WO2015045420A1 - 鋼板の摩擦撹拌接合方法及び接合継手の製造方法 - Google Patents
鋼板の摩擦撹拌接合方法及び接合継手の製造方法 Download PDFInfo
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- WO2015045420A1 WO2015045420A1 PCT/JP2014/004984 JP2014004984W WO2015045420A1 WO 2015045420 A1 WO2015045420 A1 WO 2015045420A1 JP 2014004984 W JP2014004984 W JP 2014004984W WO 2015045420 A1 WO2015045420 A1 WO 2015045420A1
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- joining
- friction stir
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- heating device
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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
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
- B23K20/123—Controlling or monitoring the welding process
- B23K20/1235—Controlling or monitoring the welding process with temperature control during joining
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/1205—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using translation movement
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
- B23K20/1225—Particular aspects of welding with a non-consumable tool
-
- 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
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/34—Methods of heating
- C21D1/42—Induction heating
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/50—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for welded joints
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/50—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for welded joints
- C21D9/505—Cooling thereof
-
- 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
-
- 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
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- the present invention relates to a friction stir welding method for steel sheets, and particularly intends to improve joint strength.
- a rotating tool is inserted into an unjoined portion of the overlapped or butted workpieces and moved while rotating, and the workpiece is softened by frictional heat with the rotating tool and the softened portion is moved.
- This is a method of joining without adding a filler material by utilizing plastic flow generated by stirring of a rotary tool.
- a butt portion that is in a state where the steel plates are just butt but not yet joined is referred to as an “unjoined portion”, while a portion joined and integrated by plastic flow is referred to as a “joined portion”. Shall be called.
- FIG. 1 an example in the case of implementing friction stir welding with respect to the butt
- the end faces of the steel plates 21 and 22 are brought into contact with each other to form an unjoined portion 20, and the rotary tool 10 is moved along the unjoined portion 20 while rotating.
- the rotary tool 10 is arranged above the steel plates 21 and 22 and is configured to rotate by a motor (not shown).
- a backing material 30 is installed in the lower part of the steel plate to support the steel plate against the pressure of the rotary tool.
- the rotary tool 10 rotated by the drive of a motor moves to the arrow F direction, while the probe 12 contacts the steel plates 21 and 22 by the unjoined part 20.
- the probe 12 creates a partial region of the plastic material around it, and the upper part 11 of the rotating body presses the steel plates 21 and 22 from above to prevent the material from being lost from the plastic zone. Therefore, the abutting portions of the unjoined portions 20 are heated and softened, and the steel plates 21 and 22 are solid-phase joined by a plastic material formed by plastic flow to form the joined portions 25.
- Patent Document 1 proposes a joining method using a gas flame as a heating device.
- FIG. 2 schematically shows the friction stir welding procedure when a gas flame is used as the heating device.
- the members 1 and 2 are heated by using various gas flames 70 such as oxygen acetylene, oxygen propane, and oxygen natural gas as a heat source.
- the substantially cylindrical gas nozzle portion 71 to which the gas flame 70 is injected is disposed in the vicinity of the front of the probe 62 in the movement direction and moves in conjunction with the movement of the probe 62.
- the injection position of the gas flame 70 in the unjoined part 13 is always located in front of the joining device in the moving direction. Further, the injection width of the gas flame 70 is set so as to be approximately the same as the diameter of the shoulder 61 of the rotor 60 when the tip of the gas flame 70 hits the surfaces of the members 1 and 2 and expands. Has been. As a result, only the vicinity of the probe 62 in the unbonded portion 13 is heated, and the temperature in the vicinity of the probe and its peripheral region is increased.
- a gas flame 70 is ejected from the gas nozzle portion 71 of the heating device 72, and the rotor 60 of the joining device 3 is rotated to insert the probe 62 that rotates integrally therewith into the unjoined portion 13, and the probe is inserted.
- the probe 62 is moved relative to the members 1 and 2 along the butted portion. Thereby, the to-be-joined members 1 and 2 are joined and the junction part 14 is formed.
- the unbonded portion is heated by the heat of the gas flame 70, and the contact portion between the probe 62 and the shoulder 61 is quickly softened, and the bonding by the probe 62 is performed. It aims to be easy.
- Patent Document 2 uses an induction heating device as a heat source.
