WO2017121989A1 - Procédé de soudage par friction-malaxage - Google Patents

Procédé de soudage par friction-malaxage Download PDF

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Publication number
WO2017121989A1
WO2017121989A1 PCT/GB2017/050030 GB2017050030W WO2017121989A1 WO 2017121989 A1 WO2017121989 A1 WO 2017121989A1 GB 2017050030 W GB2017050030 W GB 2017050030W WO 2017121989 A1 WO2017121989 A1 WO 2017121989A1
Authority
WO
WIPO (PCT)
Prior art keywords
workpieces
probe
shoulder
joining body
joining
Prior art date
Application number
PCT/GB2017/050030
Other languages
English (en)
Inventor
Xingguo Wei
Jonathan Peter MARTIN
Original Assignee
The Welding Institute
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by The Welding Institute filed Critical The Welding Institute
Publication of WO2017121989A1 publication Critical patent/WO2017121989A1/fr

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12Non-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
    • B23K20/122Non-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
    • B23K20/1265Non-butt welded joints, e.g. overlap-joints, T-joints or spot welds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21FWORKING OR PROCESSING OF METAL WIRE
    • B21F15/00Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire
    • B21F15/02Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire wire with wire
    • B21F15/06Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire wire with wire with additional connecting elements or material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21FWORKING OR PROCESSING OF METAL WIRE
    • B21F15/00Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire
    • B21F15/02Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire wire with wire
    • B21F15/06Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire wire with wire with additional connecting elements or material
    • B21F15/08Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire wire with wire with additional connecting elements or material making use of soldering or welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21FWORKING OR PROCESSING OF METAL WIRE
    • B21F27/00Making wire network, i.e. wire nets
    • B21F27/08Making wire network, i.e. wire nets with additional connecting elements or material at crossings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21FWORKING OR PROCESSING OF METAL WIRE
    • B21F27/00Making wire network, i.e. wire nets
    • B21F27/08Making wire network, i.e. wire nets with additional connecting elements or material at crossings
    • B21F27/10Making wire network, i.e. wire nets with additional connecting elements or material at crossings with soldered or welded crossings

