WO2017167964A1

WO2017167964A1 - Friction stir welding method, pin, and machining device for connecting components made of different materials, and corresponding welded connection

Info

Publication number: WO2017167964A1
Application number: PCT/EP2017/057694
Authority: WO
Inventors: Bernd Richter; Stefan HABERSETZER; Stefan FRÖHLKE
Original assignee: Kuka Industries Gmbh
Priority date: 2016-03-31
Filing date: 2017-03-31
Publication date: 2017-10-05
Also published as: DE102016105927A1

Abstract

The invention relates to a technology for connecting at least two components (120, 130) made of different materials by means of friction stir welding (FSW). The first component (120) consists of a material with a first low melting temperature, in particular aluminum, and the second component (130) consists of a material with a second and substantially higher melting temperature, in particular steel. The invention provides a friction stir welding method, a welding pin (111), an FSW tool (110), and a component receiving area (161), which can be used together in the friction stir welding method, and to a welded connection and a machining station. A first and a second component (120, 130) are positioned so as to contact the component receiving area (161), thereby forming a butt joint between a first abutting edge (121) of the first component (120) and a second abutting edge (131) of the second component (130). The course of the butt joint overlaps with the course of the recess (165) in the component receiving area (161). An FSW welded connection is produced between the first and the second component (120, 130) while guiding the FSW tool (110) along the course of the butt joint, wherein plasticized material is transported into the recess (165) in the component receiving area (161).

Description

ROTARY DIE WELDING METHOD, PEN AND MACHINING DEVICE FOR JOINING COMPONENTS FROM DIFFERENT MATERIALS:

CORRESPONDING WELDING CONNECTION

DESCRIPTION

The invention relates to a technology for connecting components by friction stir welding, wherein the components may consist of the same or different materials.

The presently disclosed technology includes at least one welding method, a component connection or weld joint produced by the welding method, a friction stir welding tool with an associated one

Welding pin and a processing device for

Execution of the welding process with the respective features in the preamble of the independent claims. Friction stir welding, also referred to as FSW (FSW = Friction Stir Welding), is basically known in practice. In known FSW processes, two components to be connected are connected together by material bond. The components are so to each other

positioned so that a defined butt joint is formed. A FSW tool that has a rotating

Welding pin and a likewise rotating shoulder, is guided with the welding pin to the surface of both components in the area of the butt joint. The frictional contact of the FSW tool with the surface causes the material of the components to be close to the surface

Contact zone heated and that until the material plasticized both components, that is softened.

This usually occurs no melting of the

Materials on. The material of both components remains in the (plasticized) solid phase. By feeding the FSW tool along the

Butt joint (welding direction) and a rotation of the

Welding pin is in the known methods, the plasticized material of both components to the

Welding pin transported around and mixed. In the welding direction behind the FSW tool, a closed weld forms from the blended

plasticized material of both components.

A first aspect of the present disclosure is the joining of components from different ones

Directed materials.

The previously known FSW processes are used for the majority of the connection of components made of identical materials or similar alloys of the same base metal material, in particular aluminum or

Aluminum alloys. In addition, isolated components of the same base metal material or from

different base metal materials and each with the same or very similar melting points

Friction stir welding connected.

The disclosure according to the first aspect follows the aim of demonstrating an improved FSW technology, which has a wider applicability of friction stir welding for

offers different material combinations. A second aspect of the present invention relates to the manufacture of welded joints by

Friction Stir Welding, if special demands on the weld in terms of appearance or

Texture of the weld surface on the

Visible side.

It is an object of the present disclosure, a

show alternative technology for joining components by friction stir welding. The invention solves this problem by the

characteristic features in the standalone

Claims.

The aforesaid aspects of the present disclosure may each be alone or preferred in

Combination can be used. The disclosed features can contribute to the solution of the problem in both aspects and can therefore be combined as desired.

The friction stir welding method according to the first aspect of the present disclosure is for connecting two

Components, wherein the first component made of a material having a first low melting temperature and the second component made of a material having a second and significantly higher melting temperature. In particular, the material of the first component can be plasticized in a temperature range below the

Temperature range, which would be required for plasticizing the material of the second component. On the other hand, the difference between the

Melting points are so high that when reaching the temperature range in which the material of the second

Component could be plasticized, already the melting point of the material of the first component would be exceeded.

The first component may for example consist of aluminum or an aluminum alloy. The second component may consist of a steel material. In addition, other material combinations are possible. The friction stir welding method according to the first aspect of the present disclosure includes at least the

subsequent steps, which can be performed in the specified or any other order.

The first and second components are positioned to form a butt joint between a first abutment edge of the first component and a second abutment edge of the second component. The positioning can be done in any way, for example, by a suitable component holder with a clamping device. The first component is contacted by a friction stir welding tool (FSW tool), preferably in a surface area adjacent to the butt joint.

The material of the first component is plasticized and the welding pin of the FSW tool is immersed in the material of the first component, in particular until the shoulder of the FSW tool rests against the outer surface of the first component. The welding pin of the FSW tool is moved substantially perpendicular to the second abutting edge of the second component and pressed against this. At the same time, the welding pin and the shoulder of the FSW tool are in

Rotation held, possibly further material of the first component is plasticized.

The FSW tool and in particular the welding pin are guided along the second abutting edge of the second component, wherein the course of the abutting edge

Welding direction or welding path defined.

The friction stir welding method according to the first aspect of the present disclosure may be preferably carried out completely without plasticizing the material of the second member. As will be explained in detail below, in a welded joint formed by the present method, good

Strength properties are generated, which are based on proportion or predominantly on the formation of a positive connection between the weld and the second component and possibly on diffusion processes.

A welded joint according to the first aspect of the present disclosure is disposed between a first one

Component and a second component formed, which consist of materials having different melting temperatures. Between the components is a through

Friction stir welding produced weld in front of the

Substantially consists of plasticized and re-solidified material of the first component. On the second component is a shock edge, which by positive locking embedded in the weld. Possibly. For example, a plasticized and re-solidified material of a filler material, which differs from the material of the second component and in particular has a melting temperature which corresponds to or is close to the melting temperature of the material of the first component, may be contained in the weld seam.

A friction stir welding method according to the second aspect of the present disclosure includes at least the

subsequent steps, which can be performed in the specified or any other order.

A first and a second component are in contact with a component receiving and forming a butt joint between a first abutting edge of the first

Positioned component and a second abutting edge of the second component and preferably fixed in this position. In the component receiving a recess is provided, whose course overlaps with the course of the butt joint.

In particular, the courses of the recess and the butt joint can be identical. The component holder has at least in the area next to the butt joint in the

Essentially flat contact surface for supporting the

Components on. The recess is opposite to this

Retracted contact surface. It can be groove-shaped

be formed and have different cross-sectional shapes, which are explained below. Alternatively, the recess may be open on the side away from the FSW tool or from the components, so that any excess of plasticized material can escape to the outside. The shape of the recess is in relation to the expected size of the

Weld, in particular, is a profile depth of the recess in a ratio to the wall thickness of

Components and a profile width of the recess is in proportion to the expected seam root width of the weld.

The first and the second component may preferably consist of a metal or plastic. The basic shape of the first and the second component in the region of the butt joint is preferably plate-shaped or sheet-shaped. The too

connecting material sections can be, for example, plate-shaped or sheet-like webs of profiles. Alternatively, any other component shapes are possible, between which a butt joint can be formed, is present under the sufficient free space.

An FSW weld is made between the first and second components using a FSW tool, guiding the FSW tool along the course of the butt joint (and thus along the path of the recess). In other words, he is right

Course of the welding path with the course of the butt joint and the course of the recess match. At least the material of one of the components, preferably the material of both components, is plasticized by the FSW tool, without melting the materials. A part of the plasticized material is conveyed into the recess in the component holder and formed there. The formation of the plasticized material is preferably carried out under adjacent contact of the material with a contour of the recess. The shaping takes place in particular for the formation of a profiled

Weld reinforcement. The profiled seam exaggeration is essentially formed as a negative mold of the recess. The extent of contact between the plasticized material and the recess can be largely controlled by the shape of the recess, which will be discussed below

is explained.

The seam protuberance formed in the recess has a cross-sectional shape, which is predetermined by the cross-sectional profile of the recess in a defined manner. It is thus a profiled seam superelevation, in which in particular at least one projection width or a supernatant height or a shoulder region of the

Seam overshoot is shaped according to the shape of the recess.