- a control mechanism that sets the temperature until the joining with the rotary tool to a predetermined temperature, the time until the friction stir welding is started is shortened, thereby improving the controllability of the heating range and the heating temperature. Along with the improvement, it is said that it is possible to prevent cracking of the joining portion regardless of the material.
- Patent Document 3 uses laser light as a heat source.
- the unjoined part is heated before joining with the rotary tool, and after the unjoined part reaches a predetermined softening temperature, the irradiation of the laser beam is stopped to suppress wear of the joining tool. You can do that.
- a technique using a gas flame, induction heating, or laser light as an auxiliary heat source when performing construction has been proposed.
- Patent Documents 1 to 3 can reduce bonding defects or increase the bonding speed, but can be embrittled by temper softening or hardening in the heat-affected zone. This caused a problem that sufficient joint strength could not be obtained.
- the present invention advantageously solves the above-described problems, and there is no risk of occurrence of bonding defects or damage to the bonding tool, and furthermore, there is no risk of temper softening or embrittlement due to hardening in the heat-affected zone at high speed. It aims at providing the friction stir welding method of the steel plate which improved joint strength under the joining speed of this.
- the inventors investigated the relationship between the temperature distribution immediately before the start of the joining by the rotary tool and the joint state in the friction stir welding of the steel plates.
- (1) When the heated region is wide, a good joint can be obtained due to the influence of softening, but the range of the heat-affected zone is expanded because of the large influence of heat generation by the steel plate and rotary tool.
- (2) On the contrary, when the region to be heated is too narrow, the joining with the rotary tool becomes insufficient, and defects are likely to occur. (3) Therefore, in the friction stir welding of steel sheets, the knowledge that management of the temperature range immediately before the joining was particularly important was obtained.
- the inventors heated the bonded parts under various conditions using a heating device arranged in front of the rotating tool in order to manage the temperature range immediately before the bonding.
- the inventors studied earnestly about the influence of the surface temperature distribution in the direction perpendicular to the traveling direction on the joint state at the position where the joining by the rotary tool is started. That is, when the welded joint obtained as described above has been intensively studied from the structure, hardness, fracture form, etc., by increasing the temperature at the joining start position to a certain temperature, high-speed joining can be achieved by softening the steel plate. It becomes possible.
- the gist configuration of the present invention is as follows. 1. A rotating tool is inserted into an unjoined part where two or more steel plates are overlapped or abutted, and the rotating tool is moved along the part to be joined while rotating, and the frictional heat between the rotating tool and the steel plate is moved.
- T Ac1 is a temperature defined by the following equation using the amount of added elements in the steel sheet.
- T Ac1 723-10.7 [% Mn] -16.9 [% Ni] +29.1 [% Si] +16.9 [% Cr] +290 [% As] +6.38 [% W]
- [% M] represents the content (mass%) of the M element in the steel sheet.
- the thermal conductivity TC B of the backing material disposed at a position facing the welding tool with the unbonded portion interposed therebetween is 0.5 ⁇ TC S ⁇ TC B ⁇ the thermal conductivity TC S of the steel plate.
- 1.0 ⁇ TC S Friction stir welding method that satisfies the above relationship.
- the friction of the steel sheet in which the C content of the steel sheet containing a larger amount of C among the C contents of two or more steel sheets is 0.1% by mass or more and 0.6% by mass or less.
- T Ac1 is a temperature defined by the following equation using the amount of added elements in the steel sheet.
- T Ac1 723-10.7 [% Mn] -16.9 [% Ni] +29.1 [% Si] +16.9 [% Cr] +290 [% As] +6.38 [% W]
- [% M] represents the content (mass%) of the M element in the steel sheet.
- a rotating tool is inserted into an unjoined portion in which two or more steel plates are overlapped or abutted, and the rotating tool is moved along a portion to be joined while rotating.
- the present invention relates to friction stir welding in which steel plates are joined using softening of steel plates due to frictional heat and plastic flow generated by stirring.
- any friction stir welding apparatus may be used as long as it can press and rotate the rotary tool to join the steel plates, and any control method such as position control or pressure control may be used.
- a tool having a flat portion called a shoulder and a projection called a probe that is concentric with the shoulder is usually used.
- the shape of the probe is not limited, and processing such as a screw-like spiral may be performed.
- the material is not particularly limited, but a ceramic or a metal material excellent in high temperature strength is suitable.
- FIG. 3 shows the relationship between the temperature conditions at the joining start position, the presence or absence of joining defects and tool breakage, and the joint efficiency when joining is performed while heating the steel sheet under various conditions in the forward direction of the joining tool.
