WO2012036070A1 - 異材接合方法 - Google Patents
異材接合方法 Download PDFInfo
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- WO2012036070A1 WO2012036070A1 PCT/JP2011/070508 JP2011070508W WO2012036070A1 WO 2012036070 A1 WO2012036070 A1 WO 2012036070A1 JP 2011070508 W JP2011070508 W JP 2011070508W WO 2012036070 A1 WO2012036070 A1 WO 2012036070A1
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- energization
- welding
- steel plate
- aluminum alloy
- spot welding
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Classifications
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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
- B23K11/10—Spot welding; Stitch welding
- B23K11/11—Spot welding
- B23K11/115—Spot welding by means of two electrodes placed opposite one another on both sides of the welded parts
-
- 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
- B23K11/20—Resistance welding; Severing by resistance heating taking account of the properties of the material to be welded of different metals
-
- 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
- B23K11/24—Electric supply or control circuits therefor
-
- 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
- B23K11/34—Preliminary treatment
-
- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/18—Dissimilar materials
- B23K2103/20—Ferrous alloys and aluminium or alloys thereof
Definitions
- the present invention relates to a method for joining different materials by spot welding between a steel plate and an aluminum alloy plate.
- the aluminum alloy plate referred to in the present invention is a general term for rolled plates such as a hot-rolled plate and a cold-rolled plate of aluminum alloy.
- a steel plate means a cold-rolled steel plate, it is also only called a steel plate below.
- panels such as outer panels ⁇ ⁇ ⁇ (outer plate) and inner panel (inner plate) ⁇ of panel structures such as automobile hoods, fenders, doors, roofs, and trunk lids are made of Al—Mg—Si AA to JIS 6000 series.
- the use of aluminum alloy plates such as cocoons (hereinafter simply referred to as 6000 series) and Al—Mg based AA to JIS 5000 series cocoons (hereinafter simply referred to as 5000 series) is being studied.
- joining of dissimilar material joined bodies includes not only welding but also mechanical joining such as self-piercing rivets and bolts, and joining using an adhesive. It has been put into practical use. However, there are practical problems such as complicated joining work and increased joining costs.
- the aluminum oxide plate is heated in the atmosphere to form a uniform oxide film, and in a state where the contact resistance on the aluminum surface is increased, two layers of aluminum-steel are duplicated.
- a method of spot welding using a layer steel plate as an insert material has also been proposed.
- the thickness of the oxide containing Si, Mn, Al, etc. generated on the steel plate surface is controlled by elements such as Si, Mn, Al added for increasing the strength of the steel plate. It is also known that adhesion between a surface coating such as galvanization and a steel plate and spot weldability between steel plates are improved (see Patent Document 1).
- Patent Documents 2 and 3 a steel plate and an aluminum alloy plate whose plate thickness is limited to 3 mm or less may be spot-welded in such a manner that two or more steel plates are overlapped or the steel plate is sandwiched between aluminum alloy plates.
- Patent Document 4 proposes to improve the joint strength by defining the nugget area and the thickness of the interface reaction layer in the spot weld.
- Patent Documents 5 and 6 it is proposed to improve the joint strength by finely defining the composition, thickness, area, etc. of each product compound on the steel plate side and the aluminum alloy plate side at the weld interface. Yes.
- Patent Documents 7 to 9 in a high-strength steel sheet having a specific composition, a new outer oxide layer or internal oxide having a specific composition of Mn and Si is generated on the surface of the steel sheet, thereby providing a high joint strength of the dissimilar material joined body. It has been proposed to aim.
- the bonding strength is ensured by suppressing the formation of fragile intermetallic compounds under suitable welding conditions and ensuring a wide area. For this reason, if dust is generated from the surface of the steel sheet, heat is input to generate dust and sufficient bonding strength cannot be obtained. In addition, since dust (sparks) fly during welding, the construction environment is not good.
- Such dust generation is caused by heat generation due to contact resistance between the steel sheet surface and the electrode.
- the following three methods can be considered as a method of suppressing this, but each has a problem described.
- (3) The tip R of the electrode is reduced to reduce the contact area (the contact surface pressure increases and the contact resistance decreases): Since the nugget diameter is reduced, the strength per spot hit point is reduced.
- the present invention has been made in view of such problems, and its purpose is to improve spot welding conditions, suppress generation of dust from the steel sheet surface, reduce welding current as much as possible, and achieve high joint strength.
- An object of the present invention is to provide a spot welding method capable of obtaining a dissimilar material joint having the above.
- the gist of the present invention for achieving this object is a method of joining a cold-rolled steel sheet and an aluminum alloy sheet by spot welding to different materials, and the thickness ts of the cold-rolled steel sheet to be joined is 0.3 to 3.
