WO2014207999A1 - インダイレクトスポット溶接方法 - Google Patents
インダイレクトスポット溶接方法 Download PDFInfo
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- WO2014207999A1 WO2014207999A1 PCT/JP2014/002797 JP2014002797W WO2014207999A1 WO 2014207999 A1 WO2014207999 A1 WO 2014207999A1 JP 2014002797 W JP2014002797 W JP 2014002797W WO 2014207999 A1 WO2014207999 A1 WO 2014207999A1
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- WIPO (PCT)
- Prior art keywords
- welding
- electrode
- spot welding
- welding electrode
- indirect spot
- Prior art 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/10—Spot welding; Stitch welding
- B23K11/11—Spot 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
- 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
-
- 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
- B23K11/30—Features relating to electrodes
- B23K11/3009—Pressure electrodes
-
- 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
- B23K11/30—Features relating to electrodes
- B23K11/31—Electrode holders and actuating devices 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
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/18—Sheet panels
- B23K2101/185—Tailored blanks
-
- 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
- B23K2103/02—Iron or ferrous alloys
- B23K2103/04—Steel or steel alloys
-
- 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
- B23K2103/16—Composite materials, e.g. fibre reinforced
-
- 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
- B23K2103/16—Composite materials, e.g. fibre reinforced
- B23K2103/166—Multilayered materials
- B23K2103/172—Multilayered materials wherein at least one of the layers is non-metallic
Definitions
- a member in which at least two metal plates are overlapped is pressed against the metal plate while pressing the welding electrode from one surface side, and the metal plate on the other surface side is separated from the welding electrode.
- the present invention relates to an indirect spot welding method in which a power feeding terminal is attached to the welding electrode and the welding electrode and the power feeding terminal are energized for welding.
- FIG. 1 (a) shows the direct spot welding method.
- a current is applied while pressing a pair of electrodes 3 and 4 from above and below between the two stacked metal plates 1 and 2, and the resistance heating of the metal plates is used.
- This is a method for obtaining a spot-like welded portion 5.
- Each of the electrodes 3 and 4 includes pressurization control devices 6 and 7 and a current control device 8, so that the pressurizing force and the current value to be energized can be controlled by these.
- a pair of electrodes 13 and 14 are pressed from the same surface (in the same direction) at a distance from two stacked metal plates 11 and 12 while being pressed.
- a current is passed to obtain the spot welds 15-1 and 15-2.
- the electrode 23 is pressed against one metal plate 21 while pressing the two metal plates 21, 22, and the other metal plate 22 is pressed.
- the direct spot welding method is used.
- the series spot welding method or the indirect spot welding method is used. Used.
- the stacked metal plates are pressed by the electrode only from one direction, and the opposite side is a hollow with no support. It is in a state. Therefore, it is impossible to apply a high pressure locally to the welded portion as in the direct spot welding method in which the metal plate is sandwiched between the electrodes from both sides.
- the electrode sinks into the metal plate during energization the contact state between the electrode-metal plate and the metal plate-metal plate changes with time. For these reasons, there is a problem that the current flow path is not stable between the stacked metal plates, and it is difficult to form a normal melt-bonded portion.
- Patent Document 1 In order to solve the above-mentioned problem, for series spot welding, in Patent Document 1, “To form a nugget at a contact point where metal plates are overlapped, a large current is passed in the initial stage of welding to form an electrode nugget. , A steady current is passed ”. Patent Document 2 states that “a seat surface that is one step higher than the other part is formed at a position where the electrode is brought into contact, and the seat surface is pressed and contacted so as to crush, so that it is sufficient without a back electrode. It is described that a welding strength can be obtained.
- Patent Document 3 states, “When a series spot welding or indirect spot welding is energized, a time zone in which a current value is kept high and a current value are made low. A welding method that consists of alternately repeating the time period to maintain, and further, the time period in which the current value is kept high as the time period in which the current value is kept high and the time period in which the current value is kept low are alternately repeated. A welding method comprising “gradually increasing the current value” is disclosed.