- This data uses a joining tool with a shoulder diameter d of 12 mm, a joining speed of 1 m / min, an Ac 1 temperature of 720 ° C., and a thickness of 1.0 to 3.0 mm. It was obtained after various implementations.
- T Ac1 is a temperature defined by the following formula using the amount of additive element of the steel sheet, and corresponds to Ac 1 point of steel.
- T Ac1 723-10.7 [% Mn] -16.9 [% Ni] +29.1 [% Si] +16.9 [% Cr] +290 [% As] +6.38 [% W]
- [% M] represents the content (mass%) of the M element in the steel sheet.
- the heating means may be any as long as it can be heated to a predetermined temperature, and is not particularly limited, but heating means using high-frequency induction heating or laser light is advantageously suitable.
- heating means using high-frequency induction heating or laser light is advantageously suitable.
- the arrangement position of the heating device is preferably a distance from 1 mm to 100 mm in front of the tool, and the heating range is preferably from 0.1 cm 2 to 100 cm 2 .
- the heating method may operate separately or in conjunction with the movement of the tool. For example, in the case of a device that moves on the tool side, the heating device that is attached to this device and moves at the same speed as this device. However, when the joint side is fixed to the stage and the stage moves, a heating device installed on the stage can be considered. Examples of the heating device include an induction heating device and a laser.
- the positional relationship between the joint and the heating device is not limited as long as it is forward in the direction of travel of the tool.
- friction stir welding is performed on the side where the travel direction and rotational direction of the tool are the same ( On the advanced side (left side in FIG. 1) and on the side where the traveling direction and the rotation direction are opposite (retreating side, right side in FIG. 1), the advanced side has higher resistance and is more likely to cause defects. It is known. Therefore, by moving the heating range to the advanced side, the bondability is stabilized even at high speed.
- the heating range is shifted to the advancing side, it is desirable that the position in the heating range where the maximum temperature is reached is somewhat shifted from the junction centerline and within the junction width.
- the thermal conductivity (TC B ) of the backing material is too high at the time of bonding, the heat balance at the time of bonding cannot be maintained, causing defects. On the other hand, if TC B is too low, it causes excessive heat input.
- the TC B of the present invention preferably satisfies the following relationship with the thermal conductivity (TC S ) of the bonded material from the viewpoint of appropriately controlling the temperature distribution. Therefore, it is preferable that the thermal conductivity of the backing material is about 0.5 to 1.0 times the thermal conductivity of the material to be joined. That is, for TC B and TC S , 0.5 ⁇ TC S ⁇ TC B ⁇ 1.0 ⁇ TC S It is preferable to satisfy this relationship.
- the friction stir welding method according to the present invention is particularly suitable for a steel plate containing carbon in the range of 0.1 mass% to 0.6 mass% as an additive element. It is valid. This is because, by applying the present invention, the steel sheet can be joined at a particularly high speed as compared with the conventional joining speed.
- heating range is preferably within a range from 0.1 cm 2 to 100 cm 2.
- the reheating method may operate separately or in conjunction with the movement of the tool.
- the heating that is attached to this device and moves at the same speed as this device.
- a heating apparatus installed on the stage can be considered.
- the heating device include an induction heating device and a laser.
- the cooling condition is preferably a cooling rate of about 50 to 1000 ° C./s and cooling to 200 ° C. or less.
- the steel plates can be joined at a high speed. That is, the general joining speed in friction stir welding is about 0.05 to 0.2 m / min, but according to the present invention, high carbon steel, which is considered difficult to join at high speed, is joined. Even in this case, bonding at a speed of 0.5 m / min or more is possible.
- Tool rotation speed 100-1500rpm
- the tool rotation speed is controlled to an appropriate value. There is a need. If the rotation speed of the tool is less than 100 rpm, heat generation and plastic flow may be insufficient, resulting in a problem that an unbonded portion is formed in the bonded portion, or an excessive load is applied to the rotating tool to cause damage.
- the tool rotation speed is preferably in the range of 100 to 1500 rpm.
- Tool rotation torque 50 to 1000 N ⁇ m
- the tool rotational torque is less than 50 N ⁇ m, heat generation and plastic flow may be insufficient, resulting in a problem that an unjoined part is formed in the joined part, or an excessive load is applied to the rotating tool and the tool is damaged.