- the thickness ta of the aluminum alloy plate to be joined is set to 0.3 to 4.0 mm, the interelectrode pressure: 2.5 to 4.5 kN, the interelectrode current Iw: 14 to 26 kA, and the energization time Tw: Before forming a nugget by performing spot welding under each condition of 200 msec or less per 1 mm of the steel plate thickness (ts), the inter-electrode applied pressure: 2.5-4 0.5 kN, interelectrode current Ib: 6 to 12 kA, energization time Tb: 200 mmsec or less per 1 mm of steel plate thickness (ts), under the conditions that no dust is generated between the steel plate and the electrode and the aluminum alloy plate side is not melted , Do pre
- the present inventors examined a method for suppressing the generation of dust from the surface of the steel plate during spot welding of the steel plate-aluminum alloy plate. As a result, it is effective to suppress the generation of dust by performing “pre-energization” in which a relatively low current is energized in advance with the electrode set for the main welding before the spot welding main welding. I found out.
- This pre-energization raises the temperature of the steel sheet to reduce the deformation resistance, and the contact pressure between the steel sheet and the electrode can be improved by reducing the deformation resistance and reducing the unevenness of the contact portion of the steel sheet with the electrode.
- this pre-energization not only the above-described dust generation between the steel sheet surface and the electrode can be suppressed, but also the steel sheet can be preheated, so that an effect of reducing the current in spot main welding can be expected.
- a dissimilar material joint (welded joint) with high joint strength can be obtained, and the spot main welding state (welding efficiency) can be improved.
- Pre-energization In the present invention, prior to spot main welding, pre-energization is performed in advance under conditions that do not generate dust between the steel plate and the electrode and do not melt the aluminum alloy plate side.
- the pre-energization conditions are as follows: For the electrodes brought into contact with each other, the interelectrode pressure: 2.5 to 4.5 kN, the interelectrode current Ib: 6 to 12 kA, the energization time Tb: the steel plate thickness (ts) The condition is 200 msec or less per 1 mm.
- the contact resistance becomes relatively small, heat generation can be suppressed, and generation of dust from the steel sheet surface can be suppressed.
- the non-contact portion becomes large, the contact resistance becomes relatively large, heat generation increases, and the amount of dust generated from the steel sheet surface increases. This mechanism is why the generation of dust from the steel sheet surface is suppressed when the electrode pressing force is increased.
- the steel plate is preheated, the steel plate temperature rises, and the deformation resistance is reduced.
- corrugation of the contact part with the electrode of a steel plate can be made small by pressurization of an electrode, and the contact state of a steel plate and an electrode is improved. Therefore, the substantial contact area between the steel plate and the electrode can be increased, the contact resistance between the steel plate surface and the electrode can be reduced, the amount of heat generated between the steel plate and the electrode can be reduced, and dust generation from the steel plate surface can be reduced. Can be suppressed. Further, the preheating of the steel plate by this pre-energization has the effect of reducing the current in spot main welding.
- Interelectrode current Ib in pre-energization there is a current range (upper limit) for preventing aluminum from being melted by the pre-energization, and the interelectrode current Ib in the pre-energization is 12 kA or less.
- the pre-energized interelectrode current Ib is set to 6 kA or more. Therefore, the range of the pre-energized interelectrode current Ib is 6 to 12 kA.
- Energizing time Tb for pre-energization does not have a significant effect on the generation of dust between the steel sheet surface and the electrode, the energization may be instantaneous, and there is no lower limit for the energization time. However, if the energization time is long, the steel plate / aluminum is preheated too much, and a brittle intermetallic compound phase may be formed thicker than necessary, and the welding time becomes long, resulting in poor efficiency. Accordingly, the energization time Tb is set to a condition of 200 msec or less per 1 mm of the steel plate thickness (ts) in relation to the steel plate thickness ts.
- Pre-energized interelectrode pressure is in the range of 2.5 to 4.5 kN, as in spot spot welding. If the inter-electrode pressure is too small, the unevenness of the contact portion between the steel plate and the electrode cannot be reduced even by pre-energization, and the contact state between the steel plate and the electrode cannot be improved. Therefore, the substantial contact area between the steel plate and the electrode cannot be increased, the contact resistance between the steel plate surface and the electrode cannot be reduced, and the amount of heat generated between the steel plate and the electrode cannot be reduced. The generation of dust cannot be suppressed.
- Spot welding conditions Spot spot welding is performed without any time delay (continuously) after the previous energization. Further, even if there is a gap between the pre-energization and spot main welding, the time is set to 1 second or less. If there is a gap between pre-energization and spot spot welding, the steel plate is cooled, and the effect of pre-energization for preheating the steel plate is impaired. Also, the welding time becomes too long and is not efficient.
- the spot main welding (main energization) conditions for forming the nugget are set in order to obtain a high joint strength of the dissimilar joint between the cold-rolled steel sheet and the aluminum alloy sheet. That is, in spot spot welding, it is set in order to obtain a high bonding strength by appropriately forming a reaction layer of Fe and Al having a minimum thickness necessary for metallurgical bonding at a bonding portion.
- the necessary conditions for each spot welding spot are as follows. First, the thickness ts of the cold-rolled steel plates to be joined is 0.3 to 3.0 mm, and the thickness ta of the aluminum alloy plates to be joined is 0.3. It should be ⁇ 4.0mm. If these plate thicknesses are too thick or too thin, the prescribed spot welding conditions are not met, and application of spot welding itself becomes difficult and unsuitable.