The profiled seam superelevation can be attached to the

Workpiece can be positively used in various ways. On the one hand, it is possible the sublimation below

Specification (comparatively low) supernatant height

and / or to form a comparatively small projection width of the seam superelevation. The supernatant height and / or protrusion width can in particular be selected such that a subsequent removal of the seam exaggeration with only one subsequent work step is possible, for example by a milling tool. Furthermore, the supernatant height can be selected such that any occurring

Missing mixing zones in the edge region of the weld do not reach into the area of the direct overlap between the abutting edges of the components. By forming a seam crease with a

defined cross-sectional shape and the following

Abrasion achieves various benefits.

On the one hand, an FSW weld with a particularly high surface quality can be achieved, in particular a completely flat seam surface, which adjoins flush to the adjacent surface areas of the components. Recesses in the seam surface opposite the

adjacent component surfaces can be completely avoided. Such a seam surface is visually appealing and can be used for the visible sides of workpieces. On an elaborate

After treatment of the seam by filling and / or

Applying filler can be dispensed with. After separation of the seam superimposition is in particular a direct coating or other coating of the

Weld possible. As a result, FSW-welded workpieces can be made usable for applications that were previously open only to other joining methods, for example for the production of display panels for passenger trains.

In conventional FSW welding processes for the

Production of mechanically loaded welds a high effort to avoid mixing defects and other seam defects in the edge region of the weld is operated. With the friction stir welding method according to the second aspect of the disclosure, this effort can be reduced because the edge area containing any imperfections is removed during separation of the seam superelevation so that only the homogeneous interior areas of the mixing zone remain in the weld seam. At the Workpiece is thus produced a weld with a particularly homogeneous structure and surface quality, which is preferably free of cracking effects. A

Seam imperfection may in particular be a so-called kissing bond - an edge zone extending in the longitudinal direction of the butt joint with incomplete mixing of the plasticized materials. The reduction of the

The above-mentioned expenses can in particular allow the guidance of the FSW tool at higher speeds, so that shorter production times can be achieved.

In conventional FSW processes, care is taken to ensure that the immersion depth of the welding pin is always lower than the wall thickness of the components. Through the recess in the component holder, it is possible in the method disclosed here that the immersion depth of a

Welding pin of the FSW tool is greater than or equal to the wall thickness or material thickness of the components in the butt joint is selected. In other words, the welding pin can be the contour line of the adjacent (from the FSW tool

remote) surfaces of the components reach or exceed, without causing a collision with the component holder. Due to the increased immersion depth of the welding pin can in the direct

Overlap area between the components one

improved homogeneity of the weld or the

Mixing of the plasticized material can be achieved.

According to a preferred embodiment, an accumulation of material may be formed in the region of the butt joint, which plasticizes and at least with the material one of the components is mixed. The accumulation of material can be formed in any way, in particular by a filler material or a local

Component thickening. An accumulation of material can also be formed by inserting an additional material into the recess. The result of the accumulation of material

Increased amount of plasticized material can serve various purposes. On the one hand, a sufficient amount of additional material may be provided to the recess or an intended part of the

Fill recess in the component holder. On the other hand, for example, resulting from varying gaps in the butt joint resulting local increased or reduced requirements of plasticized material can be compensated, so that an excessive immersion of the FSW tool in the

Weld seam is reduced or excluded. As a result, a particularly homogeneous structure of the components is also on the side of the components facing the FSW tool

Weld achieved. In other words, the amount of material provided by accumulation of material (locally) can be adapted in order to influence the degree of filling of the recess and thus the seam pattern.

According to a first embodiment of the

Friction friction welding method is provided that the entire recess is filled with plasticized material. This can be achieved by the FSW tool with a certain contact pressure in

Normal direction is pressed onto the components, which possibly in the case of different widths of the butt joint a larger or smaller immersion depth can occur. This can lead to locally different seam underlays on the side of the weld facing the FSW tool. On the other hand, however, one will

uniform seam elevation achieved.

According to a second embodiment, it may be provided that the recess has a base portion and an overflow portion, wherein at least the

Base section is to be completely filled with plasticized material. Whether the overflow section with

can be filled with plasticized material

depend on whether a (eg local) surplus

plasticized material is present. Also, the at least complete filling of the base portion can be achieved by a force-guided plunging movement. Furthermore, at least as much additional material may be present that due to different widths of the butt seam caused additional or reduced demands on plasticized material can be compensated. Again, alternatively, it may be provided that in such a large range of welding length or over the entire welding length such a large excess of plasticized material is present that at least the complete filling of the recess or the base portion of the recess is ensured. Additional requirements

plasticized material due to a (locally) increased width of the impact gap then need not be compensated by an excessively deep dip. Thus, a substantially free of seam underlays education of the weld on the FSW tool to reach the right side. The excess

Volume fraction of the plasticized material can be conveyed into the overflow section of the recess and form an overhang, which is eventually separated in a subsequent processing step. In this way, a homogeneous seam pattern can be achieved on both sides of the weld. Furthermore, a minimum thickness or a uniform thickness of the weld can be achieved.

In other words, it may be preferable to provide such an amount of material accumulation that an excess of plasticized material is formed, i. at least slightly more plasticized material is required than to fill the direct overlap area between the abutting edges (volume of the weld seam) and a shoulder region of the profiled seam superimposition (profiled strand), the excess being able to escape via or into the overflow section.

The present disclosure further includes

Friction Stir Welding Tool (FSW Tool) optimized for use in the welding method of the first or second aspect, and one

Processing device for carrying out the

Welding process.

Further advantageous embodiments of the invention are in the following description, the attached

Drawings and the dependent claims specified. The invention is illustrated by way of example and schematically in the drawings. Show it:

Figures 1 to 3: the disclosure according to

Welding method according to the first aspect in a diagonal view and two sectional views;

Figures 4 and 5: two embodiments of a

Welded joint according to the first aspect of the present disclosure;

FIGS. 6A to 8B are enlarged sectional views of a first embodiment of the welding method of FIG. 1;

FIGS. 7A to 7C are enlarged sectional views of a further embodiment variant of the welding method of FIG. 1 and a component receptacle according to the second aspect of the disclosure;

FIGS. 8A to 8C: exemplary embodiments of a FSW tool;

Figure 9: an enlarged sectional view of a

Welded joint according to the first aspect of the disclosure;

Figure 10: a schematic representation of a

Processing device for

Carrying out a welding process; Figures IIA to HC: sectional views of

Explanation of a welding method and a component holder according to the second aspect of the disclosure; Figures 12 to 14: variants of the welding method and the component holder of Figures HA to HC and thus producible

Cross-sectional shapes of a

Seam elevation. Figure 15: An oblique view of a

Weld seam with a seam superelevation and a workpiece area after separation of the seam superelevation.

Hereinafter, first embodiments according to the first aspect of the disclosure will be explained with reference to FIGS. 1 to 10.

FIG. 1 shows an oblique view of two components

(20,30), which by the disclosure according to

Friction friction welding method according to the first aspect

get connected. The two components (20, 30) are shown in Figure 1 in a sectional view. Figure 2 shows a longitudinal sectional view according to the arrow II in Figure 1. Figure 3 shows a cross-sectional view according to arrow III in Figure 1. The first component (20) consists of a material having a first low melting temperature. It has a first abutment edge (21). The second component (30) exists made of a material having a second and significantly higher melting temperature and has a second abutting edge (31).

The components (20, 30) are so mutually

positioned so that a butt joint is formed between the first abutment edge (21) of the first component (20) and the second abutment edge (31) of the second component (30).

Between the abutting edges (21, 31) so a butt joint is formed. In the example of FIGS. 1 to 3, the first component (20) below the butt joint extends even further in the direction of the second component (30). As will be explained below, this additional extension in the welding process can be advantageously used to form a macro-positive fit. Alternatively, the first component (20) without such an extension may be formed below the butt joint.

The first component (20) has an accumulation of material (24) in a region adjacent to the butt joint, which is defined here by a protrusion of the first component (20) via the outer surface (32) of the second component (30) located on the side of the FSW tool ) is formed. Such

Material accumulation (24) may alternatively be formed in other ways. The first component (20) is replaced by a

Friction friction welding tool (FSW tool) (10) contacted in a region of the outer surface (22) of the first component (20) adjacent to the butt joint. The FSW tool (10) and in particular, the welding pin (11) arranged thereon and a shoulder (12) are rotated separately or together. As a result of the frictional contact of the FSW tool on the surface (22) of the first component (20), the material of the first component (20) is locally plasticized, first progressing in the region of material accumulation (24) and then progressing inwards.

Figure 6A is an illustrative cross-sectional view of the butt joint between the components (20, 30) and attachment of the FSW tool in an area adjacent the butt joint.