- the tool rotation torque is preferably in the range of 50 to 1000 N ⁇ m.
- FIG. 4 shows a friction stir welding apparatus used for carrying out the present invention.
- the induction heating device 4 is disposed in front of the welding tool 60 in the traveling direction, and the induction heating device 8 is disposed behind the welding tool 60, so that the heating can be performed by these induction heating devices.
- the tool 60 has a shape having a protruding probe 62 and a flat shoulder 61 made of tungsten carbide as a base material. Moreover, in order to suppress the oxidation of a junction part, it joined, spraying argon gas from the advancing direction front of the tool 60.
- Friction stir welding was performed under the conditions shown in FIG. In addition, the joint butting was a so-called I-shaped groove with no angle. The frequency when heating by the induction heating device was 30 to 300 kHz. The results of investigating whether or not joining is possible when the friction stir welding is performed are shown in Table 1.
- ⁇ indicates that the tool can be joined without damaging the tool, and if there is no visible defect over the entire length of the joint, the x indicates that the tool is damaged or a defect that is visible somewhere in the entire length of the joint. The case where there was.
- the term “defective” refers to a case where there are irregularities or through-holes that are more than half the plate thickness due to insufficient stirring or excessive stirring, or a case where there is a crack in the weld.
- Example 2 Similar to Example 1, friction stir welding was performed under the conditions shown in Table 2 using the friction stir welding apparatus shown in FIG. The joining conditions were almost the same as in Example 1, but in Example 2, a backing material was used for joining. Table 2 also shows the results of investigating the possibility of joining, the joint efficiency, and the stability of the bead width when the friction stir welding is performed. Regarding the bead width, the minimum bead width and the maximum bead width were measured, and the difference was 20% or less of the minimum bead width.