- the inventors first as a welding method for forming a normal molten nugget, “At least two metal plates are pressed against each other while pressing the welding electrode against the metal plate from one side, and the metal plate on the other side is fed to a position separated from the welding electrode.
- Patent regard Document 4 disclosed indirect spot welding method, pressure F 1 for the first time period t 1 Segmented from start of energization to the two time zones t 1, t 2, the current value It has been found that welding can be carried out more effectively by limiting the pressure F 2 and the current value C 2 of C 1 , the next time zone t 2 as shown in the following formulas (1) to (4), respectively.
- Disclosed in Document 5. 1.2 F 2 ⁇ F 1 ⁇ 5 F 2 (1) 0.25 C 2 ⁇ C 1 ⁇ 0.85 C 2 (2) 35 T 2.3 ⁇ F 2 ⁇ 170 T 1.9 (3) 2 T 0.5 ⁇ C 2 ⁇ 5.5 T 0.9 (4) Where T is the total thickness (mm) of the stacked metal plates.
- the inventors have developed the above-described technology, and the two-step control is changed to the three-step control.
- An indirect spot that presses the electrode while applying pressure attaches a power supply terminal to the metal plate on the other surface side at a position apart from the welding electrode, and conducts welding between the welding electrode and the power supply terminal
- the electrode pressing force and the current value to be energized are divided into three time zones t 1 , t 2 , t 3 from the start of energization, and in the first time zone t 1 , the pressure is applied with the pressing force F 1 and Energized at a current value C 1 , and at the next time zone t 2 , pressurized with a pressure F 2 lower than F 1 and energized at a current value C 2 higher than C 1 , and further at the next time zone t 3 .
- the inventors “At least two metal plates are pressed against each other while pressing the welding electrode against the metal plate from one side, and the metal plate on the other side is fed to a position separated from the welding electrode.
- welding is performed by electrically insulating the overlapping surface between the metal plates except for the place where welding is performed.
- An indirect spot welding method characterized by being able to stably form a molten nugget while suppressing current dispersion at the time.
- the inventors “At least two metal plates are pressed against each other while pressing the welding electrode against the metal plate from one side, and the metal plate on the other side is fed to a position separated from the welding electrode.
- indirect spot welding in which a terminal is attached and welding is performed by energizing between the welding electrode and the power supply terminal, a state in which a viscous substance having an insulating property is interposed on the entire overlapping surface between metal plates
- Indirect spot welding method characterized in that welding is performed at a.
- a welding electrode is pressed against the metal plate from one surface side while being pressed, and the metal plate on the other surface side is spaced apart from the welding electrode.
- indirect spot welding in which a power supply terminal is attached and welding is performed by energizing between the welding electrode and the power supply terminal, in particular, the overlapped metal plates are pressed by the electrode only from one direction, and the opposite side is supported.
- the member loaded with the electrode pressing force is bent, and the contact state between the members is changed by the bending. For this reason, in indirect spot welding in which welding is performed using heat generated by contact resistance, it is inevitable that the welding quality is affected by the deflection of the member.
- the present invention advantageously solves the above-mentioned problem, and the indirect spot welding method, in particular, the stacked steel plates are pressed by electrodes only from one direction, and the opposite side is in a hollow state without support.
- An indirect spot welding method that can form a normal melt nugget and obtain a weld portion having a sufficiently satisfactory strength regardless of the rigidity of the member in indirect spot welding for welding a certain portion. The purpose is to provide.
- the inventors have obtained the following knowledge. a) When the stacked steel plates are pressed with an electrode only from one direction and indirect spot welding is performed in a hollow state with no support on the opposite side, they face each other like a direct spot welding method sandwiched by electrodes from both sides 1 Since the pressing force cannot be supported by the pair of electrodes, the member loaded with the electrode pressing force is bent, and the contact state between the members is changed by the bending. Therefore, in indirect spot welding in which welding is performed using heat generated by contact resistance, the welding quality is affected by the deflection of the member. That is, the welding quality varies depending on the rigidity of the member used for welding. In particular, when the rigidity of the member is low, the deflection becomes large and the contact area between the members becomes large, so that the current density at the contact portion is low, and it is difficult to obtain a welded portion having satisfactory strength. Become.
