lubricant to be carried up the side wall of the die and across the outer end of the slug and to be drawn into the interior of the slug in contact with the steel, as
  • the steel wedge edge and shank are free from oxides and matter such as grease, oil, etc.
  • the stel may be cleaned chemically or mechanically, for example by disc sanding to a surface finish of 60 60 RMS (root mean square). The time interval between cleaning and pressing should be such that the steel remains substantially free from oxides.
  • FIG. 1 is a cross section of an aluminium slug for the production of an aluminium/steel 18 joint in accordance with the present invention
  • FIG. 2 is a cross section of a steel wedge member for use in conjunction with the slug of FIG. 1 and FIG. 3 is a front view of the wedge member of FIG.
  • FIG. 4 is a diagrammatic cross section of the restrain ing die
  • FIG. 5 is a diagrammatic cross section of the completed joint in the die.
  • FIG. 6 is a diagrammatic cross section showing an alternative form of slug.
  • the aluminium slug of FIG. 1 is a casting or cut from an extruded section of an aluminium alloy having suitable physical properties.
  • the slug 1 has sides 2 which taper from top to bottom by about 3 percent.
  • the bottom end has faces 3 which meet at an apex 4 at an angle of about 100.
  • the width of the slug is reduced by the provision of a pair of shoulders 5, so that the faces 2' are initially maintained out of contact with the sides of the dies.
  • the wedge member 6 of FIGS. 2 and 3 which may, for example, be fabricated from steel plate, has a main body portion 7 of a shape dictated by the service which the joint is to perform. Thus the main body portion 7 may be shaped for connection to another structure by means of bolts or welding or other suitable means.
  • the wedge member 6 is provided with a shank portion 8 and a wedge-shaped edge portion 9. It is with the side faces of the shank portion 8 and of the wedge-shaped edge portion 9 that a strong pressure-welded bond is formed by the method of the present invention.
  • the restraining die 10 of FIG. 4, within which the joint between the aluminium alloy slug 1 and the wedge member 6 is formed, comprises an outer ring 11, having a tapered central aperture 12 to receive die side members 14 and a die base member 15, which is provided with an ejector member 16.
  • the outer surfaces of the side members 14 conform in curvature and taper with the central aperture in ring 11.
  • the inner surfaces of the side members are shaped to provide a die space with sides corresponding to the taper of the sides 2 of the aluminium slug 1, whilst the die base member 15 is longitudinally grooved to conform with the shape of the faces 3 of the slug 1.
  • the opposed faces of the member 14 are provided with inclined portions 17 to define the sides of the tapered space to receive the slug 1 and reverse tapered portions 18 which commence at a level approximately corresponding with the shoulders 5 of the slug 1, with the result that when the wedge member 6is pressed into the slug 1 the upper part of the slug above the shoulders 5 moves laterally to the wedge member 6 whilst the upper part of the slug below the shoulders Sis extruded upwardly into the choke space defined between the reverse tapered face portions 18 and the parallel shank 8.
  • the reverse tapered sides are inclined at an angle of /z 2 /2", preferably about 1 /2 to the medial plane of the die cavity, so that the included angle between the faces 18 is 1 5, preferably about 3.
  • the slug is first heated to a temperature in the range of 475 525C, after which it is placed into the die.
  • the freshly cleaned wedge-shaped steel member 6 is then placed in position and pressed downwardly into the die by a hydraulic ram, which moves at a speed sufficient to drive the wedge to the position illustrated in FIG. 5 in a time interval of 3 10 seconds.
  • the assembly of slug 1 and wedge member 6 is then ejected from the die by pressing the bottom member 15 upwardly, which lifts the side members 14 in relation to the ring 11 and permits them to separate from each other and from the completed joint.
  • the aluminium/steel pressure-welded joint assembly may then be connected to aluminium and to steel members respectively by appropriate welding techniques.
  • a slug 19 may be cut from plate, as shown in FIG. 6.
  • the final shape is obtained during the pressing operation in which the aluminium is forged to the shape of the die cavity.
  • the plate slug 19 is cen' tered in the die cavity by means of two narrow aluminium spacers 20.
  • the spacers prevent contact of the plate slug 19 with the parting lubricant on the walls of the die cavity and thus perform the same function as the shoulders 5 on the extruded slug 1.
  • the spacers are shaped so that they may be put in position before the heated slug is introduced into the die cavity. For this purpose they are provided with flanges which rest on the top of the die.