The welding pin (11) of the FSW tool (10) is immersed in the plasticized material (40) of the first component (20) or the accumulation of material (24), wherein gradually further inward material of the first component (20) is plasticized. The immersion movement is shown in transition from FIG. 6A to FIG. 6B and in FIG. 1 with the reference number (ZI).

marked. The immersion movement can take place substantially perpendicular to the outer surface (22) of the first component (20) or the accumulation of material (24). Alternatively, the FSW tool (10) may already have an inclination during fitting or dipping in accordance with at least one of the angles of inclination (AI, A2) described below (see FIG. 1).

The immersion movement is preferably carried out at least so far that the at the dorsal end of the welding pin (11) adjacent and outwardly extending shoulder (12) of the FSW tool (10) on the surface (22) of the first component (20) and the accumulation of material (24) comes to rest. The immersion depth of the

Welding pin can be greater than the wall thickness of the second component (30). Due to the further rotation of the welding pin (11) and the shoulder (12) and in particular the frictional contact between the shoulder (12) and the surface of the first component (20) or

Material accumulation (24) is further plasticized material of the first component (20) and the material cluster (24).

The welding pin (11) is pressed substantially perpendicularly against the second abutting edge (31) of the second component (30). In this case, any material of the first component (20) located between the welding pin (11) and the abutting edge (31) of the second component (30) is likewise plasticized and displaced. The shape of the first

Impact edge (21) is dissolved, while the shape of the second abutment edge (31) is substantially retained.

The pressing movement is shown in the transition from Figure 6B to Figure 6C and in Figure 1 by the reference numeral (Z2). The pressing (Z2) on the second abutting edge (31) is preferably carried out without plasticizing the material of the second component (30). In particular, it is preferably further avoided that the material of the first component (20) is heated beyond the plasticization or melts. The dynamics

(Rotational speed, immersion speed,

Guide speed) of the welding process can in Depending on the materials of the components (10, 30) are adjusted accordingly.

The pressing (Z2) of the welding pin (11) on the second abutting edge (31) is preferably carried out under a predetermined contact force (FN) in the normal direction or perpendicular to the abutting edge (31) of the second component (30).

The FSW tool (10) is guided along the second abutting edge (31) of the second component (30), wherein the welding pin (11) preferably permanently contacts the abutment edge (31). The course of the second abutting edge (31) thus predetermines the welding direction (SR) or welding path. The guiding movement or welding movement along the

Bumper (31) is indicated in Figure 1 by the reference numeral (Z3). Particularly preferably, the vertical contact pressure (FN) is applied to the second abutting edge (31) during the movement of the FSW tool (10) in the welding direction (SR).

maintained and, if necessary, varies in height. In other words, the welding pin (11) is pressed against the abutting edge (31) of the second component during the entire movement along the welding direction (SR), without, however, plasticizing the abutment edge (31) or the material of the second component (30).

By moving the FSW tool (Rotation +

Guiding movement), the plasticized material (40) is shaped such that the second abutment edge (31) is received in the weld (41) by positive engagement (42, 42a, 42b). The positive locking can be used as a macro- Positive fit (42b) and / or as a micro-positive connection (42a) are generated. Various aspects are explained below, which individually or together or in any combination can make a contribution to the formation of the plasticized material (40) or to the formation of a positive connection (42, 42a, 42b).

According to a first aspect, during the

Welding process Roughening and / or elevations (36) in the abutting edge surface (33) contacted by the welding pin (11) and possibly an outer surface (35) of the second

Component (30) generated. Further below, features of the FSW tool (10) explaining the formation of

Ruffles and / or elevations (36). Alternatively or additionally, you can already before the

Implementation of the welding process introduced

Roughing, elevations or other suitable

Surface structures on the second component (30)

be provided, which support a positive connection (42, 42 a, 42 b) with the weld (41). The following will be representative of the entirety of the aforementioned

Structures of the term ruffles or elevations (36) used.

The pressing of the welding pin (11) to the second

The abutting edge (31) may further assist in locally heating the material of the second member (30) and increase the pressure with which the plasticized material (40) is conveyed onto the abutting edge (31). Heating and pressure can cause diffusion

favoring the formation of one or more diffusion zones (43) in the contact area between the Weld (41) and the second component (30) lead. By such diffusion zones (43), in addition to the positive connection (42, 42a, 42b), a proportionate material bond can be generated. Furthermore, depending on the material type and homogeneity, a slight plasticization of the second component (30) may occur, although the shape of the second abutment edge (31) is not or only insignificantly changed.

During the welding process is preferred

plasticized material (40) by a movement of the FSW tool (10), in particular a rotation and

Guide the welding pin (11), introduced into the roughening or elevations (36) on the second component (30) in particular pressed and / or flushed. The

Roughening or elevation (36) can on the one hand be the roughenings or elevations produced by the welding pin (11). Alternatively or additionally, it may be the roughening or elevations (36) or otherwise suitable surface structures on the second component (30), which have been produced, for example, by a previous machining of the abutment edge (31) and / or on another outer contour of the second component (FIG. 30), in particular on an outer surface (32, 35) of the second component (30) or in the region of a transition between an outer surface (32, 35) and the abutting edge (31).

By introducing the plasticized material (40) into the roughenings or elevations (36), a micro-form closure (42a) is created between the weld seam (41) and the second component (30). FIG. 9 shows an enlarged sectional view of a welded joint according to the present disclosure and various

Roughing or elevation (36) on the second component

(30). The roughening or elevation (36) increases the size of the surface between the plasticized material (40) and the second component

(30), which continues the formation of diffusion zones

(43) favored.

According to a further aspect, the alternative or

may be provided in addition to the preceding aspect, the abutting edge (31) of the second component (30) in the weld (41) or the plasticized material

(40) of the first component (20) embedded (macro-form closure). The embedding can take place on the outer surface (32) facing the FSW tool and / or on the outer surface (35) facing away from the FSW tool (10). In the example of FIG. 9, portions of the weld (41) extend over both outer surfaces (32, 35) by way of example. Furthermore, an additional roughening or groove (37) is produced in the region of the outer surface (32) facing away from the FSW tool, into which likewise plasticized material (40) of the weld seam

(41) is introduced.

During the welding process, the plasticized material (40) is preferably shaped so that the weld (41) formed therefrom seals the abutting edge (31) in the

Cross-section surrounds at least two, preferably on three sides.

As in the cross-sectional view of Figure 3

can be seen, the FSW tool (10) during the Welding preferred by a tangential to

Abutting edge (31) of the component (30) extending axis (Kl) to the first component (20) to be inclined. The inclination can be present during the entire welding process.

Alternatively, the inclination between the immersion (ZI) and the pressing (Z2) can be brought about. It can possibly be adapted to an inclination profile of the second abutting edge (31). The (first) angle of inclination about the axis (K1) is indicated in FIG. 3 by reference number (AI).

characterized. The inclination (AI) is preferably selected such that the plasticized material (40) is formed through the shoulder (12) of the FSW tool (10) towards the abutting edge (31) of the second component (30). In other words, by the inclined position of the FSW tool (10) relative to the components (20, 30) and the butt joint, the (first) inclination angle (AI) and by the rotation of the shoulder (12) causes the plasticized Material (40) tends to be displaced or conveyed to the side of the second component (30), which supports the above-mentioned shaping of the plasticized material (40) for producing a positive connection (42, 42a, 42b).

As shown in FIG. 2, the FSW tool (10) can alternatively or additionally be inclined away from the welding direction (SR) about an axis (K2) running normal to the abutting edge (31) of the second component (30). The associated (second) angle of inclination about the axis (K2) is indicated in Figure 2 by reference numeral (A2).

The employment of the FSW tool (10) to the components (20, 30) and the butt joint under the second Tilt angle (A2) causes the in the

Welding direction (SR) leading part of the shoulder (12) has a greater distance from the outer surface (32) of the second component (30) than the welding direction (SR) trailing part. Optionally, the trailing part of the shoulder (12) on the second component (30) abut.

The angle of inclination (A2) can in particular be selected so that the leading part of the shoulder (12) just projects beyond the outer surface (22) of the first component (20) or a material accumulation (24) arranged there.