- the gist configuration of the present invention is as follows. 1. A member in which at least two steel sheets each having a ferrite phase as a main phase are overlapped is pressed against the steel plate from one side while pressing the welding electrode, and the steel plate on the other side is separated from the welding electrode.
- a rigid body having magnetism is provided around the welding electrode from the surface side against which the welding electrode is pressed.
- An indirect spot welding method characterized in that the overlapping region around the welding electrode is fixed by a magnetic force generated from the rigid body.
- FIG. 1 It is a diagram showing a welding procedure of indirect spot welding according to the present invention, wherein (a) is a step of interposing an insulating viscous material on the polymerization surface between the metal plates, (b) is to generate a magnetic force After fixing the periphery of the electrode with a rigid body, the step of pressing the welding electrode from one side of the metal plate while pressing, (c) shows the step of energizing between the welding electrode and the power supply terminal. It is the figure which showed the welding procedure of indirect spot welding in an Example.
- FIG. 2 (a) indirect spot welding, in which welding is performed by fixing a superposed member by bringing a rigid body that generates a magnetic force into contact with the periphery of the electrode from the side where the welding electrode is pressed in accordance with the present invention.
- the outline is shown by a schematic view of the arrangement of each part viewed from the side.
- the outline of the configuration is the same as that shown in FIG. 1 (c), and is therefore denoted by the same reference numeral.
- 26-1 and 26-2 are rigid bodies that generate magnetism.
- the rigid body 26 that generates a magnetic force is arranged around the electrode 23 on the surface side against which the welding electrode is pressed, and is fixed to the support via a shank.
- This support (not shown) is a bracket for fixing a pressure control device to which the welding electrode 23 is connected via a shank, or is independent of the system to which the welding electrode 23 is connected and is welded.
- the structure is configured to move following the welding electrode 23 when the position is changed.
- a plurality of rigid bodies 26-1 to 26-6 that generate magnetic force having independent circular and polygonal contact surfaces are provided. 26-4 is arranged around the electrode 23, or, as shown in FIG. 2 (c), a rigid body 26 that generates a magnetic force having a circular annular or polygonal annular contact surface surrounds the electrode 23 are arranged as follows.
- Either a magnet or a permanent magnet may be used as a magnet that is a source of magnetic force.
- an electromagnet when used, it can be easily fixed to a member before welding and removed from the member after welding. This is advantageous.
- the surface in contact with the member is a flat surface and needs to be made of a material having high rigidity.
- a permanent magnet when used, an alnico magnet, an iron-chromium-cobalt magnet, a ferrite magnet, a neodymium magnet, a samarium-cobalt magnet, etc. are advantageously adapted.
- an iron-based material is advantageously adapted, and a flat portion may be provided on an iron core using the iron-based material so as to contact the member.
- the area of the plane portion necessary for fixing the member is 1000 mm 2 or more in total.
- the magnetic flux density of a rigid body that generates magnetic force is 0.2 to 0.6 Tesla on the surface that contacts the member. If it is less than 0.2 Tesla, a magnetic force sufficient to fix the member cannot be obtained. On the other hand, if it exceeds 0.6 Tesla, iron scraps around the welded part are attracted and adhered to the welded part, which may cause a welding failure.
- the superposed member needs to be a metal material based on a ferromagnetic material having a characteristic attracted by magnetic force.
- a steel plate mainly composed of a ferrite phase is suitable.
- some steel sheets are designed to obtain high elongation by containing residual austenite, and such steel sheets have a higher fraction of ferrite as the fraction of retained austenite increases. Decreases, so the magnetism becomes weaker.
- the material having rigidity is a material corresponding to a metal, an intermetallic compound, or an inorganic material.
- a magnet is mixed with an organic material such as rubber like a magnet sheet and deformed flexibly. Materials that can be excluded are excluded.
- a viscous, insulating material is applied to the entire surface of the superposed member.