Definitions

  • the present invention relates to a friction stir welding method and apparatus used to join multiple workpieces, for example for joining workpieces such as cables in an end-to-end fashion.
  • Friction stir welding is a method in which a probe of material harder than the workpiece material is caused to enter the joint region and opposed portions of the workpieces on either side of the joint region while causing relative cyclic movement (for example rotational or reciprocal) between the probe and the workpieces whereby frictional heat is generated to cause the opposed portions to take up a plasticised condition; optionally causing relative movement between the workpieces and the probe in the direction of the joint region; removing the probe; and allowing the plasticised portions to consolidate and join the workpieces together.
  • Examples of friction stir welding are described in EP0615480 and W095/26254. The benefits of friction stir welding have been widely reported in the prior art, especially in comparison to conventional fusion welding techniques.
  • Friction stir welding is commonly executed using a simple cylindrical or slightly tapered probe or "pin" protruding from a larger diameter flat, domed or tapered shoulder, although in some instances a 'shoulderless' tool has been used comprising of a probe with no appreciable shoulder feature.
  • Typical examples of the common pin tool are described in GB2306366. Many modifications of the simple pin tool are known in the prior-art.
  • Typical workpiece materials commonly joined using friction stir welding are of a relatively low melting temperature and are in this context generally termed as being low temperature metals or materials, that is materials with a melting temperature below 1 100 degrees centigrade. The most commonly friction stir weldable of these materials are metals based upon aluminium, magnesium, copper, lead and other similar materials. It is also possible to join high temperature metals based upon iron, titanium, nickel and others, but often more traditional joining methods using melting/fusion are preferred due to cost issues, particularly in relation to the tool materials required.
  • JP2003-071576 describes a method of joining metal wires or foils, whereby their ends are buried in a terminal plate in a side-by-side fashion and a friction stir weld tool is traversed across each wire through the plate to join the wires and plate together. It is not possible to join workpieces end to end in any fashion using this method.
  • JP2003-126972 describes a method of joining metal wires, plates or foils arranged in parallel (e.g. side-by-side or stacked) using a friction stir welding tool, either with or without a covering plate, whereby the tool is traversed through or across the workpieces. It is not possible to join workpieces end to end in any fashion using this method.
  • JP2004-160477 discloses a method of friction stir welding (typically square section) aluminium sleeves to (typically circular section) aluminium wires.
  • a joined assembly can potential be combined with another, again using friction stir, either side-by-side or end-to-end.
  • end-to-end joining of wires it will inevitably leave a relatively large local increase in cross-section in the form of the sleeve which, especially when scaling up in thickness, may prove excessive and need considerably machining if reduction to original cross-section is required.
  • WO2005/082567 discloses a method of joining (insulation coated) wires by aligning their ends side-by-side, clamping and shaping/crimping them in a die and inserting a friction stir welding tool from the end to join the ends together. This allows joining of the ends without stripping the insulation, but it is not possible to join workpieces end to end in this fashion.
  • JP2014-057994 describes a method of joining (metal coated) wires by aligning portions of their length side-by-side and creating an elongate joint by traversing a tool for a distance along the butted lengths. Although this no doubt creates a joint, it is not convenient nor often feasible to align lengths of workpieces in this manner, or bend them to shape. It is not possible to join workpieces end to end in any fashion using this method.
  • EP1046453A2 describes a friction agitation joining apparatus for joining a plurality of abutted members which includes rotatable chucking portions for chucking opposite ends of the abutted members. This apparatus is suitable for joining abutted pipes, but it is not possible to join other types of workpieces end to end in any fashion using this apparatus.
  • JPH10180467A describes a similar friction agitation joining apparatus to EP1046453A2.
  • the apparatus is suitable for joining pipes together and includes support rollers, but it is not possible to join other types of workpieces end to end in any fashion using this apparatus.
  • JPH10166165A describes a method and device for friction welding capable of dealing with long and large joining faces, as well as vertical, horizontal, or inclined joining faces. However, it is not possible to join workpieces end to end in any fashion using either the method or the device described.
  • WO2015/045490A1 describes a friction stirring tool, a friction stir welding device, and a friction stir welding method with which the parts of the metal materials that are to be welded can be friction stir welded in a suitable manner, while limiting the load applied to the tool, even if the thickness of the parts to be welded varies.
  • the above inventive method is particularly useful for joining workpieces which are not conducive to the more traditional clamping methods used in existing friction stir processes.
  • the inventive method enables the end-to-end joining of cables, where the cable strands cannot be entirely stirred together and do not provide enough material to form a satisfactory joint using existing friction stir processes.
  • the insert or joining body used in methods according to the invention provides the necessary extra material.
  • the cyclic motion of the probe may comprise rotation of the probe, reciprocal motion of the probe, or both.
  • the probe has an accompanying shoulder, where the probe extends from the shoulder. The shoulder can be used to confine displacement of the stirred material, forcibly displace material and optionally provide heating by rotation.
  • the probe and the shoulder are able to move relative to one another, although it is possible to provide a tool in which the probe and the shoulder form a single element.
  • the use of a probe and shoulder which move relative to one another, typically along an axis parallel to the axis along which the probe extends from the shoulder, known in the art as 'retractable pin', provides a method of controlling the placement of stirred material to form a properly consolidated joint, whereby when the probe retracts into the shoulder at least some of the displaced material moves into the area voided by the probe. It is often the case that the joint produced protrudes outside the axis of the original workpiece to leave a thick or bulbous section.