By the employment of the FSW tool (10) by the second inclination angle (A2) and the guide of the FSW tool (10) along the abutting edge (31) and the

Rotation of the shoulder (12) is caused on the one hand, the material accumulation (24) is plasticized by the shoulder (12) and on the other hand that the

plasticized material (40) in the direction of the side facing away from the FSW tool (10) side of the weld (41) is promoted. In other words, that will

displaced plasticized material (40) under pressure in the direction of the butt joint, so that a complete covering of the surface of the second component (30) in the region of the weld (41) by the plasticized material (40) is favored. The employment of the FSW tool under the second inclination angle (A2) is also for the

A welding method according to the second aspect of the disclosure is effective to convey plasticized material into the recess. The material accumulation (24) can be formed according to the example in Figures 1 to 3 and 6A to 6C by a projection of the first component (20) via the FSW tool (10) directed outer surface (32) of the second component (30). Alternatively or additionally, a

Material accumulation (24) by a arranged next to or above the butt joint strip of an additional material (25) may be formed (see Figures 7A to 7C).

As is apparent from the illustrations in FIGS. 6C and 7C

can be seen, plasticized material (40), which in particular comes from the accumulation of material (24) next to or above the butt joint, on the side of the FSW tool (10) located outer surface (32) of the first component (30) promoted or be shaped. As a result, the abutting edge (31) of the first component (30) is guided into the weld seam (41) by a macro-positive connection (42b) on the outer surface (32) facing the FSW tool (10) and / or in the transition region between the abutting edge (). 31) and the outer surface (32) embedded. In other words, the weld (41) protrudes outward beyond the abutting edge (31).

The height and width of the projection of the weld (41) over the outer surface (32) can be determined by the shape of the shoulder (12), the degree of angle (AI, A2), the amount of material accumulation (24) and the rotation of the

FSW tool (10) are influenced. While FIGS. 6C and 7C show relatively thick protrusions on the outer surface (32) facing the FSW tool (10), in the example of FIG. 5 a relatively narrow projection of the weld seam (41) is shown. By doing Example of Figure 4 is shown a weld joint (50) without a projection of the weld (41) over the FSW tool facing outer surface (32). This shape of the weld (41) can be generated when the FSW tool is delivered so far that it at least selectively the second edge (31) and / or the

Outer surface (32) of the second component (30)

contacted.

In the example of FIGS. 6A to 6C and 1 to 3, the first component (20) has a significantly greater wall thickness than the second component (30). It extends in particular still at least a little way below the butt joint in the direction of the second component (30). The welding pin (11) is designed and guided such that it covers at least the entire abutting edge (31) in cross section during the welding movement. The

Immersion depth of the welding pin (11) is thus greater than the wall thickness of the second component. The welding pin (11) may possibly a piece in both

Directions beyond the abutting edge (31) protrude. As a result of the rotation and guidance of the welding pin (11), a region of the material of the first component (20) is also plasticized below (side facing away from FSW tool (10)) of the second component (30). The guidance and adjustment of the FSW tool described above also pressurize the area plasticized beneath the butt joint or below the second component (30) so that the plasticized material is also conveyed there against the surface of the second component (30) Pressed and a clinging adherence to the

Outside surface (35) are favored. In Figures 7A to 7C is an alternative

Implementation variant shown. Here, the first component (20) and the second component (30) in the region of the abutting edges (21, 31) have substantially matching wall thicknesses. The components (20, 30) are arranged on or in a component receptacle (61) and optionally tensioned. In the component receptacle (61) is further in the area below the butt joint a recess (65)

provided, which can serve to form the Schweißwulstes. It is referred to below as Wulstformausnehmung (65). The Wulstformausnehmung (65) also forms a variant for the recess (165) for forming a seam superelevation according to the second aspect of the

Revelation, which is explained in detail below. Analogous to the above explanations, in the procedure illustrated in FIGS. 7A to 7C, the FSW tool (10) with the welding pin (11) in an area adjacent to the butt joint is attached to the first component (20)

Material accumulation (24) of the additional material (25) recognized and immersed in plasticizing the accumulation of material (24) and the material of the first component (20). As shown in Figure 7B

As can be seen, a portion of the plasticized material (40) by the movement of the FSW tool (10) can be promoted in the bead recess (65), which by further delivery of the FSW tool and / or the employment of the FSW tool the second

Tilt angle (A2) can be increased. The plasticized material (40) can during the

Welding movement through the bead mold recess (65) and the conveying action described above in the direction of the FSW tool (10) facing away from outer surface (35) are promoted or formed to form there a supernatant and to embed the abutting edge (31) of the second component (30) by macro-positive fit (42 b). FIGS. 8A to 8C show preferred embodiments of a friction stir welding tool (10) (FSW tool) according to the present disclosure. The welding pin (11) of the FSW tool (10) preferably has a conical basic shape, wherein the opening angle substantially to the first

Inclination angle (AI) corresponds. Furthermore, the shoulder (12) of the FSW tool (10) preferably has a concave shape. Between the shoulder (12) and the lateral surface (17) of the welding pin (11) may preferably be provided an angle of 90 degrees or less. Due to these shapes, the o.g. Promotional effects on the plasticized material (40) generated or amplified.

The welding pin (11) is preferably made of a material having such a strength and resilience that it withstand market normal service life of a processing of the second abutting edge (31). For this is

For example, a tungsten-rhenium alloy suitable.

The welding pin (11) can by different

Formation features contribute to forming rugosities or elevations (36) in the abutting edge (31) and / or the conveying effect on the plasticized material and

in particular to promote the introduction of the plasticized material in the roughening or elevations (36). According to the illustration in FIG. 8A, the welding pin (11) can have friction or cutting surfaces (15) disposed annularly or spirally at least on the lateral surface (17). Furthermore, the welding pin (11) may have one, two or more longitudinal grooves (16) in the lateral surface (17). The longitudinal grooves (16) may have an inclination to the direction of rotation, so that a proportionate

Promotional effect is generated in the direction of the tip of the welding pin (11). According to a further aspect, which can be combined with the aforementioned training features, the

Welding pin (11) in a longitudinal section through the

Have rotational axis concave outer contour (13) (see Figure 8B). The concave outer contour (13) may have at least one edge portion which during the

Welding process, the abutting edge surface (33) of the second component (30) deformed. In particular, the transition between pointing to the FSW tool

Outer surface (32) and the abutting edge surface (33) are deformed such that the macro-positive connection (42 b) is reinforced at this transition region (see.

Sectional view in Figure 9).

The formation of rugosities or cracks (36) can be further assisted in the welding process by maintaining the contact force (FN) of the welding pin (11) against the second abutting edge (31) or

is set.

According to another alternative, the (currently applied or effective) contact pressure (FN) against the second abutting edge (31) are detected, for example by a force or torque sensor on the

Component recording and / or by a force or moment measurement in the FSW tool (10) or a FSW tool (10) leading manipulator (62).

Furthermore, the height of the contact force (FN) of the

Welding pin (11) against the second abutting edge (31) are controlled to a desired force. The desired force can be specified locally differently depending on the contour of the components (20, 21).

Another way to support the formation of ruffles or elevations (36), the alternative or in addition to the force measurement or force control

can be provided, consists in the detection and optionally regulating a contact between the welding pin (11) on the FSW tool (10) and the second abutting edge (31). It can in particular a

Contacting sensor (63) may be arranged on the second component (30) or brought into contact therewith (see Figures 1 and 9) in order to detect parameters resulting from contact with the welding pin (11). To this

Parameters may include, in particular, vibrations whose frequency and / or amplitude can be measured. Accordingly, a contacting sensor can be designed as a vibration sensor (63). Alternatively, any others

Measuring method for detecting the presence and / or the strength of a contact between the welding pin (11) and the second abutting edge (31) possible. The strength of the contacting can be regulated in particular to a desired contacting strength. FIG. 8C shows a further embodiment of the invention

Welding pin (11), which may be combined with the above aspects or provided on its own. At the distal end of the welding pin (11) is a radially extending and beyond the lateral surface (17) of the welding pin (11) protruding friction or

Cutting contour (18) arranged. Like from the

As shown in FIG. 8C, this friction or cutting contour (18) can be brought into contact with the outer surface (35) of the second component (30) facing away from the FSW tool (10) during the welding process in order to provide additional roughening there as well to create an additional elevation (37). Due to the above-mentioned conveying effect on the plasticized

Material (40) can also be this additional roughening or the additional elevation (37) to form a macro-form closure (42b) are filled (see.

Sectional view in Figure 9).

FIG. 10 shows a processing device for

Performing a friction stir welding process according to the present disclosure. The processing device

(60) comprises a component receptacle (61), the

For example, according to the above explanations or the following description of the second aspect of

Revelation can be trained. The component holder

(61) may in particular have a bead-shaped recess (65).