- electrode welding pressure for spot welding 2.5 to 4.5 kN
- current Iw between electrodes 14 to 26 kA
- energization time Tw each condition of 200 msec or less per 1 mm of steel plate thickness (ts)
- spot welding is performed to form a nugget. If these conditions are not met, spot welding is inappropriate even in relation to the pre-energization, and high bonding strength cannot be obtained.
- the plate thickness condition is obvious, it is also a plate thickness condition for pre-energization.
- the same general-purpose spot welding apparatus including the pre-energization can be used for spot welding under the conditions of the present invention, and it is not necessary to change the welding apparatus or combine different welding apparatuses with the pre-energization.
- the pre-energization and spot spot welding are performed at the same electrode position.
- use of a flux is unnecessary, you may use it if necessary.
- an indication of the minimum thickness of the reaction layer of Fe and Al necessary and minimum for the metallurgical joining is preferably as the average thickness of the nugget depth direction (steel plate thickness direction) of the reaction layer at the joining interface. Is controlled in the range of 0.1 to 20 ⁇ m, more preferably 1 to 20 ⁇ m.
- the reaction layer having such a thickness is referred to as an “optimal thickness reaction layer”.
- a reaction layer a layered Al—Fe based compound layer is formed on the steel plate side, and a granular or acicular Al—Fe based compound and Al—Fe— are formed on the aluminum alloy plate side.
- each layer has a mixture of Si—Mn compounds. If the average thickness of these fragile reaction layers in the nugget depth direction is too thick, the bonding strength is significantly reduced. On the other hand, if the average thickness of the reaction layer in the nugget depth direction is too thin, metallurgical bonding becomes insufficient, and sufficient bonding strength cannot be obtained. Therefore, the thickness of the reaction layer of Fe and Al is preferably in the range of the above average thickness.
- spot welding conditions such as inter-electrode pressure, inter-electrode current, and energization time are not met, spot welding is inappropriate, and a reaction layer of Fe and Al with a minimum thickness necessary for these metallurgical joinings. Cannot be appropriately formed in the joint, and high joint strength cannot be obtained.
- the pressure between the electrodes is too low, there are few contact points between the steel plate and the aluminum alloy plate, so the interface reaction during spot welding becomes non-uniform and the optimum thickness reaction layer cannot be obtained.
- the pressure between the electrodes is too high, the melted portion scatters from the nugget during spot welding, resulting in insufficient joint strength.
- This relational expression is 20 ⁇ (Ib 2 ⁇ Tb + Iw 2 ⁇ Tw) ⁇ ts / ta ⁇ 55 (kA 2 ⁇ sec).
- Ib pre-energization current
- Tb pre-energization energization time
- Iw spot welding current
- Tw spot welding energization time
- ts steel plate thickness
- ta plate thickness of aluminum alloy plate.
- the present invention without improving the steel plate side and the aluminum alloy plate side which are welding materials in advance, generation of dust is prevented with minimal improvement only by addition (adoption) of pre-energization on the spot welding side, and high A dissimilar material joint having bonding strength can be obtained. Therefore, it is possible to obtain a dissimilar material joint having high joint strength by spot welding without affecting the properties (characteristics) on the steel plate or aluminum alloy plate side and without increasing the production cost of the steel plate or aluminum alloy plate. .
- the main object is a high-strength steel plate (high tensile) having a tensile strength of 450 MPa or more including Si, Mn, and the like.
- the component composition of the cold-rolled steel sheet is preferably C: 0.01 to 0.30%, Si: 0.1 to 3% by mass, on the assumption that a predetermined amount of Si, Mn and the like are included. .00% and Mn: 0.1 to 3.00%, respectively, and the balance is preferably composed of Fe and inevitable impurities.
- a composition containing Al: 0.002 to 0.1% and the balance of Fe and inevitable impurities may be used.
- Nb 0.005 to 0.10%
- Ti 0.005 to 0.10%
- Zr 0.005 to 0.10%
- Cr 0.05 to 3.00%
- Mo 0.01 to 3.00%
- Cu 0.01 to 3.00%
- Ni 0.01 to 3.00%
- the balance may be composed of Fe and inevitable impurities.
- P, S, N, and the like as impurities in the steel sheet deteriorate various properties such as toughness, ductility, and bonding strength of the steel sheet, so P: 0.10% or less (including 0%), S: It regulates to 0.05% or less (including 0%) and N: 300 ppm or less (including 0%), respectively.
- the unit (content of each element) of the chemical component in this invention is mass% altogether including an aluminum alloy. The reasons for limiting each component element of the steel sheet are as follows.
- C is an element necessary for increasing the strength, but if the content is less than 0.01%, the strength of the steel sheet cannot be secured, and if it exceeds 0.30%, the cold workability decreases. Therefore, the C content is in the range of 0.01 to 0.30%.