  • the probe and the shoulder of the tool are able to move relative to one another and removing the probe comprises causing the probe to retract into the shoulder whilst at least some of the displaced material moves into the area voided by the probe and further comprises using the shoulder to force further displaced material into the area voided by the probe.
  • the workpieces and joining body are held within a die.
  • the stirred material is confined within a space defined by the die.
  • the stirred materials is confined within a space defined by the die and the shoulder of the tool.
  • the die is conveniently a removable item, in some cases the die could be integral to the joining body and as such remain in place after joining is completed. This could be enabled by containing, coating or partially containing or coating the joining body within a higher melting point material which acts as the die.
  • the invention is equally applicable to joining of workpieces comprising of multiple branches, such as extruded units used to create parts of a larger branched structure or extended structure.
  • the joining body may comprise two or more openings for receiving respective workpieces, and at least one of said openings may pass through the joining body.
  • Coated, uncoated or composite workpieces can all equally be joined and, although reference is made primarily to metals, there is no reason why polymer workpieces cannot be joined.
  • the invention can be applied without stripping insulation or removing any present moisture-blocking compound.
  • the joining body will be composed of the same material as the workpieces, however in some cases the joining body material may differ. This could be in the case where heat treatment or mechanical working of the joint/workpieces is required (e.g. heat-treatable aluminium alloys), or when dissimilar workpieces are to be joined.
  • the joining body could be made of a combination of materials in itself, or multiple pieces which could be temporarily attached to the ends of the workpieces. Material combinations of joining body and workpiece are likely to follow the conventional rules of materials, particularly metallurgy as laid down in the art of both friction welding, fusion welding and heat treatment in general. Although multiple workpieces are described, it is possible for the workpieces to be different ends of a long workpiece, such as a cable.
  • a die configured to receive two or more workpieces and a joining body
  • the joining body defining in use a joint region between the workpieces
  • a friction stir welding probe c. a friction stir welding probe, and means for causing cyclic motion of the probe when it is plunged into the joining body to carry out a friction stir welding process.
  • the probe has an accompanying shoulder, the probe extending from the shoulder
  • the probe and the shoulder are able to move relative to one another, for example the probe is operable to retract into the shoulder whilst the shoulder forces displaced material into the area voided by the probe.
  • the die comprises a lower assembly and a detachable upper assembly, whereby the upper assembly is removable to allow the die to receive the workpieces and joining body.
  • Figures 1 a-1 c show a schematic illustration of the assembly steps of workpieces, joining body and die.
  • Figures 2a-2d show a schematic illustration of a welding procedure according to an example of the invention.
  • Figure 3 shows a schematic illustration of disassembly of the die and a product made using an example of a method according to the invention.
  • Figure 4 shows a photograph of a disassembled die.
  • Figure 5 shows a joining body for use in examples of methods according to the invention.
  • Figure 6 shows a product made by an example of a method according to the invention.
  • Figure 7 shows a possible configuration of workpieces and joining body for application of the invention.
  • Figure 8 shows a possible configuration of workpieces and joining body for application of the invention.
  • Figure 9 shows a possible configuration of workpieces and joining body for application of the invention.
  • Figures 1 a-1 c illustrate the procedure for setting up (Figure 1 a) the die 20, composed of upper die assembly 1 and lower die assembly 3, placing ( Figure 1 b) of insert or joining body 4 (can be a single piece or multiple pieces) in the die 20 and locating ( Figure 1 c) workpieces 5 in apertures 22 in the joining body 4 aligned with die holes 2.
  • the die may be made of multiple sub- assemblies depending upon the requirements of the joint, workpieces and joining body to be used.
  • Figures 2a-2d illustrate the steps of carrying out a friction stir welding operation in accordance with the invention using a tool 6, comprising a shoulder 7 and probe 8.
  • a tool 6 comprising a shoulder 7 and probe 8.
  • This figure is referred to in terms of the sub-figures a, b, c & d, for clarity.
  • the co-rotating probe 8 and shoulder 7 are moved toward the assembled insert or joining body 4 and workpieces 5, into the interior of the die 20.
  • the plunging of the probe causes material of the insert or joining body 4 and workpieces 5 to soften, mix together 1 1 and be displaced by the probe to partially or completely fill the die 20.
  • the displaced material meets the shoulder 7, which compacts the material within the die 20 and provides a heating effect due to frictional contact which maintains the displaced material in a plasticised state.
  • a process dwell may occur at this point to allow proper mixing of the material of insert or joining body 4 and workpieces 5, especially in the case of a stranded or coated workpiece such as a cable.
  • Such a dwell may include adjustment of rotational speed of the shoulder/probe (together, or separately if applicable) and pressing force, depending upon material properties and machine feedback.
  • the probe 8 is withdrawn whilst the shoulder 7 pushes the material back into the space vacated by the probe.
  • Material mixing 1 1 is shown purely for illustration and is not to scale nor or a true representation of material mixing that occurs throughout the die 20, workpiece 5, and insert/joining body 4 regions.
  • the probe 8 is completely withdrawn and consolidation of the joint occurs.
  • the existence of an exit hole in the joined part depends upon the amount of material available from the insert or joining body 4 and workpieces 5 when compared to the die 20 size and plunge depth of the probe/shoulder, and whether the rotation/pressing of the retracted probe/shoulder is sufficient to fully refill the space voided by the probe 8. In most cases an exit hole occurs to some extent, but not always.