  • the opposed faces of the die are parallel throughout their length.
  • the slug is made from heavy gauge aluminium plate, as in the case of FIG. 6.
  • the shank of the wedge member is tapered to define, in conjunction with the side walls of the die, the choke space into which the extruded metal flows in the course of the formation of the pressure weld.
  • the plate may be slightly thinner than the width of the die and initially held in position by means of appropriately spaced spacers as in the arrangement of FIG. 6 so as to maintain an initial absence of contact between the slug and the lubricant on the die walls.
  • the two side faces of the slug may be machined to provide recessed surfaces, similar to those shown at 2' in FIG. 1.
  • a method of'forming a welded joint between aluminium and steel without formation of significant quantities of intermetallic phases at the steelaluminium interface which comprises driving a straight-edged steel wedge member into one end of a heated aluminium member located in a restraining die having side walls and a closed end remote from said one end of said aluminium member, the die and aluminium member being so mutually shaped that a clearance is provided initially between the aluminium and the side wall of the die adjacent said one end of the alu- 4 minium member to avoid the introduction of extraneous material from the side surface of the aluminium to the aluminium/steel interface, said wedge member having bare steel surfaces for direct contact with aluminium and further having a wedge-shaped edge portion and a shank portion, while maintaining the shank portion spaced from the die walls, and extruding aluminium of said aluminium member into the space between the die walls and the shank during the driving of the wedge member under conditions arranged to develop at the steel-aluminium interface, a pressure sufficient to cause pressure welding of aluminiu
  • a method according to claim 1 including heating the aluminium member to 400 550C before driving the wedge member, and completing the driving of the wedge member in a period of 3 seconds to avoid undue heating of the steel member before completion of the formation of the joint.
  • extruding step comprises extruding the aluminium between a shank portion and corresponding portions of the die walls shaped to define a choke zone tapering in a direction away from said closed die end.
  • extruding step comprises extruding the aluminium into spaces respectively defined between opposed side faces of the shank portion which are substantially parallel to each other and corresponding portions of the die walls which are inclined to each other at an included angle in the range of 1 5.
  • a method according to claim 1 including providing initial clearance between said aluminium member and the die walls adjacent said one end of the aluminium member by disposing in said die an aluminium member having an initial cross-sectional shape which corresponds to that of the corresponding portion of the cavity defined by the die, except that a recessed shoulder is provided at each side of the aluminium member adjacent said one end thereof.
  • a method according to claim 1 including disposing in the die an aluminium member having an initial crosssectional width less than that of the cavity defined by the die, and placing, in the end of the die remote from said closed end, aluminium spacers extending downwardly for a sufficient distance to maintain the portion of the aluminium member adjacent said one end thereof out of contact with the walls of the die.
  • a method according to claim 1 including disposing said aluminium member in a cavity, defined by the side walls of a die having a closed lower end, which has a downwardly tapering lower portion and an upwardly tapering upper portion to provide a choke zone in conjunction with the shank of the wedge member.
  • a method of producing a direct pressure-welded joint between aluminium and steel free of significant quantities of intermetallic phases at the steelaluminium interface comprising a. disposing a heated aluminium slug in a die cavity defined by opposed side walls and a closed lower end of an upwardly opening die, with one end of said slug facing upwardly, while b. initially spacing at least the upper end portion of said slug from said die walls, and
  • extruding step comprises extruding the aluminium into 1 l.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Arc Welding In General (AREA)
  • Butt Welding And Welding Of Specific Article (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Extrusion Of Metal (AREA)
US00314666A 1971-12-14 1972-12-13 Forming pressure-welded joints Expired - Lifetime US3857163A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB5811171A GB1414129A (en) 1971-12-14 1971-12-14 Forming pressure-welded joints