- Si is important as an element that can ensure the required strength without degrading the ductility of the steel sheet, and for that purpose, a content of 0.1% or more is necessary. On the other hand, when it contains exceeding 3.00%, ductility will deteriorate. Therefore, the Si content is in the range of 0.1 to 3.00% for this reason.
- Mn is also indispensable as an element for ensuring the strength and toughness of the steel sheet, and if the content is less than 0.1%, the effect cannot be obtained. On the other hand, when the content exceeds 3.00%, the strength is remarkably increased and cold working becomes difficult. Therefore, the Mn content is in the range of 0.1 to 3.00% for this reason.
- Al is an element effective for improving the toughness of steel by capturing solid solution oxygen as a deoxidizing element of molten steel and preventing the occurrence of blowholes.
- the Al content is less than 0.002%, these sufficient effects cannot be obtained.
- the Al content exceeds 0.1%, the weldability is adversely affected, or the toughness of the steel increases due to an increase in alumina inclusions. Deteriorate. Therefore, the Al content is in the range of 0.002 to 0.1%.
- Nb, Ti, Zr, Cr, Mo, Cu, Ni Inclusion of one or more of Nb, Ti, Zr, Cr, Mo, Cu, and Ni contributes to increasing the strength and toughness of the steel in common.
- Ti, Nb, and Zr are precipitated as carbonitrides in the steel to increase the strength, and the microstructure of the steel is refined to improve the strength, toughness and the like.
- the toughness is greatly deteriorated. Therefore, when these are selectively contained, the ranges are Nb: 0.005 to 0.10%, Ti: 0.005 to 0.10%, and Zr: 0.005 to 0.10%.
- Cr, Mo, Cu, and Ni improve the hardenability of the steel and improve the strength.
- the toughness of the steel is greatly deteriorated. Therefore, when contained, Cr: 0.05 to 3.00%, Mo: 0.01 to 3.00%, Cu: 0.01 to 3.00%, Ni: 0.01 to 3.00% The range.
- the main object is a high-strength steel plate (high tensile) having a tensile strength of 450 MPa or more from the use of automobile members and the like.
- Low-strength steels are generally low-alloy steels, and the oxide film is almost iron oxide. Therefore, diffusion of Fe and Al is facilitated, and a brittle reaction layer is easily formed.
- the strength of the steel sheet is insufficient, the deformation of the steel sheet increases due to pressurization with the electrode tip during spot welding, and the oxide film is easily destroyed, so the reaction with aluminum is abnormally accelerated and brittle. Intermetallic compounds are easily formed.
- the aluminum alloy plate to be joined in the present invention is an Al—Mg—Si based AA or 6000 standard aluminum alloy plate according to JIS standards.
- the shape of the alloy material is not particularly limited depending on the use of each part of the automobile body, and the above-described widely used plate material, shape material, forging material, casting material, and the like are appropriately selected.
- the strength of the aluminum alloy plate is preferably higher in order to suppress deformation due to pressurization during spot welding, as in the case of the steel plate.
- the composition of the 6000 series aluminum alloy plate is, by mass, Mg: 0.1 to 1.2%, Si: 0.1 to 1.5%, Cu: 0.00. It is preferable to make a 6000 series aluminum alloy containing 001 to 1.0%, Fe: 0.01 to 0.4, Mn: 0.01 to 1.0, with the balance being Al and inevitable impurities. In order to further improve the BH property, it is preferable to use an excess Si type 6000 series aluminum alloy plate in which the mass ratio Si / Mg between Si and Mg is 1% or more.
- the total amount of one or two of Cr: 0.001 to 0.2% and Zr: 0.001 to 0.2% is 0.30% or less, or Zn: One or two of 0.001 to 0.25% and Ti: 0.001 to 0.10% may be selectively included.
- Li may be contained in the range of 0.01 to 0.5%.
- each element in the 6000 series aluminum alloy is as follows.
- Si Si, together with Mg, forms an aging precipitate that contributes to strength improvement at the time of artificial aging treatment at low temperatures such as solid solution strengthening and paint baking treatment, and exhibits age hardening ability, for example, 180 MPa or more It is an essential element for obtaining the required strength (proof strength). If the content is insufficient, such an effect cannot be obtained. If the content is too large, the formability such as press formability and bending workability is remarkably deteriorated, and the weldability is greatly hindered.
- Mg also forms an aging precipitate that contributes to strength improvement together with Si during the above-mentioned artificial aging treatment such as solid solution strengthening and paint baking treatment, exhibits age hardening ability, and as a panel, the required proof stress It is an essential element for obtaining. If the content is insufficient, such an effect cannot be obtained. If the content is too large, moldability such as press formability and bending workability is remarkably lowered.
- Cu has the effect of accelerating the formation of aging precipitates that contribute to the improvement of strength in the crystal grains of the aluminum alloy sheet structure under conditions of artificial aging treatment at a relatively low temperature and short time. Moreover, solid solution Cu also has the effect of improving moldability. If the content is insufficient, such an effect cannot be obtained, and if the content is too large, the corrosion resistance and weldability are remarkably deteriorated.