The processing device (60) further comprises a manipulator (62), which is preferably designed as a 6- or 7-axis industrial robot. Of the Manipulator (62) performs a FSW tool (10), which is preferably formed according to one of the above variants.

The component receptacle (61) is designed to receive and position the first component (20) and the second component (30). The component receptacle (61) can be made in one or more parts.

The processing device (60) comprises a controller (64), in particular a manipulator control, which is designed to carry out a friction stir welding process according to the present disclosure. The

Processing device (60) may preferably comprise the above-mentioned contacting sensor (63), which

is preferably connected to the controller (64). Further, instructions may be included in the controller (64) to control the strength of the contact and / or the amount of contact force (FN) in response to the measurement result of the contactor (63).

Alternatively or additionally, at least one force or moment sensor (66) may be provided on the processing device (60) and / or on the manipulator (62) in order to detect the contact force (FN) of the welding pin against the second abutting edge (31). In the controller (64) instructions for controlling the welding process and in particular the contact pressure (FN) depending on the measurement result of at least one force or

Moment sensors (66) are present. From the measurement results of Kontaktierungssensors (63) and / or the force or torque sensor (66) conclusions as appropriate about the plasticized material (40) can be drawn, for example, in terms

Ductility and viscosity.

The processing device (60) or the manipulator (62) and its control can alternatively or

additionally be designed to

Friction friction welding method according to the second aspect of the disclosure. In such a case, the processing device (60) may include a release means with which a seam overhang (144) may be partially or completely severed after making a weld joint (150). The release agent may, for example, a milling or grinding device or one of a

Manipulator be guided milling or grinding tool. The component holder (61, 161) can be a separate

Section having the recess (65, 165) and, if necessary. The lying directly adjacent to the abutting edge

Areas of the components (20, 30, 120, 130) during the

Welding supports, as well as one or more other sections that are used for positioning and clamping the

Components (20, 30, 120, 130) are used. The section with the recess (65, 165) can after the production of the

Weld (141) are removed to allow access to the side facing away from the FSW tool side (25, 35, 125, 135) and to bring the aforementioned release agent into engagement with the seam exaggeration.

Hereinafter, with reference to the figures IIA to 15 embodiments of the welding method and the Component receptacles according to the second aspect of the disclosure explained. The explanation will be made initially independently of the first aspect of the disclosure. Hereinafter, advantageous combinations of aspects will be described. As far as illustrated elements and structures

Corresponding to FIGS. 1 to 10 explained above, the same reference numerals have been used with prefixed numeral 1, for example components 20 -> 120, 30 -> 130. Unless defined otherwise, all shown or described for the first aspect of the disclosure

Features corresponding to the second aspect of

Epiphany .

In the friction stir welding method according to the second aspect of the disclosure, components (120, 130) may be connected to the same or different materials. This includes those defined in the first aspect of the disclosure and other combinations of materials. In particular, materials with the same or

similar melting point can be used and during the production of the FSW welded joint, the

Materials of the components (120, 130) and, if necessary, an additional accumulation of material plasticized and

be stirred together. The material accumulation can be formed, in particular in analogy to the above statements.

Particularly preferably, the friction stir welding method for joining sheets, plates or webs with in

Substantially matching and in particular the same wall thickness can be used. However, in the area of Butt-joint a material thickening in at least one of the components (120, 130) to form a

Material accumulation be formed. Again alternatively or additionally, a material accumulation by a

Be formed additional material. The accumulation of material is not shown for reasons of simplified illustration in Figures IIA to 15.

Figures IIA to HC show two components (120, 130) and a component receptacle (161) in cross section. Each of the components (120, 130) has a butt edge (121, 131) and the components are positioned relative to each other to form a butt joint. Between the abutting edges (121, 131) a butt joint is formed. In the

Component receptacle (161) is in cross section next to

Butt joint or next to the course of the butt joint a

Recess (165) formed. The recess can also be referred to as a recess. She creates one

additional and at least partially limited space next to the butt joint (on the side facing away from the FSW tool).

The component receptacle (161) is disposed on the side or outer surface (125,135) of the components, which faces away from the FSW tool (110). These sides or outer surfaces may later represent the visible side. The sides or outer surfaces (122, 132) facing the FSW tool (110) are also referred to as the machining side.

In the friction stir welding method according to the second aspect of the disclosure, basically any FSW Tool (110) can be used. In particular, it may be the FSW tool described above according to the first aspect of the disclosure. The welding pin (111) is set in a rotational movement and with the outer surface (122, 132) at least one of the components (120,130) in

Brought in contact. In the example of FIG. 11A, the welding pin (111) is delivered substantially centrally to the butt joint, so that it contacts the surfaces (122, 132) of both components (120, 130). By the rotation of the welding pin (111) is

Friction heat generated in the at least one component (120, 130), whereby the material of the at least one

Component (120, 130) is plasticized. The welding pin

(111) becomes in the material in a substantially in the axial direction of the welding pin (111) directed movement or in a substantially perpendicular to the outer surface (122, 132) of the components (120, 130) directed movement with the plasticization

immersed, being also more inward

Material areas are plasticized.

The immersion movement of the welding pin (111) or of the FSW tool (110) can at least take place so far that one adjacent to the welding pin (111) arranged

Welding shoulder (112) comes into contact with at least one outer surface (122, 132) of one of the components (120, 130). Particularly preferred may be the weld shoulder

(112) come into contact with the outer surfaces (122, 132) of both components (120, 130). The welding shoulder (112) can be formed in one or more parts. It may be partially or completely offset in a rotational movement, in particular with the rotational movement of the welding pin (111).

matches. Alternatively, different

Rotational movements, in particular

Rotation speeds, on the one hand for the

Welding pin (111) and on the other hand be provided for one or all components of the welding shoulder (112). For the sake of simplification, it is assumed below that there is a one-piece welding shoulder (112) which rotates in accordance with the welding pin (111).

Between the welding shoulder (112) and the at least one component (120, 130), a frictional contact can exist during the production of the welded joint, which also contributes to the plasticization. The FSW tool (110) is moved along the butt joint, i. along the course of the

Butt-kick moves. In this case, further material of the at least one component (120, 130) is plasticized and conveyed around the welding pin (111) so that a weld seam (141) formed from the plasticized material (140) forms behind the movement path of the welding tool (110).

A portion of the plasticized material (140) is further conveyed into the recess (165) and formed there to form a seam bump (144). The conveying effect on the plasticized material in the direction of the recess (165) can be influenced or reinforced by various factors, in particular by a structure of the Welding pin (111), a contact pressure of

Welding shoulder (112) in the direction of the components (120, 130), the shape of the weld shoulder (112) and a slope (Nl, N2) of the FSW tool (110) and the

Welding shoulder (112).

The shaping of the seam superelevation is based essentially on an abutting contact between the plasticized material (140) and a surface area of the surface

Recess (165). Accordingly, by specifying the profile, in particular the cross-sectional shape of the

Recess (165) partially or completely defined to be reached form of seam exaggeration (144). The recess (165) can in particular as

Be formed negative mold a desired seam elevation.

In the example of Figures IIA to HC is a

Selected cross-sectional shape of the recess (165), both a projection width (b) and a supernatant height

(h) specifies the seam superelevation (144) and which is to completely specify the shape of the seam superelevation,

in particular if the recess (165) is completely filled with plasticized material. Below are alternative forms or profiles of the recess

(165) explains. As shown in FIG. HB, the insertion depth of the welding pin (111) can be selected to be so great that its tip reaches or exceeds a contour line (HO) of the surfaces (125, 135) of the components (120, 130) on the visible side. The immersion depth is preferably such that the welding pin (111) does not contact the bottom of the recess (165) to damage the FSW tool (110) and the component holder (165)

avoid. The seam elevation (144) can be used in various ways. FIG. 15 shows an oblique view of the visible side (125, 135) of the components (120, 130) after the manufacture of the FSW welded connection (150). In the upper left-hand area, a state of the welded connection (150) is shown in which the seam superelevation (144) is shown as

Profile protrusion on the components (120,130) remains. The seam superelevation can have a uniform profile over the course of the weld. Alternatively you can

different profiles of the seam superelevation in different areas of the weld are generated, in particular by correspondingly different shapes of the recess and / or different post-processing. By doing

In the example on the top left in FIG. 15, two alternating profiles are shown purely schematically. The outer and slightly more profiled shapes relative to the base are, for example, by a recess (165) with a

Cross-sectional shape according to Figures IIA to HC generated, wherein the formation of suture defects is avoided by controlling the heat supply and / or discharge. In between, a section with a slightly lower height (h) is the

Seam elevation (144). In this case, control of the heat supply and / or discharge has been dispensed with or such a control is provided that a kissing bond (145) is permitted or specifically produced. The change between the profile shapes of the seam superelevation (144), shown at the top left in FIG. 15, represents an example of the Generation of desired break points (mixing defects / Kissing Bond 145, for example) in the course of the weld or the seam exaggeration (144), which will be explained in more detail below. Next to it (bottom right) is shown in FIG. 15 an area in which the seam superelevation (144) after the

Production of the weld (141) has been separated. The separation can be done in any way

in particular by a machining process or a grinding experienced and one of the aforementioned release agent.