  • Figure 3a shows the completed joint 9, with the upper die assembly 1 removed, followed by complete ejection of the part 10 (in figure 3b). Following ejection, it is likely that some post-processing will be required, such as by machining, heat treating or finishing the joined parts.
  • Figure 4 shows a photograph of the dissembled die 20, comprising upper die assembly 1 in the form of several sub-assemblies, and lower die assembly 3, also made up of several sub-assemblies.
  • Figure 5 shows a photograph of an insert or joining body 4, as used in some methods according to the invention, with opening 23.
  • Figure 6 shows a photograph of a completed joint 9, made between two cable workpieces 5 comprising aluminium strands.
  • the exit hole 12 of the probe 8 is clearly visible, however the deepest point of this can be seen to be outside of the primary joint line (axis/intersection of the joined workpiece). In some cases, the hole can be completely filled but it is not generally necessary, especially when post-process machining of the joint occurs - it is of more importance that the joint is correctly consolidated.
  • Figure 7 shows a configuration where the insert or joining body 41 and workpieces 51 form a node.
  • the joining body 41 has three openings 24 for receiving respective workpieces.
  • Figure 8 shows a T-joint configuration with the insert or joining body 42 and two workpieces 52.
  • Such a configuration may be achieved by providing an insert or joining body 42 with a first opening 25 which passes through the joining body and a second opening 26 which may open into the first opening 25.
  • FIG. 7 The configurations of figures 7 and 8 may be achieved either with a joining body which is a single piece or from a joining body comprising multiple pieces.
  • Figure 9 shows multiple connections used to form an extended structure, where each of the workpieces 53 is made up of identical (or non-identical) pieces, which could be extrusions.
  • the joints 91 could be made from either the top, bottom or side, whilst in a three-dimensional lattice they would be made from a convenient open side. Further pieces can be added once a joint is completed and (optionally) post-processed to form a large branched structure. Many different configurations of workpiece are obviously possible.
  • a co-rotating probe and shoulder are used for simplicity of operation and equipment, it is possible if necessary to use differing rates of rotation for the shoulder and probe, different directions of rotation for the shoulder and probe, a probe which performs reciprocal motion, or even a probe which both rotates and performs reciprocal motion. It is also possible to use a stationary shoulder either alone or with an additional source of energy, such as that provided by resistance heating, induction heating, laser heating etc. It is also possible to use a friction stir probe without a shoulder, optionally using other methods to compact/force/move material, such as a multi-piece die where parts of the die are movable in relation to each other, enabling 'squeezing' of the material within the die.
  • Cooled fixtures are likely useful in reducing Heat Affected Zone (HAZ) effects and minimising changes/damage to parent material or components. Certain materials may also require an inert or protective atmosphere.
  • HAZ Heat Affected Zone
  • TWI Powerstir FSW machine The machine was specifically designed for welding thick section materials and therefore has the capability of delivering high torque and forces potentially required during methods according to the invention when applied to thick workpieces.
  • the joining body to be large enough to house the 22mm diameter cable but small enough to be fully plasticised during welding.
  • it was manufactured from aluminium AA6082-T6 and the bore adapted to provide easy fit of the cables.
  • the joined cable assembly must be easily released from the die. This was achieved by an ejector screw and a tapered bottom die. • The probe assembly must fully cover and mix the cable diameter.
  • the die must contain the displaced material (consumable joining body and cable mixed) during the plunging of the probe. Friction stir welding tool
  • the FSW tool set comprises of a probe and shoulder. They were designed to be used with an existing FSW welding head.
  • Both the probe and shoulder were manufactured from H13 tool steel, machined to shape and then heat treated to RC 44.
  • Welds can be carried out using position and/or force control of the tool components.
  • a strategy biased toward force control can be employed to avoid errors in material volume calculation, help deal with gaps or inconsistencies in parent material, allow for environmental variability, compensate for material loss (e.g. plasticised material forced into parent workpiece or out of die) and provide more consistency with regard to joint properties,
  • a position control strategy will likely require less complicated equipment set-up, which may be beneficial for field equipment, in terms of size, robustness etc. Of course, a mixture of the two can conceivably be used.
  • position control is where the tool is positioned/moved relative to a datum point along the plunge axis, typically parallel to the axis along which the probe extends from the shoulder. This is an open loop control strategy.
  • the tool shoulder could be programmed to move to a set position along the plunge axis with respect to the joining body/workpieces, irrespective of the imparted force.
  • Force control is where the tool is positioned along the plunge axis relative to the force it imparts. This is closed loop control strategy, using force feedback from sensors/transducers etc.
  • force control for example, the tool shoulder would be programmed to push on/into the joining body/workpieces, along the plunge axis, with a programmed force. The shoulder will move along the plunge axis into the workpieces until the set force is reached. If the force imparted by the shoulder as measured by the sensors is seen to decrease below the programmed force, then the shoulder will plunge deeper into the workpieces.
  • a technique that uses a more force control bias is possible, where the probe and shoulder are positioned on the top of the consumable joining body initially before the probe is extended under position control whilst the shoulder is lifted under force control. This allows constant contact to be maintained with the expelled material. Once the probe plunge is completed the probe is withdrawn and the shoulder pushed under force control to complete the joint. This technique is not as sensitive to the factors detailed above which affect the amount of expelled material, but requires more complex equipment.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