- Fe has the same function as Mn, Cr, Zr, etc., generates dispersed particle (dispersed phase), prevents grain boundary movement after recrystallization, prevents crystal grain coarsening, Has the effect of miniaturizing. If the content is insufficient, such an effect cannot be obtained. If the content is too large, coarse crystallized products are likely to be generated, and the fracture toughness and fatigue characteristics are deteriorated.
- Mn has the effect of producing fine crystal grains because it has the effect of generating dispersed particles (dispersed phase) during soaking heat treatment and hindering grain boundary migration after recrystallization.
- the press formability and hemmability are improved as the crystal grains of the aluminum alloy structure are finer. If the content is insufficient, such an effect cannot be obtained, and if the content is too large, the mechanical properties are lowered. In addition, formability such as bending workability is lowered.
- Zn contributes to improvement of strength by solid solution strengthening, and also has an effect of remarkably accelerating age hardening of the final product during aging treatment. If the content is insufficient, such an effect cannot be obtained. If the content is too large, the sensitivity to stress corrosion cracking and intergranular corrosion is remarkably increased, and the corrosion resistance and durability are lowered.
- Ti has the effect of refining the crystal grains of the ingot to make the extruded material structure fine crystal grains. If the content is insufficient, such an effect cannot be obtained, and if the content is too large, coarse crystal precipitates are formed, and the required properties such as the bending crushability and corrosion resistance as a reinforcing material, and the bending of the extruded material This may cause deterioration of workability.
- Cr, Zr The transition elements of Cr and Zr, like Mn, generate disperse particle (dispersed phase) ⁇ ⁇ composed of intermetallic compounds such as Al-Cr and Al-Zr to prevent coarsening of crystal grains It is effective to do. If the content is insufficient, such an effect cannot be obtained, and if the content is too large, coarse crystal precipitates are formed, and if the content is too large, the above-described bending crushability and corrosion resistance as a reinforcing material are required. Degrading properties and mechanical properties. In addition, formability such as bending workability is lowered.
- the thickness (plate thickness) of the welded portion of the steel plate or aluminum alloy plate is selected or determined not only from the design based on the spot welding, but also from the design conditions such as required strength and rigidity of the applicable member such as an automobile member. Is done.
- the thickness t (of the part to be welded) of the cold-rolled steel sheet is practically selected from 0.3 to 3.0 mm.
- the thickness of the steel plate is too thin, the necessary strength and rigidity as an automobile member cannot be ensured, which is inappropriate.
- spot welding for example, due to the pressurization by the electrode tip, the deformation of the steel plate is large and the oxide film is easily broken, so that the reaction with aluminum is promoted. As a result, a brittle intermetallic compound is easily formed.
- spot welding joining itself becomes difficult.
- the thickness t (of the part to be welded) of the aluminum alloy plate is selected from the range of 0.3 to 4.0 mm, similarly assuming an automobile member or the like. If the thickness of the aluminum alloy plate is too thin, the strength as an automobile member is insufficient and inappropriate. In addition, the nugget diameter cannot be obtained, and melting can easily reach both surfaces of the aluminum alloy plate. High bonding strength may not be obtained. On the other hand, when the thickness of the aluminum alloy plate is too thick, the welding joint itself becomes difficult as in the case of the plate thickness of the steel plate.
- Pre-energization test First, the effective range of the energization current was verified, in particular, that there was no dust generation from the steel plate and no melting of the aluminum between the steel plate and the aluminum plate in the pre-energization described above. The results are shown in Table 3.
- the welding test was conducted using a 980 MPa class high-tensile cold-rolled steel sheet having a component thickness shown in Table 1 and a thickness ts of 1.4 mm, and 0.2% when the plate thickness ta of each component composition shown in Table 2 was 1.2 mm.
- a 6000 series aluminum alloy cold-rolled sheet having a proof stress of 250 MPa was superposed.
- pre-energization was simulated, spot welding with one-stage energization without using flux was performed, and the occurrence of dust from the steel sheet and the presence or absence of aluminum melting between the steel sheet and the aluminum sheet were confirmed. did.
- the electrode used was an R-type dome-shaped electrode made of a Cu—Cr alloy, and the positive electrode was an aluminum alloy plate and the negative electrode was a steel plate.
- the interelectrode current Ib is 12 kA or less, assuming that the interelectrode current is 2.5 to 4.5 kN and the energization time Tb is 200 msec or less per 1 mm of the steel plate thickness (ts). Is an effective range. That is, at the upper limit value of 12 kA defined by the interelectrode current Ib, any applied pressure (regardless of the applied pressure) does not generate dust between the steel plate and the electrode and does not melt the aluminum alloy plate side. However, when the inter-electrode current Ib is increased to 14 to 18 kA or the like, dust is generated between the steel plate and the electrode due to the applied pressure, or the aluminum alloy plate side is melted.
- the lower limit of the inter-electrode current Ib for pre-energization is defined as 6 kA in consideration of the current control range of a general spot welder, and this significance is supported.
- Spot welding test Spot welding was performed with various changes in pre-energization and main welding conditions, and the occurrence of dust between the steel sheet and the electrode, electrode wear, and bonding strength were confirmed. The results are shown in Table 4.