- a better weld can be obtained by performing welding in a state where the material is interposed and the overlapping surface between the steel plates excluding the welding area is electrically insulated by such a viscous material.
- an insulating viscous material is interposed between the overlapping surfaces of the steel plates, that is, the overlapping surfaces between the steel plates excluding the welding area are electrically insulated by the viscous material.
- the welding procedure for indirect spot welding in which welding is performed in the above state is shown.
- an insulating viscous substance 27 is interposed between the overlapping surfaces of the stacked steel plates. Thereby, between metal plates can be electrically insulated.
- a rigid body 26 that generates a magnetic force is brought into contact with the periphery of the electrode from the surface side against which the welding electrode 23 is pressed, and then the one side of these steel plates is fixed.
- the welding electrode 23 is pressed from the side while being pressed. By this electrode pressurization, the viscous substance 27 is pushed away in the welding area, and a close contact surface between the steel plates is secured. In a state where the electrode is pressurized as described above, welding is performed by energizing between the welding electrode 23 and the power supply terminal 24 as shown in FIG.
- the bending of the member is suppressed, and the current passing between the steel plates is limited to the welding area, and a high current density is obtained. Therefore, the welded portion has satisfactory strength regardless of the rigidity of the member. Can be formed stably.
- the viscous material having insulating properties is composed of a material having an insulating property to such an extent that the specific resistance is sufficiently large and the current between the steel plates during welding is cut off when placed between the steel plates. And the proper viscosity and coating thickness, that is, when the steel plate is pressed by the electrode, the viscosity and coating thickness are such that the viscous material is pushed away in the welding area to ensure electrical conduction between the steel plates. What has thickness is preferable.
- the viscosity is preferably in the range of 0.1 Pa ⁇ s to 1000 Pa ⁇ s. If the viscosity is smaller than this range, when the steel plate is pressurized by the electrode, the viscous material will be excessively pushed away, and the effect of limiting energization to the welding area cannot be obtained sufficiently. On the other hand, if the viscosity is greater than this range, when the steel sheet is pressurized by the electrode, the viscous material is not sufficiently pushed away from the welding area, and there is a risk that energization in the welding area may not be performed. is there. A more preferable viscosity range is 0.7 Pa ⁇ s to 20 Pa ⁇ s.
- the coating thickness is preferably about 0.1 to 3.0 mm. If the coating thickness is smaller than this range, when the steel plate is pressed by the electrode, the viscous substance will be excessively pushed away, and the effect of limiting the energization to the welding area cannot be obtained sufficiently. On the other hand, if the coating thickness is larger than this range, when the steel plate is pressed by the electrode, the viscous material is not sufficiently pushed away from the welding area, and the energization in the welding area is not performed. Because there is a fear. A more preferable coating thickness is 0.5 to 2.0 mm.
- the viscous substance of the present invention includes, for example, a liquid heat curable epoxy organic resin and the above organic resin adhesive.
- a thermosetting adhesive such as an epoxy-based organic resin
- it can be solidified by heating at the time of baking coating of the steel sheet, which is usually performed after welding, so that such unsolidified adhesive can be solidified. Therefore, it is not necessary to provide a special process.
- the thickness of the steel plate as the material to be treated, but the total thickness of the steel plate is 2.0 mm or less, and it is particularly useful when applied to a case where there is a concern about the influence of bending during welding. is there.
- the indirect spot welding method according to the present invention was performed on a member in which two rectangular steel plates each having a side of 500 mm or more were overlapped.
- a cold-rolled steel sheet SPC270
- the overlapped members are supported on a jig with an interval of 300 mm, and are welded by fixing members made of two steel plates overlapped with electromagnets at two locations on both sides of the welded portion. went.
- the electromagnet was attached to a support installed in the same system as the fixing of the pressure control device via a shank.
- Each electromagnet has a structure in which a flat portion is provided on an iron core using an iron-based material and is in contact with a member.
- the flat portion is a square having a side of 50 mm.
- the surface magnetic flux density of the flat portion was 0.5 tesla.