Particularly preferably, the supernatant height (h)

and / or the projection width (b) be predetermined such that the separation of the seam superelevation (144) can take place in a single processing step. FIG. HC shows a sectional view of the weld seam (141) before or without severing the seam protuberance (144). In the enlarged section of the

Seam exaggeration (144), a mixing defect is exemplified in the form of a so-called kissing bond (145). There, the plasticized materials of the components (120, 130) and any additional material have not or not completely stirred, for example, because a solidification on the surface of the plasticized material (140) has occurred too early. Such mixing defects can have a tear effect and the mechanical strength of the

Reduce weld. For mechanically loaded

Welded joints is therefore desired to avoid such defects. According to the present disclosure

different measures should be provided to

To avoid mixing defects or other surface defects in the finished weld. Below are described applications in which defects in at least portions of the weld (141) are tolerated or desired.

To influence the formation of imperfections, a heating and / or cooling device (167) can be provided on or in the component receptacle (161). This may serve to regulate heat input or heat removal to or from the plasticized material (140).

In particular, the surface of the recess (165) can be heated or cooled to prevent the solidification of the

To delay or to plasticized material

accelerate.

If heating by heating is provided, solidification of the plasticized material may be delayed, at least in the region of the instantaneous position of the FSW tool 110 or the welding pin 111, so that there is more time for the plasticized material to stir and a homogeneous one Blending is favored.

If a cooling, in particular a local cooling of the recess (165) is provided, a rapid or complete solidification of the plasticized material and thus a solidification of the weld can be promoted. A heating device and / or a cooling device may possibly act in coordination with the guiding movement of the FSW tool (110) on the component receptacle (161). In particular, a heater in the flow to the movement of the FSW tool act and a

Cooling device may act in the wake of the movement of the FSW tool (110). According to a preferred

Execution can be a combined heating and

Cooling device on the component receiving (161) are moved along so that always heated an area in the flow to the welding pin (111) and a region in the wake of the welding pin (111) is cooled.

Alternatively, in each case a separate heating or

Cooling device to be moved along the component holder. Again, alternatively, a local actuation of a heating and / or cooling device, which extends along the recess (165), take place, in particular in coordination with the guidance of the FSW tool (110).

Figures 12 to 14 show alternative embodiments of a component receptacle (161) with differently shaped recesses (165 ^x , 165 ^xx , 165 ^xxx ) and thus can be generated cross-sectional shapes of a seam superelevation (144,146). In the example of FIG. 12, a profile width (B) of the recess (165 ^× ) is provided, which is smaller than or equal to the expected seam root width (N) of the weld seam (141). As a result, only a projection width (b) of the seam superelevation (144) is predetermined by the recess (165 ^× ). The tread depth (H) is shown in FIG

By contrast, the example of FIG. 12 is not fixed or chosen so large that the recess (165 ^x ) does not

completely filled with plasticized material (140). In other words, at least one

Expansion direction for the expansion of the plasticized Material released. If there is an increased or reduced requirement for plasticized material in the course of the weld seam (141), which results, for example, from larger or smaller widths of the butt joint

corresponding locally more or less plasticized

Penetrate material into the recess (165 ^x ). However, at least one approach (148) of the seam exaggeration (144) can over the entire length of the weld (141) a

have predetermined cross-sectional shape. With others

Words, the recess (165) a first

Base portion (no reference numeral), which is to be filled completely by plasticized material (140) to form a projection (148) of the seam overhang (144) with a uniform cross-sectional profile, and an adjacent overflow section (170), not or only partially with plastic material is filled, especially if an excess of

plasticized material (141) is present. In the example of FIG. 12, an overflow section (170) is the

Recess (165 ^x ) through an opening in the bottom of the

Recess (165 ^x ) formed. FIG. 13 shows a

alternative cross-sectional shape of the recess (165), in which a comparatively low profile depth (H)

(For example, 0.2 mm to 0.3 mm or a maximum of 2 percent to 10 percent of the wall thickness of the components (120, 130)) is provided and a profile width (B), which is larger and in particular significantly larger than the intended near-root width (N). An overflow section (170 ^× ) is here in the region of the projection of the recess (165) over the expected width (N) of the seam root

educated. By the recess shown in FIG (165), the supernatant height (h) of the seam exaggeration (144) is determined while the overhang width (b) remains substantially indefinite.

FIG. 14 shows another alternative cross-sectional shape of the recess (165 ^{,, Λ} ), which is essentially a

Further development of the cross-sectional shape of Figure 12 is. The recess (165,, ^>'> ) lays at least in the area of

Approach (148) of the seam exaggeration (144)

Projection width (b) fixed, while the supernatant height (h) is unlimited. The recess (165,, ^>'> ) further has a profile constriction (168), in which the width of the seam exaggeration (144) is further limited. The profile constriction (168) is also the limit

between the base portion and the overflow portion (170) of the recess (1 6 5). Behind the

Profile constriction (168) can be a profile widening

be present, in which the introduced plasticized material can form a drop or a straight overhang. The plasticized material conveyed into the recess (165 ^{,, ''>} ) during the welding process is formed into a profile strand (146) with a longitudinal constriction (147). The Längseinschnürung (147) may be chosen so small in width that a predetermined breaking point

is formed. At the end of a welding operation, the connected components (120, 130) can be released from the component receptacle (161), with one still above the

Longitudinal necking (147) protruding component

(Teardrop / overhang) of the profile strand (146) is demolished or separated. The separation can be done in any way. In particular, a separating device (169) can be arranged on or in the component receptacle (161). be provided, which acts in the region of Längseinschnürung (147), which is illustrated by the dividing line (T) in Figure 14. Alternatively, one of the abovementioned separating means can effect the separation of the part of the seam superelevation (141) or of the profiled strand (146) which extends beyond the longitudinal constriction (147).

As FIG. 15 illustrates, different cross-sectional profiles for the seam superelevation (144) can be provided in the course of the weld seam (141),

in particular different predetermined projecting height (h) and / or projection widths (b). Uniform or in the course of different cross-sectional profiles can be used for example as design elements or design structures on the visible side. It may further be provided that mixing defects such as a kissing bond (145) are avoided in at least parts of the weld (141) and allowed or generated in the other parts. In this way, for example, preferential breaking points on the weld seam (141) can be created in order to influence the crash behavior of a workpiece.

Modifications of the invention are possible in various ways.

All of the examples described, shown, claimed or otherwise

reveal features can in any way

combined, replaced, supplemented or omitted. If the components (20, 30, 120, 130) have a different melting point or a different plasticizing behavior, the

Welding method are used according to the first aspect of the disclosure, but also the material of the second component (30, 130) is plasticized. However, the proportion of the plasticized material of the second component in the weld (141) or the

Blending zone be significantly lower than the proportion of the material of the first component and / or an additional material. The cross-sectional shapes of the recess (165, 165 165 ^Λ 165) proposed according to the second aspect of the disclosure may also serve to provide a

(additional) positive connection between the weld and the second component (30, 130) to produce.

The materials of the two components (20, 30) may also be non-metals, such as plastics (in particular the first component) or ceramics (especially the second component). The manipulator (62) may be a machine tool. Instead of

Guide the FSW tool (10) relative to the fixedly positioned components (20, 30) may be any other kinematics. For example, two or more components (20, 30) in a movable

Pickup (61) be recorded and positioned. The components can be moved by the movement of the

Component receptacle (61) opposite a stationary

arranged FSW tool (10) be guided.

Optionally, the manipulator (62)

(Industrial robot) the component holder (61) or the components (20, 30) move to the immersion movement (ZI), to cause the pressing movement (Z2) and the welding movement (Z3).

The FSW tool (10) can during the welding process in total with a uniform

Rotation speed to be rotated. Alternatively, different rotational speeds and optionally different rotational directions for the welding pin (11) and the shoulder (12) may be provided. The direction of rotation of the shoulder (12) is preferably oriented counter to the movement of the FSW tool (10) along the second abutment edge (31) (see Figure 1), i. against a direction of rotation when rolling the

Welding pin (11) on the abutting edge (31) would occur. The same applies to the direction of rotation of the

Welding pin (11).