- the steel plate and the aluminum alloy plate were the same as those used for the pre-energization, the compositions shown in Tables 1 and 2 and the same strength level, and the thickness of each plate was varied. These are processed into a cruciform tensile specimen shape as described in JIS A3137 and overlapped. Without using flux, the same welding machine is used, pre-energization, spot welding, nuggets are formed, dissimilar materials are joined, and welded joints ( Dissimilar material joints) were manufactured.
- Both the steel plate and the aluminum alloy plate are processed into the shape of the above-mentioned cross tensile test piece (50 mm width ⁇ 150 mm length), stacked on top of each other, and then set with an electrode at the center of the stack and pressed.
- spot main welding was performed in the same state without any time delay (continuously).
- the same single-layer rectifying resistance spot welder (capacity 90 KVA) was used, and the pre-energization and spot of each of 5 points were performed under the conditions of pressurizing force, welding current and welding time shown in Table 4. Welding was performed.
- a dome-shaped electrode having a radius of curvature R at the electrode tip made of the same Cu—Cr alloy was used, and the positive electrode was an aluminum alloy plate and the negative electrode was a steel plate.
- Evaluation of dust generation or electrode consumption The evaluation of dust generation between the steel plate and the electrode or the consumption of the electrode was performed visually. Examples where no flaws occurred between the steel plate and the electrode at each of the five points of the spot welding were marked as ⁇ , while flaws occurred at the first and second points but could be improved by changing the welding conditions. The case where dust was generated and could not be improved by changing the welding conditions was evaluated as x. In addition, only the electrode wear is 10 times, pre-energization and spot welding are performed. ⁇ The electrode that does not wear after spot welding is ⁇ , and the beginning of wear is “galling”. ⁇ , where x was clearly consumed was evaluated as x.
- the dissimilar joints of the inventive examples are pre-energized and spot-welded for main energization under appropriate conditions. That is, not only the individual conditions of spot spot welding and pre-energization are satisfied, but also the respective energization conditions of each other further satisfy the above relational expression.
- the inventive example can be welded without generation of dust between the steel plate and the electrode or the consumption of the electrode, and the dissimilar joint joint of the inventive example has excellent bonding strength (peeling strength).
- Comparative Examples 1 and 2 are not pre-energized, so to speak, are conventional spot welding. For this reason, spot spot welding state falls and the joint strength of a dissimilar material joint is also inferior.
- Comparative Examples 3 and 12 the current for main energization (spot main welding) is too small. For this reason, although the spot spot welding state is good, the joint strength of the dissimilar material joint is poor.
- Comparative Examples 5 and 11 the energization time of the pre-energization is too long. For this reason, although the spot spot welding state is good, the joint strength of the dissimilar material joint is poor.
- Comparative Examples 15 and 20 the current for main energization (spot main welding) is too high. For this reason, spot spot welding state falls and the joint strength of a dissimilar material joint is also inferior by the magnitude of this current.
- Comparative Examples 7, 8, 10, 19, and 22 satisfy the individual conditions of spot spot welding and pre-energization, but the respective energization conditions do not satisfy the above relational expression. For this reason, although the spot spot welding state is good, the joint strength of the dissimilar material joint is inferior. Therefore, when taken together with the case of the above-mentioned invention example, even if each individual condition of spot main welding and pre-energization is satisfied, each energization condition should not further satisfy the above relational expression, It is proved that high joint strength and good welded state cannot be achieved at the same time.
- a spot welding method that improves the spot welding side, suppresses generation of dust from the surface of the steel sheet, can reduce the welding current as much as possible, and can obtain a dissimilar material joint having high joint strength. it can.
- Such a dissimilar material joining method can be usefully applied as a welding method for various structural members in the transportation field such as automobiles and railway vehicles, machine parts, and building structures.