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US3857163A true US3857163A (en) 1974-12-31

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US00314666A Expired - Lifetime US3857163A (en) 1971-12-14 1972-12-13 Forming pressure-welded joints

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US (1) US3857163A (no)
JP (1) JPS4866550A (no)
AU (1) AU464612B2 (no)
BR (1) BR7208796D0 (no)
CA (1) CA967794A (no)
GB (1) GB1414129A (no)
NL (1) NL7217000A (no)
NO (1) NO138688C (no)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030031892A1 (en) * 2001-07-16 2003-02-13 Masashi Fujita Joined structure of different metal materials
US20180071858A1 (en) * 2015-04-15 2018-03-15 Komatsu Ltd. Method for producing metal member
US20180085848A1 (en) * 2015-04-15 2018-03-29 Komatsu Ltd. Method for producing metal member

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS54151535A (en) * 1978-05-16 1979-11-28 Hitachi Cable Ltd Bonding dissimilar metals
JPS551922A (en) * 1978-06-21 1980-01-09 Hitachi Ltd Jointing method for aluminum parts
DE3149285C2 (de) * 1981-12-12 1985-11-21 MTU Motoren- und Turbinen-Union München GmbH, 8000 München Verfahren zur Verbindung der Rohre einer Wärmetauschermatrix mit dem Wärmetauscherboden eines Sammelbehälters

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2807082A (en) * 1952-08-26 1957-09-24 Zambrow John Welding process
US3234772A (en) * 1962-05-03 1966-02-15 Irc Ltd Method for forming nib housings and other small articles
US3436806A (en) * 1967-01-26 1969-04-08 North American Rockwell Method of forming an aluminum-ferrous tubular transition joint
US3474523A (en) * 1966-09-01 1969-10-28 Euratom Method of welding
US3634934A (en) * 1968-12-26 1972-01-18 Johnson Matthey & Mallory Ltd Manufacture of composite materials
US3664012A (en) * 1969-07-05 1972-05-23 Bosch Gmbh Robert Method of making a commutator
US3699636A (en) * 1971-02-17 1972-10-24 Whittaker Corp Metal bonding process
US3703032A (en) * 1970-08-14 1972-11-21 Trw Inc Diffusion bonding process

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2807082A (en) * 1952-08-26 1957-09-24 Zambrow John Welding process
US3234772A (en) * 1962-05-03 1966-02-15 Irc Ltd Method for forming nib housings and other small articles
US3474523A (en) * 1966-09-01 1969-10-28 Euratom Method of welding
US3436806A (en) * 1967-01-26 1969-04-08 North American Rockwell Method of forming an aluminum-ferrous tubular transition joint
US3634934A (en) * 1968-12-26 1972-01-18 Johnson Matthey & Mallory Ltd Manufacture of composite materials
US3664012A (en) * 1969-07-05 1972-05-23 Bosch Gmbh Robert Method of making a commutator
US3703032A (en) * 1970-08-14 1972-11-21 Trw Inc Diffusion bonding process
US3699636A (en) * 1971-02-17 1972-10-24 Whittaker Corp Metal bonding process

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030031892A1 (en) * 2001-07-16 2003-02-13 Masashi Fujita Joined structure of different metal materials
US6833199B2 (en) * 2001-07-16 2004-12-21 Honda Giken Kogyo Kabushiki Kaisha Joined structure of different metal materials
US20180071858A1 (en) * 2015-04-15 2018-03-15 Komatsu Ltd. Method for producing metal member
US20180085848A1 (en) * 2015-04-15 2018-03-29 Komatsu Ltd. Method for producing metal member
US10888951B2 (en) * 2015-04-15 2021-01-12 Komatsu Ltd. Method for producing metal member
US10906126B2 (en) * 2015-04-15 2021-02-02 Komatsu Ltd. Method for producing metal member

Also Published As

Publication number Publication date
AU464612B2 (en) 1975-09-04
NL7217000A (no) 1973-06-18
BR7208796D0 (pt) 1973-08-30
AU4998972A (en) 1974-06-13
NO138688C (no) 1978-10-25
CA967794A (en) 1975-05-20
GB1414129A (en) 1975-11-19
JPS4866550A (no) 1973-09-12
NO138688B (no) 1978-07-17

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