- Example 3 As in Example 1, friction stir welding was performed under the conditions shown in Table 3 using the friction stir welding apparatus shown in FIG. The joining conditions are almost the same as in the case of Example 1, but in Example 3, the joining was performed using the cooling device 9 and the rear heating device 8. Table 3 also shows the results of investigation on the joint efficiency and the standard deviation of the joint efficiency of 10 samples obtained under the same conditions when the friction stir welding is performed. ⁇ and ⁇ are those that can be joined, and ⁇ indicates that the tool can be joined without breakage, there is no visible defect over the entire length of the joint, and the bead width is stable.
- the ⁇ mark indicates that the tool can be joined without being damaged, and if there is no visible defect in the joint, the ⁇ mark indicates that the tool has been damaged or that there is a visible defect somewhere in the entire length of the joint.
- the term “defective” refers to a case where there are irregularities or through-holes that are more than half the plate thickness due to insufficient stirring or excessive stirring, or a case where there is a crack in the weld.
- the standard deviation of the joint efficiency of the sample is the percentage obtained by dividing the joint strength by the strength of the base material, and the value is more than 5% and less than 8%, and more than 3% and less than 5% Was evaluated as ⁇ when it was 3% or less.
Abstract
Description
なお、本明細書では、例えば鋼板を突き合わせただけで未だ接合されてない状態にある突き合わせ部分を「未接合部」、一方、塑性流動により接合されて一体化された部分を「接合部」と呼ぶものとする。
同図に示したとおり、この摩擦撹拌接合方法では、鋼板21,22の端面を互いに突き合わせて未接合部20とし、この未接合部20に沿って回転工具10を回転させながら移動させる。回転工具10は、鋼板21,22の上部に配置して、モータ(図示省略)によって回転するよう構成されている。鋼板の下部には裏当て材30を設置し、回転工具の加圧に対し鋼板を支えている。そして、モータの駆動によって回転する回転工具10は、プローブ12が未接合部20で鋼板21,22に接触しながら矢印F方向に移動する。このときプローブ12は、その周りに可塑性材の部分領域を作り、回転体上部11は、上方向から鋼板21,22を押圧し、可塑性ゾーンから材料が失われるのを防いでいる。従って、鋼板21,22は、未接合部20の突き合わせ部分が発熱して軟化し、塑性流動してできた可塑性材によって固相接合され、接合部25が形成される。
例えば、特許文献1には、加熱装置としてガス炎を用いた接合方法が提案されている。図2に、加熱装置としてガス炎を用いた場合の摩擦撹拌接合要領を模式で示す。この方式は、酸素アセチレン、酸素プロパン、酸素天然ガス等の各種ガス炎70を熱源として被接合部材1,2を加熱するものである。この加熱装置72において、ガス炎70が噴射される略円筒状のガスノズル部71は、プローブ62の移動方向前方の近傍部位に配置されると共に、プローブ62の動きと連動して移動する。さらに未接合部13におけるガス炎70の噴射位置は常に接合装置の移動方向前方に位置するものとされている。また、ガス炎70の噴射幅は、被接合部材1,2の表面にぶつかってその先端部が広がった状態になったときに回転子60のショルダ61の径と略同一寸法になるように設定されている。これにより未接合部13のうちプローブ62近傍だけを加熱して、このプローブ近傍及びその周辺領域の温度を上昇させるようになっている。
図2に示した加熱装置72を用いた摩擦撹拌接合では、ガス炎70の熱によって未接合部が加熱され、プローブ62及びショルダ61との接触部を迅速に軟化させて、プローブ62による接合を容易とすることを狙いとしている。
このように、従来の摩擦擦撹拌接合では、施工を行う際の補助熱源として、ガス炎や誘導加熱、レーザ光を用いる技術が提案されている。
その結果、
(1)加熱される領域が広い場合は、軟化の影響によって良好な接合部が得られるものの、鋼板、回転工具による発熱の影響が大きいために、熱影響部の範囲は拡大する、
(2)逆に、加熱される領域が狭すぎる場合は、回転工具による接合が不十分となり、欠陥を生じやすくなる、
(3)したがって、鋼板の摩擦撹拌接合においては、接合直前における温度範囲の管理が特に重要である
との知見を得た。