An independent object of the present

Revelation is a friction stir welding method for

Connecting at least two components (120, 130) comprising the following steps:

- Positioning a first and a second

Component (120, 130) in contact with a component receptacle (161) to form a butt joint between a first abutment edge (121) of the first component (120) and a second abutment edge (131) of the second component (130), wherein the course of the butt joint with the course of a recess (165) in the component receptacle (161) overlaps; Making a FSW weld (150)

between the first and second components (120, 130) using a FSW tool (110) and guiding the FSW tool (110) along the course of the butt joint, wherein plasticized material (140) enters the

Recess (165) in the component receiving (161) promoted and formed there to a profiled seam exaggeration (144). The configuration of the recess (65) may correspond to each of the examples of FIGS. 7A to 7C as well as IIA to HC, 12, 13 and 14, and the respective ones

associated features individually or in any

Combination have.

A further independent feature of the present disclosure is a component receptacle (161) for supporting at least two components (120, 130) for a FSW welding process, wherein the components (120, 130) are formed between a first abutment edge (120). 121) of the first component (120) and a second abutment edge (131) of the second component (130) are positionable and fixable in or on the component receptacle (161), and wherein the component receptacle (161) has a recess running along the stump abutment (161). 165, 165 165 ^Λ 165) into which plasticized material (140) can be conveyed during an FSW welding operation, and wherein the recess (165, 165, 165 ^{, x} , 165,, ^>'> ) is designed to be the introduced plasticized material Material (140) to a seam exaggeration (144) with

at least one defined supernatant height (h) or a defined projection width (b) to form. The

Recess may further be adapted to the plasticized material (140) to a profile strand (146) with a Längseinschnürung (147) to form. Alternatively or additionally, the component receptacle (161) may have a heating and / or cooling device (167), which is designed to regulate a heat supply and / or heat dissipation in the region of the recess (165). As an alternative or in addition, the component receptacle (161) can have a separating device (169), which can be used for this purpose

is formed to separate at least a portion of the seam exaggeration (144), in particular in the region of

Long neck (147).

LIST OF REFERENCE NUMBERS

FSW tool

welding pin

shoulder

Concave outer contour

Friction or cutting surface

Ridge / longitudinal groove

lateral surface

Friction or cutting contour

First component (low melting point)

First abutting edge

outer surface

material accumulation

Second component (high melting point)

Second abutting edge

Outside surface on side of the FSW tool

Shock edge surface

material accumulation

Outside surface facing away from FSW tool

Roughening / elevation

Plasticized material

Weld

Positive-locking connection

a micro-positive connection

b Macro form-fitting

Diffusion zone

welded joint

Bearbeitungsvorriehtung

Component holder / clamping tool manipulator

Contacting sensor / vibration sensor

control

Wulstformausnehmung

Force sensor / torque sensor FSW tool

welding pin

shoulder

First component

First abutting edge

Outer surface on FSW tool side / machining side Outer surface facing away from FSW tool / visible side

Second component

Second abutting edge

Outside surface on side of FSW tool / machining side

Shock edge surface

Outside surface facing away from FSW tool / visible side

Plasticized material

Weld

Overhang profile / profiled seam exaggeration Kissing Bond / mixing defect

extruded

Längseinschnürung

Approach of seam exaggeration

welded joint 160 processing device

161 Component holder / clamping device

165 recess / profiling groove

167 heating and / or cooling device

168 profile constriction

169 separating device

170 overflow section

b protrusion width of the seam superelevation

B profile width

h supernatant height of the seam superelevation

H tread depth

HO contour line of surface (s) next to weld

N seam root width

T dividing line

AI First angle of attack, inclination towards the first component

A2 Second angle of attack, inclination opposite

welding direction

FN contact force (perpendicular to second edge)

Kl axis tangential to abutting edge

K2 Axis normal to abutting edge

SR welding direction

ZI immersion movement

Z2 pressing movement

Z3 sweat movement

Claims

Friction friction welding method for connecting two

Components (20, 30), wherein the first component (20) made of a material having a first low

Melting temperature, in particular of aluminum, and the second component (30) of a material having a second and significantly higher melting temperature, in particular made of steel, comprising the following steps:

Positioning the first and second

Component (20, 30) to form a butt joint between a first abutment edge (21) of the first component (20) and a second

Abutting edge (31) of the second component (30);

Contacting the first component (20) by a FSW tool (10) in a surface area (22) adjacent the butt joint;

Local plasticizing of the material of the first component (20) and immersion (ZI) of the

Welding pin (11) of the FSW tool (10) in the plasticized material (40);

Substantially perpendicular pressing (Z2, FN) of the welding pin (11) of the FSW tool (10) to the second abutting edge (31) of the second

Component (30), in particular without plasticizing the material of the second component (30); Guiding (Z3) the FSW tool (10) in a welding direction (SR) along the second

Abutting edge (31) of the second component (30), characterized in that the first

Component (20) and the second component (30) in contact with a component receiving (61, 161) are positioned, wherein the course of the butt joint with the course of a recess (65, 165) in the

Component receiving (61, 161) overlaps and wherein plasticized material (40, 140) in the recess (65, 165) in the component receiving (61, 161) is promoted.

A friction stir welding method according to claim 1, wherein said substantially non-plasticized second

Bumper edge (31) by positive engagement (42, 41 a, 42 b) in the weld (41) is received.

Friction friction welding method according to claim 1, or 2, wherein the plasticized material (40) is formed such that the weld seam (41) formed therefrom surrounds the abutment edge (31) in cross-section at least two, preferably three sides.

Friction friction welding method according to one of

preceding claims, wherein a macro-positive fit (42b) is produced by embedding the abutting edge (31) of the second component (30) in the plasticized material (40) of the first component (20). Friction friction welding method according to one of

preceding claims, wherein an insertion depth of a welding pin (111) of the FSW tool (110) is greater than or equal to the wall thickness of the components (120, 130) selected in the butt joint.

Friction friction welding method according to one of

preceding claims, wherein the movement of the FSW tool (10) in the welding direction (SR) while maintaining the vertical contact force (FN) to the second abutting edge (31) of the second component (30).

Friction friction welding method according to one of

preceding claims, wherein roughening

and / or elevations (36) are produced in the abutting edge surface (33) of the second component (30) contacted by the welding pin (11).

Friction friction welding method according to one of

preceding claims, wherein plasticized material (40) by movement of the FSW tool

(10), in particular a rotation and guidance of the welding pin (11), in roughening or elevations

(46) on the second component, in particular on the second abutting edge (31), is introduced, so that the roughening or elevations (46) by micro-positive connection (42 a) in the weld (41)

be embedded. Friction friction welding method according to one of

preceding claims, wherein the FSW tool

(10) in such a way about a tangential to the abutting edge (31) of the second component (30) extending axis (Kl) to the first component (20) inclined towards (AI) is that the plasticized material (40) by a shoulder

(12) of the FSW tool (10) is formed toward the abutting edge (31) of the second component (30).

10.) friction stir welding according to one of

preceding claims, wherein the FSW tool

(10) about a normal to the abutting edge (31) of the second component (30) extending axis (K2) of the

Welding direction (SR) is tilted away (A2).

11.) friction stir welding according to one of

preceding claims, wherein the welding pin

(11) of the FSW tool (10) has a conical basic shape whose opening angle corresponds to the angle of attack (AI) of the FSW tool (10) to the first component (20) out. 12.) friction stir welding according to one of

preceding claims, wherein at the first

Component (20) in a region adjacent to the butt joint before welding a accumulation of material (24) is provided, which is plasticized during the welding process and molded by the FSW welding tool (10).

13.) friction stir welding according to one of

previous claims, wherein the first component (20) at least in a region adjacent to the butt joint in comparison to the second component (30) a

Increased wall thickness, in particular wherein the outer surface (22) of the first member (20) on the engaging side of the FSW tool (10) before welding against the outer surface (32) of the first component (30) to form a

Material accumulation (24) is offset to the outside.

14.) friction stir welding according to one of

preceding claims, wherein a

Material accumulation (24) is formed by an additional material.

15.) friction stir welding according to one of

preceding claims, wherein a

Material accumulation (24) on the first component (20), which is arranged in particular in an area adjacent to the butt joint, during the welding operation

plasticized and through the shoulder (12) of the FSW tool (10) to the abutting edge (31) of the second

Part (30) is formed towards.