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Abstract
Description
(1)溶接電流を下げる:
前記高い溶接電流条件(好適溶接条件)を外れて、接合強度が得られない可能性が大きくなる。
(2)加圧力を上げる:
鋼板-アルミニウム合金板の界面からのアルミニウムのチリ発生が増大する。
(3)電極の先端Rを小さくし、接触面積を抑制する(接触面圧が上がり接触抵抗が下がる):
ナゲット径が小さくなるため、スポット打点の1点あたりの強度が低下する。
関係式:20≦(Ib2×Tb+Iw2×Tw)×ts/ta≦55(kA2・sec)
本発明では、スポット本溶接の前に、鋼板と電極間でチリを発生させず、かつアルミニウム合金板側を溶融させない条件にて、予め前通電を行う。この前通電条件は、互いの板に接触させた電極に対して、電極間加圧力:2.5~4.5kN、電極間電流Ib:6~12kA、通電時間Tb:鋼板板厚(ts)1mm当たり200msec以下の条件とする。
このため、前通電によりアルミが溶融しないための電流範囲(上限)があり、前通電における電極間電流Ibは12kA以下とする。一方、前通電時の電流が小さすぎると、鋼板を効果的に加熱できないため、変形抵抗が低減せず、鋼板と電極の接触状態を改善できない。また、一般的なスポット溶接機の電流制御範囲も考慮して、前通電の電極間電流Ibは6kA以上とする。したがって、前通電の電極間電流Ibの範囲は6~12kAとする。
前通電の時間は、鋼板表面-電極間のチリ発生には大きな影響を及ぼさず、通電は瞬間的で良く、通電時間の下限は設けない。ただ、通電時間が長いと、鋼板/アルミを予熱しすぎてしまい、脆い金属間化合物相を必要以上に厚く形成してしまう可能性があり、また溶接時間が長くなり、効率が悪くなる。したがって、通電時間Tbは、鋼板板厚tsとの関係で、鋼板板厚(ts)1mm当たり200msec以下の条件とする。
前通電の電極間加圧力は、スポットの本溶接時と同じく2.5~4.5kNの範囲とする。この電極間加圧力が小さすぎると、前通電によっても、鋼板の電極との接触部の凹凸を小さくできず、鋼板と電極の接触状態を改善できない。したがって、前記した鋼板と電極との実質的な接触面積を大きくできず、鋼板表面と電極との間の接触抵抗を小さくできず、鋼板-電極間の発熱量を低減できず、鋼板表面からのチリ発生を抑制することができない。一方、電極間加圧力が高すぎると、溶接時の鋼板-アルミ板の界面からのチリ発生が大きくなるため適切ではない。また一般的なスポット溶接機の加圧力の範囲(加圧能力)を考慮する必要もある。
スポット本溶接は、この前通電後に時間的な遅滞無く(連続して)行う。また、前通電とスポット本溶接との間隔があいたとしても、その時間は1秒間以下とする。前通電とスポット本溶接との間隔があくと、鋼板が冷却されて、鋼板を予熱する前通電の効果が損なわれる。また、溶接時間が長くなりすぎ、効率的ではない。
本発明では、前通電により接合部が予め加熱されることから、スポットの本溶接条件の選定は、この前通電条件を考慮して決定する必要がある。溶接条件の選定には、溶接時の入熱を考慮することが一般的であるが、スポット溶接では溶接時の電圧が変動するため、入熱を正確に把握することは困難である。また、鋼とアルミでは比抵抗および熱伝導が異なるため、実質的に溶接に寄与する入熱を考慮する必要がある。
この関係式は、20≦(Ib2×Tb+Iw2×Tw)×ts/ta≦55(kA2・sec)である。
但し、ここで、Ib:前通電電流、Tb:前通電通電時間、Iw:スポット溶接電流、Tw:スポット溶接通電時間、ts:鋼板板厚、ta:アルミニウム合金板の板厚である。
本発明が接合の対象とする冷延鋼板の成分組成について以下に説明する。本発明では、好ましくは、Si、Mnなどを含む引張強度が450MPa以上の高強度鋼板(ハイテン)を主たる対象とする。
Cは強度上昇に必要な元素であるが、含有量が0.01%未満では鋼板の強度確保ができず、また0.30%を超えると冷間加工性が低下する。したがって、C含有量は0.01~0.30%の範囲とする。
Siは、鋼板の延性を劣化させずに、必要な強度確保が可能な元素としても重要であり、そのためには0.1%以上の含有量が必要である。一方、3.00%を超えて含有すると延性が劣化してくる。したがって、Si含有量は、この理由からも0.1~3.00%の範囲とする。
Mnも、鋼板の強度と靱性を確保するための元素としても必要不可欠で、含有量が0.1%未満ではその効果は得られない。一方、含有量が3.00%を超えると著しく強度が上昇し冷間加工が困難となる。したがって、Mn含有量は、この理由からも0.1~3.00%の範囲とする。
Alは、溶鋼の脱酸元素として、固溶酸素を捕捉するとともに、ブローホールの発生を防止して、鋼の靭性向上の為にも有効な元素である。Al含有量が0.002%未満ではこれらの十分な効果が得られず、一方で、0.1%を超えると、逆に溶接性を劣化させたり、アルミナ系介在物の増加により鋼の靭性を劣化させる。したがって、Al含有量は0.002~0.1%の範囲とする。
Nb、Ti、Zr、Cr、Mo、Cu、Niの1種または2種以上の含有は、共通して、鋼の高強度化や高靭性化に寄与する。この内、Ti、Nb、Zrは、鋼中に炭窒化物として析出して強度を高め、鋼のミクロ組織を微細化して強度、靭性等を向上させる。但し、多量に含有させると、靭性を大幅に劣化させる。したがって、これらを選択的に含有させる場合は、Nb:0.005~0.10%、Ti:0.005~0.10%、Zr:0.005~0.10%の各範囲とする。