- the interval between the electromagnets was set to 30 mm, and welding was performed by applying a welding electrode to the middle point from the upper plate side.
- the welding electrode is made of chrome copper alloy and has a curved surface with R40mm at the tip.
- a welding electrode feed terminal is attached to the lower plate side at a position separated from the welded part, and a DC inverter type current control device is used. And welding was performed.
- the welding time, welding current, and electrode pressure are as shown in Table 2.
- Invention Examples 1 to 3 were welded according to the present invention.
- Inventive Examples 1 and 2 are those in which the welded part is fixed with an electromagnet
- Inventive Example 3 is in which the welded part is fixed with an electromagnet and welding is performed with an organic resin interposed between the steel plates.
- the welded part was not fixed with an electromagnet.
- Table 4 shows the results of examining the nugget diameter, nugget thickness, and nugget thickness / nugget diameter of the welded portion when welding was performed under the conditions shown in Table 3.
- the nugget diameter is the length on the polymerization surface between the upper steel plate and the lower steel plate in the cross section cut around the weld.
- the nugget thickness was the maximum thickness of the melted portion formed between the upper steel plate and the lower steel plate in the cross section cut at the welded portion.
- the nugget diameter ND satisfies the following formula (1) and the nugget thickness / diameter is 0.22 or more, a meteorite-shaped suitable nugget formed in a molten state is formed, which is satisfactory. It can be determined that a weld having strength is obtained.
- ND ⁇ 2.5 T (1)
- ND Nugget diameter (mm)
- T Total thickness of stacked steel plates (mm)
- each of Invention Examples 1 to 3 in which indirect spot welding was performed according to the present invention had a sufficient nugget diameter satisfying the expression (1) and a sufficient thickness with respect to this diameter. A molten nugget could be obtained. On the other hand, in Comparative Examples 1 to 3, no molten nugget was obtained. In particular, in Comparative Example 3, the deflection of the member was too great when the electrode was pressed, and the organic resin intervening between the steel plates could not be pushed away, and current could not be generated between the steel plates.