すなわち、上記のようにして得られた溶接継手を、組織、硬さおよび破断形態等から鋭意検討したところ、接合開始位置における温度を一定の温度まで上げることで、鋼板の軟化により高速な接合が可能となる。しかし一方で、温度を上げすぎた場合は摩擦撹拌接合の原理である塑性流動が逆に減少して、欠陥の原因となることが分かった。
また、接合開始位置における温度が一定の温度に達しない場合は、ツールによる発熱が主体になり、従来方法と変わらない結果、継手強度は改善されない。一方温度が高すぎる場合にはツールの摩擦熱が減少しツールによる温度分布の変化が起こらず、さらには焼入れされてしまうため、脆化の原因となることも判明した。
そこで、発明者らは、接合後の再加熱、さらには接合後・再加熱前の冷却に関しても併せて検討した結果、その有効性が確認された。
本発明は、上記の知見に立脚するものである。
1.二枚以上の鋼板を重ね合わせた、または突き合わせた未接合部に、回転工具を挿入し、この回転工具を回転させながら接合する部分に沿って移動させ、この回転工具と上記鋼板との摩擦熱による鋼板の軟化と、撹拌することにより生じる塑性流動を利用して鋼板同士を接合する摩擦撹拌接合方法において、
上記回転工具の進行方向の前方に配置した加熱装置によって、回転工具による接合前に未接合部を予め加熱するものとし、
その際、回転工具による接合が開始される位置において、進行方向に垂直な方向の表面の最高温度TUが、
0.6×TAc1<TU<1.8×TAc1
の範囲を満足し、かつ温度TL=0.6×TAc1を上回る加熱領域の幅Lが、上記回転工具のショルダ部の直径dに対し、
0.3×d≦L≦2.0×d
の関係を満足する摩擦撹拌接合方法。
なお、TAc1は鋼板の添加元素量を用いて、次式で定義される温度とする。
TAc1=723-10.7〔%Mn〕-16.9〔%Ni〕+29.1〔%Si〕+16.9〔%Cr〕+290〔%As〕+6.38〔%W〕
ここで、〔%M〕は、M元素の鋼板中の含有量(質量%)を表す。
0.5×TCS≦TCB≦1.0×TCS
の関係を満足する摩擦攪拌接合方法。
回転工具の進行方向の後方に、接合部の再加熱を司る後方加熱装置を配置し、該後方加熱装置により再加熱される領域の再加熱後の最高温度をTpとするとき、このTpが、
0.6×TAc1≦Tp≦1.2×TAc1
の関係を満足する鋼板の摩擦撹拌接合方法。
なお、TAc1は鋼板の添加元素量を用いて、次式で定義される温度とする。
TAc1=723-10.7〔%Mn〕-16.9〔%Ni〕+29.1〔%Si〕+16.9〔%Cr〕+290〔%As〕+6.38〔%W〕
ここで、〔%M〕は、M元素の鋼板中の含有量(質量%)を表す。
本発明は、二枚以上の鋼板を重ね合わせた、または突き合わせた未接合部に、回転工具を挿入し、この回転工具を回転させながら接合する部分に沿って移動させ、この回転工具と上記鋼板との摩擦熱による鋼板の軟化と、撹拌することにより生じる塑性流動を利用して鋼板同士を接合する摩擦撹拌接合に関するものである。この時、使用する摩擦撹拌接合装置としては、回転工具を加圧、回転して鋼板を接合することのできるものであれば何でもよく、位置制御か加圧制御かなどの制御方法は問わない。
0.6×TAc1<TU<1.8×TAc1
の範囲を満足し、かつ温度TL(=0.6×TAc1)を超える加熱領域の幅Lが、回転工具のショルダ部の直径dに対し、
0.3×d≦L≦2.0×d
の関係を満足する場合に、接合欠陥の発生やツールの破損なしに、しかも継手効率として、継手強度が母材強度の8割を超える高強度継手が得られている。
ここに、TAc1は、鋼板の添加元素量を用いて次式で定義される温度であり、鋼のAc1点に相当する。
TAc1=723-10.7〔%Mn〕-16.9〔%Ni〕+29.1〔%Si〕+16.9〔%Cr〕+290〔%As〕+6.38〔%W〕
ここで、〔%M〕は、M元素の鋼板中の含有量(質量%)を表す。
特に、高周波加熱装置を用いる場合は、加熱効率および加熱範囲を考慮すると、使用周波数を20kHz以上360kHz以下とすることが好ましく、かかる周波数の装置を用いることによって、上記した温度範囲への制御が容易となる。
なお、加熱方法は、ツールの移動と別個に、または連動して動作してもよく、例えばツール側が移動する装置の場合には、この装置に取り付けられ、この装置と同じ速度で移動する加熱装置が、また継手側がステージに固定されてステージが動く場合には、このステージに設置された加熱装置が考えられる。加熱装置としては誘導加熱装置やレーザが挙げられる。
そして、本発明のTCBは、温度分布を適切に制御する観点から、被接合材の熱伝導率(TCS)と以下の関係を満足することが好ましい。
したがって、裏当て材の熱伝導率は被接合材の熱伝導率に対して0.5倍以上1.0倍程度とすることが好ましい。
すなわち、上記TCBとTCSとについては、
0.5×TCS≦TCB≦1.0×TCS
の関係を満足させることが好ましい。
というのは、本発明を適用することで、従来の接合速度に比して、特に高速で接合可能な鋼板だからである。
0.6×TAc1≦Tp≦1.2×TAc1
の範囲に制御する必要がある。
また、その冷却条件は、冷却速度:50~1000℃/s程度で200℃以下まで冷却することが好ましい。
すなわち、摩擦撹拌接合における一般的な接合速度は0.05~0.2m/min程度であるが、本発明に従った場合には、高速での接合が難しいとされる高炭素鋼を接合する場合であっても0.5m/min以上の速度での接合が可能となる。
ツール回転数:100~1500rpm