本発明においては、自動車部材などの用途から、引張強度が450MPa以上の高強度鋼板(ハイテン)を主たる対象とする。これより低強度鋼では、一般に低合金鋼が多く、酸化皮膜がほぼ鉄酸化物であるため、FeとAlの拡散が容易となり、脆い反応層が形成しやすい。また、鋼板の強度が不足するために、スポット溶接時の電極チップによる加圧によって、鋼板の変形が大きくなり、酸化皮膜が容易に破壊されるため、アルミニウムとの反応が異常に促進され、脆い金属間化合物が形成しやすくなる。
本発明で接合の対象とするアルミニウム合金板は、Al-Mg-Si系のAA乃至JIS規格における6000系アルミニウム合金板とする。この合金材は、自動車車体の各部用途に応じて、形状を特に限定するものではなく、前記した、汎用されている板材、形材、鍛造材、鋳造材などが適宜選択される。ただ、アルミニウム合金板の強度についても、上記鋼板の場合と同様に、スポット溶接時の加圧による変形を抑えるために高い方が望ましい。
Si:SiはMgとともに、固溶強化と、塗装焼き付け処理などの前記低温での人工時効処理時に、強度向上に寄与する時効析出物を形成して、時効硬化能を発揮し、例えば180MPa以上の必要強度(耐力)を得るための必須の元素である。含有量が不足するとこのような効果が得られず、含有量が多すぎるとプレス成形性や曲げ加工性等の成形性が著しく低下し、更に溶接性も大きく阻害される。
鋼板やアルミニウム合金板の溶接される部分の厚さ(板厚)は、前記スポット溶接からの設計だけからではなく、自動車部材などの適用部材の必要強度や剛性などの設計条件からも選択乃至決定される。
先ず、前記した前通電の、鋼板からのチリ発生と鋼板-アルミ板間でのアルミの溶融が無い、特に、通電電流の有効範囲について検証した。この結果を表3に示す。
前通電と本溶接の条件を種々変更して、スポット溶接を行い、鋼板-電極間のチリ発生、電極の消耗、および接合強度について確認した。この結果を表4に示す。
鋼板-電極間のチリ発生あるいは電極の消耗の評価は、各々目視で行った。前記スポット溶接の5点とも各々鋼板-電極間のチリが発生しなかった例を○、1、2点にチリが発生したが溶接条件の変更で改善できるものを△、ほぼ全ての例で激しくチリが発生し、溶接条件の変更では改善できそうにないものを×と評価した。また、電極の消耗だけは、倍の10点、前通電とスポット溶接とを行い、スポット溶接後に電極の消耗が生じていないものを○、消耗の始まりである「かじり」が出だしているものを△、明らかに消耗が生じているものを×と評価した。
これら製作した各異材接合継手を引張り試験機で十字引張試験し、剥離強度(最大荷重)を求めた。これらの結果も表4に示す。剥離強度は、A6022アルミニウム合金板同士のスポット溶接による継手の接合強度(実績)=1.0kNを参考にして、1.5kN以上であれば◎、1.0kN以上であれば○、0.7~1.0kNのものを△、0.7kN未満であれば×とした。
比較例3、12は本通電(スポット本溶接)の電流が小さすぎる。このため、スポット本溶接状態は良いものの、異材接合継手の接合強度が劣る。
比較例5、11は前通電の通電時間が長すぎる。このため、スポット本溶接状態は良いものの、異材接合継手の接合強度が劣る。
比較例15、20は本通電(スポット本溶接)の電流が高すぎる。このため、スポット本溶接状態が低下し、異材接合継手の接合強度もこの電流の大きさによって劣る。
Claims (1)
- 冷延鋼板とアルミニウム合金板とをスポット溶接にて異材接合する方法であって、接合する冷延鋼板の板厚tsを0.3~3.0mm、接合するアルミニウム合金板の板厚taを0.3~4.0mmとした上で、電極間加圧力:2.5~4.5kN、電極間電流Iw:14~26kA、通電時間Tw:鋼板板厚(ts)1mm当たり200msec以下の各条件にて、スポット溶接を行ってナゲットを形成する前に、互いの板に接触させた電極に対して、電極間加圧力:2.5~4.5kN、電極間電流Ib:6~12kA、通電時間Tb:鋼板板厚(ts)1mm当たり200msec以下の、鋼板と電極間でチリを発生させず、かつアルミニウム合金板側を溶融させない条件にて、予め前通電を行い、その後1秒以内に前記スポット溶接を行うに際し、これらスポット溶接と前通電との条件が、前記各通電条件と前記各板厚とで決まる下記関係式を更に満足することを特徴とする異材接合方法。
関係式:20≦(Ib2×Tb+Iw2×Tw)×ts/ta≦55(kA2・sec)
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Also Published As
Publication number | Publication date |
---|---|
CN103097070A (zh) | 2013-05-08 |
US20130168366A1 (en) | 2013-07-04 |
EP2617510A1 (en) | 2013-07-24 |
JP2012055962A (ja) | 2012-03-22 |
KR101419191B1 (ko) | 2014-07-11 |
JP5572046B2 (ja) | 2014-08-13 |
EP2617510A4 (en) | 2015-07-29 |
CN103097070B (zh) | 2015-06-17 |
KR20130041328A (ko) | 2013-04-24 |
EP2617510B1 (en) | 2016-11-09 |
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