L'invention concerne un procédé d'assemblage de pièces comprenant : le placement de parties respectives des pièces (5) dans un corps d'assemblage (4) ; la fourniture d'une sonde de soudage par friction-malaxage (8); la plongée de la sonde (8) dans le corps d'assemblage (4) et le déplacement cyclique de la sonde pour malaxer le matériau du corps d'assemblage et des parties des pièces ; et le retrait de la sonde (8) et une action permettant au mélange malaxé de se consolider et d'assembler les pièces (5) les unes aux autres.
PCT/GB2017/050030 2016-01-12 2017-01-09 Procédé de soudage par friction-malaxage WO2017121989A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB1600592.8A GB201600592D0 (en) 2016-01-12 2016-01-12 Friction stir welding method
GB1600592.8 2016-01-12

Publications (1)

Publication Number Publication Date
WO2017121989A1 true WO2017121989A1 (fr) 2017-07-20

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Application Number Title Priority Date Filing Date
PCT/GB2017/050030 WO2017121989A1 (fr) 2016-01-12 2017-01-09 Procédé de soudage par friction-malaxage

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GB (1) GB201600592D0 (fr)
WO (1) WO2017121989A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3598580A1 (fr) * 2018-07-20 2020-01-22 TE Connectivity Germany GmbH Procédé d'assemblage d'au moins deux conducteurs électriques, dispositif d'assemblage d'au moins deux conducteurs électriques et connexion électrique entre au moins deux conducteurs
EP3609023A1 (fr) * 2018-08-10 2020-02-12 Nexans Procédé et dispositif de fabrication d'un raccordement électrique et conduite électrique

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2003071576A (ja) * 2001-08-31 2003-03-11 Hitachi Ltd 摩擦攪拌接合方法
JP2003126972A (ja) * 2001-10-19 2003-05-08 Hitachi Ltd 摩擦攪拌接合方法
US20050116012A1 (en) * 2003-11-26 2005-06-02 Packer Scott M. Method for metal and alloy joining using bulk friction stir welding
JP2014057994A (ja) * 2012-09-19 2014-04-03 Toshiba Corp 被覆導電線接合体の製造方法、被覆導電線の接合方法

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2003071576A (ja) * 2001-08-31 2003-03-11 Hitachi Ltd 摩擦攪拌接合方法
JP2003126972A (ja) * 2001-10-19 2003-05-08 Hitachi Ltd 摩擦攪拌接合方法
US20050116012A1 (en) * 2003-11-26 2005-06-02 Packer Scott M. Method for metal and alloy joining using bulk friction stir welding
JP2014057994A (ja) * 2012-09-19 2014-04-03 Toshiba Corp 被覆導電線接合体の製造方法、被覆導電線の接合方法

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3598580A1 (fr) * 2018-07-20 2020-01-22 TE Connectivity Germany GmbH Procédé d'assemblage d'au moins deux conducteurs électriques, dispositif d'assemblage d'au moins deux conducteurs électriques et connexion électrique entre au moins deux conducteurs
US11101576B2 (en) 2018-07-20 2021-08-24 Te Connectivity Germany Gmbh Method for joining two or more electrical conductors, device for joining two or more electrical conductors, and electrical connection between two or more conductors
EP3609023A1 (fr) * 2018-08-10 2020-02-12 Nexans Procédé et dispositif de fabrication d'un raccordement électrique et conduite électrique

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