回転ツールと加工物の接合部との間で摩擦熱を発生させ、その熱により軟化した接合部をツールが撹拌することにより生じる塑性流動を発生させるためには、適正なツール回転数に制御する必要がある。このツール回転数が100rpm未満では、発熱と塑性流動が不足し接合部に未接合部が生じたり、回転ツールに過大な負荷が掛かり破損したりする不具合が生じるおそれがある。一方、ツール回転数が1500rpmを超えると、発熱と塑性流動が過大となり軟化した金属が接合部からバリとして欠損するため接合部の十分な厚さが得られなかったり、回転ツールが過度に加熱されて破損したりする不具合が生じるおそれがある。よって、ツール回転数は100~1500rpmの範囲とすることが好ましい。
回転ツールと加工物の接合部との間で摩擦熱を発生させ、その熱により軟化した接合部をツールが撹拌することにより生じる塑性流動を発生させるためには、ツール回転トルクを適正範囲に設定する必要がある。このツール回転トルクが50N・m未満では、発熱と塑性流動が不足し接合部に未接合部が生じたり、回転ツールに過大な荷重が掛かり破損したりする不具合が生じるおそれがある。一方、ツール回転トルクが1000N・mを超えると、発熱と塑性流動が過大となり軟化した金属が接合部からバリとして欠損するため接合部の十分な厚さが得られなかったり、回転ツールが過度に加熱されて破損したりする不具合が生じるおそれがある。よって、ツール回転トルクは50~1000N・mの範囲とすることが好ましい。
図4に、本発明の実施に用いた摩擦撹拌接合装置を示す。この装置は、接合ツール60の進行方向前方に誘導加熱装置4を、またその後方に誘導加熱装置8を配置し、これらの誘導加熱装置により加熱できる仕組みになっている。ツール60には、タングステンカーバイドを基材とする突起状のプローブ62と平坦なショルダ61を有する形状を用いた。また、接合部の酸化を抑制するため、アルゴンガスをツール60の進行方向前方より吹き付けつつ接合を行った。
なお、図中、符号9は冷却装置、35は電源、40は加熱温度設定パネルである。
上記の摩擦撹拌接合を実施した場合における接合の可否について調査した結果を、表1に併記する。
接合の可否で、○印はツールが破損せずに接合可能であり、接合全長にわたり目視可能な不良がなかった場合、×印はツールが破損したか、接合全長のどこかに目視可能な不良があった場合を表す。ここで不良とは、撹拌不足または過剰な撹拌によって板厚の半分以上の凹凸や貫通穴がある場合、あるいは溶接部における割れがある場合を指す。
実施例1と同様、図4に示した摩擦撹拌接合装置を用いて、表2に示す条件で摩擦撹拌接合を実施した。接合条件は、実施例1の場合とほぼ同じであるが、この実施例2では、接合に際して裏当て材を使用した。
上記の摩擦撹拌接合を実施した場合における接合の可否におよび継手効率、さらにビード幅の安定性について調査した結果を、表2に併記する。ビード幅については、最小のビード幅と最大のビード幅を計測し、その差が最小のビード幅の20%以下であることをもって安定するとした。
実施例1と同様、図4に示した摩擦撹拌接合装置を用い、表3に示す条件で摩擦撹拌接合を実施した。接合条件は、実施例1の場合とほぼ同じであるが、この実施例3では冷却装置9および後方加熱装置8を用いて接合を実施した。
上記の摩擦撹拌接合を実施した場合における継手効率および同一条件で得られた10本のサンプルの継手効率の標準偏差について調査した結果を、表3に併記する。
接合の可否で、○および◎は接合可能であったものであり、◎印はツールが破損せずに接合可能であり、接合全長にわたり目視可能な不良がなく、さらにビード幅が安定していた場合、○印はツールが破損せずに接合が可能であり、接合部に目視可能な不良がなかった場合、×印はツールが破損したか,接合全長のどこかに目視可能な不良があった場合を表す。ここで不良とは、撹拌不足または過剰な撹拌によって板厚の半分以上の凹凸や貫通穴がある場合、あるいは溶接部における割れがある場合を指す。
サンプルの継手効率の標準偏差は、継手強度を母材強度で除してパーセンテージとし、その値が5%を超えて8%以下であるものを△、3%を超えて5%以下であるものを○、3%以下であるものを◎として評価した。
3 接合装置
4 誘導加熱装置
8 後方加熱装置
9 冷却装置
10 回転工具
11 回転体上部
12 プローブ
13 未接合部
14 接合部
20 未接合部
21,22 鋼板
25 接合部
30 裏当て材
35 電源
40 加熱温度設定パネル
60 接合ツール(回転子)
61 ショルダ
62 プローブ
70 ガス炎
71 ガスノズル部
72 加熱装置
Claims (7)
- 二枚以上の鋼板を重ね合わせた、または突き合わせた未接合部に、回転工具を挿入し、この回転工具を回転させながら接合する部分に沿って移動させ、この回転工具と上記鋼板との摩擦熱によって鋼板に軟化部を形成し、さらにその軟化部を撹拌することにより生じる塑性流動を利用して鋼板同士を接合する摩擦撹拌接合方法において、
上記回転工具の進行方向の前方に配置した加熱装置によって、回転工具による接合前に未接合部を予め加熱するものとし、
その際、回転工具による接合が開始される位置において、進行方向に垂直な方向の表面の最高温度TUが、
0.6×TAc1<TU<1.8×TAc1
の範囲を満足し、かつ温度TL=0.6×TAc1を超える加熱領域の幅Lが、上記回転工具のショルダ部の直径dに対し、
0.3×d≦L≦2.0×d
の関係を満足する摩擦撹拌接合方法。
なお、TAc1は鋼板の添加元素量を用いて、次式で定義される温度とする。
TAc1=723-10.7〔%Mn〕-16.9〔%Ni〕+29.1〔%Si〕+16.9〔%Cr〕+290〔%As〕+6.38〔%W〕
ここで、〔%M〕は、M元素の鋼板中の含有量(質量%)を表す。 - 請求項1において、未接合部を挟み、接合ツールに対向する位置に配置する裏当て材の熱伝導率TCBが、鋼板の熱伝導率TCSに対して