16.) friction stir welding according to one of

previous claims, wherein plasticized material (40), in particular from the

Material accumulation (24) over which on the side of the FSW tool (10) located outer surface (32) of the first component (30) is formed, in particular around the abutting edge (31) of the first component (30) in the weld (41) by macro-fit (42b) embed. 17.) friction stir welding according to one of

preceding claims, wherein at least a part of the plasticized material accumulation (24) is formed around an outer surface (35) of the first component (30) facing away from the FSW tool (10),

in particular around the abutting edge (31) of the first

To embed component (30) in the weld (41) by macro-positive connection (42 b).

18.) friction stir welding according to one of

preceding claims, wherein the welding pin (11) of the FSW tool (10) has a concave outer contour (13) and wherein

at least one edge portion of the concave outer contour (13) deforms the abutting edge surface (33) of the second component (30) during welding,

in particular for the formation of roughening or

Elevations (36). Friction friction welding method according to one of

preceding claims, wherein a pressing force (FN) of the welding pin (11) on the second abutting edge (31) is detected. 20.) friction stir welding according to one of

previous claims, wherein the height of a

Pressing force (FN) of the welding pin (11) against the second abutting edge (31) is controlled to a desired force. 21.) friction stir welding according to one of

The preceding claims, wherein the presence and optionally the strength of a contact between the welding pin (11) on the FSW tool (10) and the second abutting edge (31) are detected by sensors, in particular by a vibration sensor (63).

22.) friction stir welding according to one of

preceding claims, wherein the strength of a contact between the welding pin (11) and the FSW tool (10) is regulated to a desired contacting strength.

23.) friction stir welding according to one of

preceding claims, wherein the plasticized material (40, 140) in the recess (65, 165) is formed into a profiled seam overhang (144).

24.) friction stir welding according to one of

preceding claims, wherein the plasticized material (140) in the recess (165) is formed in accordance with the projection width (b) of the seam superelevation (144).

25.) Rührreibschweißverfahren according to one of

preceding claims, wherein the plasticized material (140) is formed in the recess (165) in accordance with the supernatant height (h) of the seam exaggeration (144).

26.) friction stir welding according to one of

preceding claims, wherein the recess (165) comprises an overflow portion (170) which is not or only partially filled with plasticized material (140), in particular depending on an excess of plasticized material (140).

27.) friction stir welding according to one of

preceding claims, wherein the plasticized material (140) in the recess (165) is formed into a tread (146) having a longitudinal waist (147).

Friction friction welding method according to one of

previous claims, wherein the

Solidification behavior of the plasticized material (140) in the area of the seam exaggeration (165) by controlled heat supply and / or heat dissipation

is regulated, in particular by actuation of a on or in the component receiving (161) arranged heating and / or cooling device (167). Friction friction welding method according to one of

preceding claims, wherein the seam overhang

(165), in particular on the

(common) contour line (HO) of the surfaces (125, 135) of the components (120, 130) or on a

Dividing line (T), which is in the range of

Längseinschnürung (147) of a profiled strand (146) formed seam superelevation (144) extends. Friction friction welding method according to one of

preceding claims, wherein in the course of

Weld (141) different

Cross-sectional profiles are provided for the seam superelevation (144), in particular different predetermined projecting height (h). Friction friction welding method according to one of

preceding claims, wherein the welding pin (11) of the FSW tool (10) has a friction or friction means arranged at the distal end of the welding pin (11)

Cutting contour (18), which in

Radial direction extends and over the lateral surface (17) of the welding pin (11) protrudes.

32.) friction stir welding according to one of

previous claims, wherein a at the distal end of the welding pin (11) of the FSW tool (10) arranged friction or cutting contour (18) during the welding operation with the FSW tool (10) facing away from outer surface (35) of the second

Component (30) is brought into contact there to an additional roughening or additional

To generate elevation (37), and in particular this additional roughening or the additional

Outline (37) to form a macro-mold closure (42b) with plasticized material (40, 140) is filled.

33.) Welding pin for use as a rotating

Welding pin in a friction stir welding tool (10) and / or in a friction stir welding process, wherein the welding pin (11) arranged at the distal end of the welding pin (11) friction or

Cutting contour (18), which in

Radial direction extends and over the lateral surface

(17) of the welding pin (11) protrudes.

34.) welding pin according to the preceding claim, wherein the welding pin (11) on the lateral surface (17) further annular or spirally arranged friction or cutting surfaces (15).

35.) Welding pin according to the preceding claim, wherein the welding pin (11) one, two or more longitudinal grooves (16) in the lateral surface (17). Welding pin according to the preceding claim, wherein the welding pin (11) has a longitudinal section through the axis of rotation concave outer contour (13).

37.) Friction Stir Welding Tool (FSW Tool) for

Use in a friction stir welding process according to one of the preceding claims, characterized

characterized in that the friction stir welding tool (10) has a rotatable welding pin (11), which according to one of the preceding

Claims is formed.

38.) friction stir welding tool after the preceding

Claim, wherein the friction stir welding tool (10) has a at the dorsal end of the welding pin (11) adjacent and outwardly projecting shoulder (12).

39.) friction stir welding tool according to one of

preceding claims, wherein the shoulder (12) has a concave shape.

40.) friction stir welding tool after the preceding

Claim, wherein the welding pin (11) has a conical

Has basic shape, the opening angle of the

Incident angle (AI) of Rührreibschweiß tool (10) to the first component (20) out corresponds.

41.) welded connection between a first component (20) and a second component (30), wherein the first component (20) made of a material having a first low melting temperature, in particular aluminum, and the second component (30) made of a material having a second and much higher

Melting temperature, in particular steel, consist, characterized in that the

Welded connection is produced by a friction stir welding method according to one of the preceding claims with a FSW tool (10), and in that on the second component there is a bumping edge (31), which by macro-positive connection (42a, 42b) in a weld (41 ) which is predominantly or completely formed from the plasticized material of the first component (20) or an additional material, but not from the material of the second component (30), and that the weld seam (41) forms the abutting edge (31). the second component (30) in cross-section on three sides (31, 33, 35) surrounds, and / or a partial region of an outer surface (35) of the second component (30) adjacent to the abutting edge (31), of the FSW tool

is remote, is embedded in the plasticized material (40) of the weld (41) by macro-positive connection (42 b).

42.) Welded connection according to one of the preceding

Claims, wherein on the side facing away from the FSW tool (10) outer surface (35) of the second

Component (30) a roughening or an elevation (37) is present, with the plasticized material of

Welded seam (41) is filled.

43.) Processing device for performing a

Friction stir welding process comprising a

Component holder (61), a manipulator (62) and guided by the manipulator (62) FSW tool

(10), wherein the component receptacle (61) thereto

is formed to receive the first component (20) and the second component (30) and to

positioning, characterized in that the processing device (61) comprises a controller (64) adapted to carry out a method according to any one of claims 1 to 32.

44.) Processing device according to the preceding

Claim, wherein on the component receptacle (61) has a recess (65) is provided on the of the

FSW tool (10) facing away from the components (20, 30) can be arranged under the butt joint.

Processing device according to one of

previous claims, wherein the

Processing device (60) a

Contacting sensor (63) includes to the

Presence and / or strength of one

Contacting between a welding pin (11) on the FSW tool (10) and a second abutting edge (31) on the second component (30) to detect, wherein the contacting sensor in particular with the

Control (64) is connected. Processing device according to one of

previous claims, wherein the

Processing device (60) and / or the

Manipulator (62) at least one force or

Moment sensor (66) to a contact pressure

(FN) of a welding pin (11) on the FSW tool (10) to a second abutting edge (31) of the second component (30) to detect. Processing device according to one of

preceding claims, wherein in the recess

(165, 165 \ 165 ^x \ 165,, ^x ) during a FSW welding operation plasticized material (140) is conveyable, and wherein the recess (165, 165 165 ^{, x} , 165,, ^'> ) is adapted to

introduced plasticized material (140) to a

Seam increase (144) with at least one defined supernatant height (h) or a defined

Protrusion width (b) to form.

48.) Processing device according to one of

preceding claims, wherein the recess

(165,, ^>'> ) is adapted to form the plasticized material (140) into a profile strand (146) having a longitudinal waist (147).

49.) Processing device according to one of

preceding claims, wherein the component receptacle (161) has a heating and / or cooling device (167) which is adapted to regulate a heat supply and / or heat dissipation in the region of the recess (165).

50.) processing device according to one of

previous claims, wherein the component receptacle (161) has a separating device (169) which is adapted to at least a part of the

Seam exaggeration (144) to separate, especially in the area of Längseinschnürung (147).