- a member in which at least two steel plates are overlapped is pressed against the steel plate while pressing the welding electrode from one surface side, and the steel plate on the other surface side is separated from the welding electrode.
- Indirect spot welding in which a power supply terminal is attached to the welding electrode and the power supply terminal is energized for welding, and the stacked steel plates are pressed by the electrode only from one direction, and the opposite side Can provide a welded portion having a satisfactory strength regardless of the rigidity of the member in the welding of a hollow portion having no support.
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Abstract
Description
いずれのスポット溶接も、重ね合わせた少なくとも2枚の金属板を溶接により接合する点では変わりはない。
図1(a)は、ダイレクトスポット溶接法を示したものである。この溶接は、同図に示すとおり、重ね合わせた2枚の金属板1,2を挟んでその上下から一対の電極3,4を加圧しつつ電流を流し、金属板の抵抗発熱を利用して、点状の溶接部5を得る方法である。なお、電極3,4はいずれも、加圧制御装置6,7および電流制御装置8をそなえており、これらによって加圧力と通電する電流値が制御できる仕組みになっている。
また、特許文献2には、「電極を接触させる位置に他の部分よりも一段高い座面を形成し、座面を押しつぶすように加圧接触させて溶接することにより、バック電極なしに十分な溶接強度が得られる」ことが記載されている。
「少なくとも2枚の金属板を重ね合わせた部材に対し、一方の面側から金属板に溶接電極を加圧しながら押し当て、他方の面側の金属板には該溶接電極と離隔した位置に給電端子を取り付け、該溶接電極と該給電端子との間で通電して溶接を行うインダイレクトスポット溶接法において、電極の加圧力および通電する電流値に関して、通電開始から2つの時間帯t1,t2に区分し、最初の時間帯t1では、加圧力F1で加圧しかつ電流値C1で通電したのち、次の時間帯t2では、F1よりも低い加圧力F2で加圧しかつC1よりも高い電流値C2で通電することを特徴とするインダイレクトスポット溶接方法。」
という、2段階制御になるインダイレクトスポット溶接方法を開発し、特許文献4において開示した。
記
1.2 F2 ≦ F1 ≦ 5 F2 ・・・(1)
0.25 C2 ≦ C1 ≦ 0.85 C2 ・・・(2)
35 T2.3 ≦ F2 ≦ 170 T1.9 ・・・(3)
2 T0.5 ≦ C2 ≦ 5.5 T0.9 ・・・(4)
ただし、Tは、重ね合わせた金属板の総板厚(mm)である。
「少なくとも2枚の金属板を重ね合わせた部材に対し、一方の面側から金属板に溶接電極を加圧しながら押し当て、他方の面側の金属板には該溶接電極と離隔した位置に給電端子を取り付け、該溶接電極と該給電端子との間で通電して溶接を行うインダイレクトスポット溶接法において、電極の加圧力および通電する電流値に関して、通電開始から3つの時間帯t1,t2,t3に区分し、最初の時間帯t1では、加圧力F1で加圧しかつ電流値C1で通電し、次の時間帯t2では、F1よりも低い加圧力F2で加圧しかつC1よりも高い電流値C2で通電し、さらに次の時間帯t3では、F2と同じかまたはF2よりも低い加圧力F3で加圧しかつC2よりも高い電流値C3で通電することを特徴とするインダイレクトスポット溶接方法。」
を開発し、特許文献6において開示した。
記
1.2 F2 ≦ F1 ≦ 3 F2 ・・・(1)
0.25 C2 ≦ C1 ≦ 0.9 C2 ・・・(2)
F3 ≦ F2 ≦ 3 F3 ・・・(3)
0.5 C3 ≦ C2 ≦ 0.9 C3 ・・・(4)
30 T2.1 ≦ F3 ≦ 170 T1.9 ・・・(5)
2 T0.5 ≦ C3 ≦ 5.5 T0.9 ・・・(6)
ただし、Tは、重ね合わせた金属板の総板厚(mm)である。
「少なくとも2枚の金属板を重ね合わせた部材に対し、一方の面側から金属板に溶接電極を加圧しながら押し当て、他方の面側の金属板には該溶接電極と離隔した位置に給電端子を取り付け、該溶接電極と該給電端子との間で通電して溶接を行うインダイレクトスポット溶接において、溶接を実施する箇所を除き金属板間の重合面を電気的に絶縁することにより、溶接時の電流の分散を抑え、安定的に溶融ナゲットを形成することができることを特徴とするインダイレクトスポット溶接方法。」