0.5×TCS≦TCB≦1.0×TCS
の関係を満足する摩擦攪拌接合方法。 - 請求項1または2において、加熱装置が高周波誘導加熱装置であり、該加熱装置の使用周波数を20kHz以上360kHz以下とする摩擦攪拌接合方法。
- 請求項1~3のいずれかにおいて、二枚以上の鋼板の各C量のうち、より多量にCを含有する鋼板のC量を0.1質量%以上0.6質量%以下とする鋼板の摩擦撹拌接合方法。
- 請求項1に記載の摩擦撹拌接合方法において、
回転工具の進行方向の後方に、接合部の再加熱を司る後方加熱装置を配置し、該後方加熱装置により再加熱される領域の再加熱後の最高温度をTpとするとき、このTpが、
0.6×TAc1≦Tp≦1.2×TAc1
の関係を満足する鋼板の摩擦撹拌接合方法。
なお、TAc1は鋼板の添加元素量を用いて、次式で定義される温度とする。
TAc1=723-10.7〔%Mn〕-16.9〔%Ni〕+29.1〔%Si〕+16.9〔%Cr〕+290〔%As〕+6.38〔%W〕
ここで、〔%M〕は、M元素の鋼板中の含有量(質量%)を表す。 - 請求項5において、回転工具と後方加熱装置との間に、接合部の冷却を司る冷却装置を配置して鋼板を冷却する鋼板の摩擦撹拌接合方法。
- 請求項1~6のいずれかに記載の摩擦撹拌接合方法を用いる鋼板の接合継手の製造方法。
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US20160214203A1 (en) * | 2013-09-30 | 2016-07-28 | Jfe Steel Corporation | Friction stir welding method for steel sheets and method of manufacturing joint |
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US20160228981A1 (en) * | 2013-09-30 | 2016-08-11 | Jfe Steel Corporation | Friction stir welding method for structural steel and method of manufacturing joint for structural steel |
US9821407B2 (en) * | 2013-09-30 | 2017-11-21 | Jfe Steel Corporation | Friction stir welding method for structural steel and method of manufacturing joint for structural steel |
US9833861B2 (en) * | 2013-09-30 | 2017-12-05 | Jfe Steel Corporation | Friction stir welding method for steel sheets and method of manufacturing joint |
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CN109070262A (zh) * | 2016-03-31 | 2018-12-21 | 杰富意钢铁株式会社 | 结构用钢的摩擦搅拌接合方法和装置 |
CN109070262B (zh) * | 2016-03-31 | 2021-09-10 | 杰富意钢铁株式会社 | 结构用钢的摩擦搅拌接合方法和装置 |
US11241755B2 (en) | 2016-03-31 | 2022-02-08 | Jfe Steel Corporation | Friction stir welding method and apparatus for structural steel |
JP2020124739A (ja) * | 2019-02-06 | 2020-08-20 | Jfeスチール株式会社 | 両面摩擦攪拌接合方法および両面摩擦攪拌接合装置 |
JP6992773B2 (ja) | 2019-02-06 | 2022-01-13 | Jfeスチール株式会社 | 両面摩擦攪拌接合方法および両面摩擦攪拌接合装置 |
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JPWO2015045420A1 (ja) | 2017-03-09 |
US9833861B2 (en) | 2017-12-05 |
EP3053697A4 (en) | 2016-08-31 |
WO2015045420A8 (ja) | 2016-03-24 |
CN105579183A (zh) | 2016-05-11 |
JP6172261B2 (ja) | 2017-08-02 |
US20160221117A1 (en) | 2016-08-04 |
KR101873126B1 (ko) | 2018-06-29 |
KR20160054001A (ko) | 2016-05-13 |
EP3053697A1 (en) | 2016-08-10 |
MX2016003933A (es) | 2016-06-17 |
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EP3053697B1 (en) | 2017-11-08 |
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