を開発し、特許文献8において開示した。
「少なくとも2枚の金属板を重ね合わせた部材に対し、一方の面側から金属板に溶接電極を加圧しながら押し当て、他方の面側の金属板には該溶接電極と離隔した位置に給電端子を取り付け、該溶接電極と該給電端子との間で通電して溶接を行うインダイレクトスポット溶接において、金属板間の重ね合わせ面全面に、絶縁性を有する粘稠な物質を介在させた状態で溶接を行うことを特徴とするインダイレクトスポット溶接方法。」
を開発し、特許文献9において開示した。
a)重ね合わせた鋼板を一方向からのみ電極で加圧し、その反対側は支持の無い中空の状態でインダイレクトスポット溶接を行う場合、両側から電極で挟むダイレクトスポット溶接法のように対向する1対の電極で加圧力を支持することができないため、電極加圧力を負荷された部材は撓みを生じ、この撓みによって部材間の接触状態が変化する。従って、接触抵抗による発熱を利用して溶接を行うインダイレクトスポット溶接においては、溶接品質が部材の撓みに影響される。
すなわち、溶接に供する部材の剛性によって溶接品質が異なる。特に、部材の剛性が低い場合には撓みが大きくなり、部材間の接触面積が大きくなるため、接触部での電流密度が低くなることから、満足な強度を有する溶接部を得ることが困難となる。
本発明は、上記の知見に立脚するものである。
1.少なくとも2枚のフェライト相を主相とする鋼板を重ね合わせた部材に対し、一方の面側から鋼板に溶接電極を加圧しながら押し当て、他方の面側の鋼板には該溶接電極と離隔した位置に給電端子を取り付け、該溶接電極と該給電端子との間で通電して溶接を行うインダイレクトスポット溶接において、該溶接電極を押し当てる面側から該溶接電極の周辺に磁性を有する剛体を接触させ、該剛体から発生する磁力によって、該溶接電極周辺の重ね合わせ領域を固定することを特徴とするインダイレクトスポット溶接方法。
図2(a)に、本発明に従い、溶接電極を押し当てる面側から電極の周辺に磁力を発生する剛体を接触させて重ね合わせた部材を固定することにより溶接を行うインダイレクトスポット溶接の溶接要領を各部位の配置を側面から見た概略図で示す。
図2(a)において、構成の骨子は、前掲図1(c)に示したところと共通するので同一の符号で示し、特に26-1および26-2が磁性を発生する剛体である。
かかる材料としては、永久磁石を用いる場合は、アルニコ磁石、鉄-クロム-コバルト磁石、フェライト磁石、ネオジム磁石、サマリウム-コバルト磁石等が有利に適合する。一方、電磁石を用いる場合は、鉄系材料が有利に適合し、この鉄系材料を用いた鉄芯に平面部を設けて部材と接触するようにすればよい。なお、部材を固定するために必要な平面部の面積は総和で1000mm2以上とすることが有利である。
まず、図3(a)に示すように、重ね合わせた鋼板間の重合面に絶縁性の粘稠な物質27を介在させる。これにより、金属板間を電気的に絶縁することができる。
ついで、図3(b)に示すように、溶接電極23を押し当てる面側から電極の周辺に磁力を発生する剛体26を接触させて重ね合わせた部材を固定したのち、これら鋼板の一方の面側から溶接電極23を加圧しながら押し当てる。この電極加圧により、溶接エリアでは粘稠な物質27が押し退けられて鋼板間の密着面が確保される。
上記のように電極加圧を行った状態で、図3(c)に示すように、溶接電極23と給電端子24との間で通電して溶接を実施する。
以上の実施条件の組合せを表3に示す。
なお、表4においてナゲット径は、溶接部を中心で切断した断面において、上鋼板、下鋼板間の重合面上での長さとした。ナゲット厚さは、溶接部を中心で切断した断面において、上鋼板、下鋼板間に跨って形成される溶融部の最大厚さとした。
ここに、ナゲット径NDが次式(1)を満たし、かつナゲット厚さ/径が0.22以上であれば、溶融した状態で形成された碁石形の好適なナゲットが形成されることにより、満足な強度を有する溶接部が得られたと判断することができる。
ND ≧ 2.5 T ・・・(1)
ただし、ND:ナゲット径(mm)
T:重ね合わせた鋼板の総板厚(mm)
これに対し、比較例1~3では溶融ナゲット得られなかった。特に比較例3では、電極加圧時に部材の撓みが大き過ぎ鋼板間に介在する有機樹脂を押し退けることができず、鋼板間に通電を起こすことができなかった。
3,4 電極
5 溶接部
6,7 加圧制御装置
8 電流制御装置
11,12 金属板
13,14 電極
15-1,15-2 溶接部
21,22 金属板
23 電極
24 給電端子
25 溶接部
26 剛体
Claims (2)
- 少なくとも2枚のフェライト相を主相とする鋼板を重ね合わせた部材に対し、一方の面側から鋼板に溶接電極を加圧しながら押し当て、他方の面側の鋼板には該溶接電極と離隔した位置に給電端子を取り付け、該溶接電極と該給電端子との間で通電して溶接を行うインダイレクトスポット溶接において、該溶接電極を押し当てる面側から該溶接電極の周辺に磁性を有する剛体を接触させ、該剛体から発生する磁力によって、該溶接電極周辺の重ね合わせ領域を固定するインダイレクトスポット溶接方法。
- 請求項1において、重ね合わせた部材の溶接エリアを除く重ね合わせ面全面に、絶縁性を有する粘稠な物質を介在させた状態で溶接を行うインダイレクトスポット溶接方法。
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