CN111432971A - 利用热喷涂层的多级接合工艺 - Google Patents
利用热喷涂层的多级接合工艺 Download PDFInfo
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Abstract
本发明提供了一种用于以搭接构造利用热接合工艺将彼此不可直接焊接的至少两种不可焊接材料接合的方法,其中使用两个步骤的顺序,包括在不可焊接材料的表面上施加热机械或机械表面保护层的第一步骤以及使用热接合工艺将喷涂层与施加层片材接合的第二步骤。
Description
本发明适用于所有现有技术不可焊接材料结合。在这种情况下,不可焊接材料结合被定义为以搭接构造布置的至少两种片材的异种材料结合,其中该材料中的至少一种材料必须是金属材料。将金属热喷涂层以明确限定的厚度、表面粗糙度和过渡电阻施加在不可焊接材料的表面上,此处该不可焊接材料为非金属材料或表现出焊接缺陷的金属材料。然后在第二步骤中,接着进行焊接工艺,其中仅将热喷涂金属层和金属材料之间的接触区域焊接在一起。
在材料工程的各个领域中,存在着如何在具有异种接合的多材料设计中使用不同材料的问题。现有技术没有可用的热焊接方法,只能使用粘结和机械接合。利用本发明,可以使用廉价且循环时间快的电阻点焊。
在下文中指出那些现有技术不可焊接异种材料结合中的一些材料结合以及如何利用本发明将它们焊接在一起的方式。
欧洲专利申请EP17157773.7涉及一种以搭接构造利用热接合工艺将彼此不可直接焊接的至少两种材料接合的方法,其中使用两个步骤的顺序,包括在(不锈)钢基底的表面上施加热机械或机械表面保护层的第一步骤以及使用热接合工艺将喷涂层与施加铝片焊接在一起的第二步骤,在整个材料构造中没有脆性金属间相。
德国专利申请102004025493和102004025492涉及用于接合部件的方法、接合元件和用于接合部件的部件。将两个或更多个接合部件、尤其是金属片材和/或塑料片材通过接合元件接合在一起。当接合该元件时,该元件可用作铆钉或螺栓。待接合的部件设置有开口,具体地,设置有可将接合元件***其中的孔。这些部件彼此定位,然后通过对接合元件进行钎焊来接合。有利的是,它可以用作传统的焊接或传统的焊枪,但是其中钎焊所需的热量输入比焊接低得多。
通过本发明,例如在建筑或设计应用中,可以将金属与玻璃或丙烯酸玻璃焊接在一起。为了实现这种金属热喷涂层,必须将金属施加在玻璃的后接触表面侧。理想地,但不是必须地,热喷涂层具有与金属材料相关的相似或接近相似的合金。然后在第二步骤中,可利用电弧焊接或电子束焊接工艺以搭接构造将金属材料与施加在金属热喷涂层上的玻璃焊接在一起。电阻焊工艺是不可能的,因为玻璃起到绝缘材料的作用。
当将金属材料与木材、塑料或纤维复合材料如玻璃纤维、碳纤维、芳族聚酰胺纤维、陶瓷纤维、天然纤维或钢纤维焊接在一起时,由如上所述的一系列步骤组成的相同类型的特征也成功地起作用。金属热喷涂层必须以喷涂元件和非金属表面的接触温度低于短期250℃、更优选低于190℃的方式施加在塑料或纤维复合材料(基质材料)的表面上。另一个优选的设计示例是将钢/聚合物复合结构(即夹层结构)与金属材料焊接。通常,聚合物或塑性材料的芯材厚度比薄金属外层厚得多。因此,在搭接构造中进行电弧或激光焊接工艺期间,存在微结构被破坏的问题,即该结构以及聚合物的特性因该现象将被破坏。利用本发明的工艺步骤,可以在夹层结构的金属外层上添加第一金属热喷涂层,其将在以下实际焊接过程中用作热缓冲,使得聚合物芯材料不会过热超过临界值。
利用本发明,不仅可以产生一种利用热喷涂层的多级接合工艺的可焊接性,该热喷涂层用于与跟非金属材料接合的金属材料结合。还可以解决针对焊接金属材料的现有技术问题,其中必须避免特定的温度范围,以免以不利的方式改变目标源的微结构。在下文指出这些特征中的一些。
可以避免易受热裂影响的材料(如奥氏体镍合金不锈钢或镍基合金)中的热裂纹。热裂被定义为在高温(高于1050℃)下,应变大小和应变率超过特定阈值时发生的材料偏析。通过在危险材料的表面(焊接接触方向)施加金属热喷涂层,可以影响危险材料区域的最终应变和应力(以及变形),并降低该区域的局部温度。热喷涂层必须是异种合金,不像锰合金奥氏体或铬合金铁素体钢那样容易热裂。危险金属不直接与接合伙伴焊接。接合仅发生在热喷涂层和接合伙伴之间。有热裂危险的材料/片材仅作为温度低于1000℃的热影响区。这适用于搭接构造中的所有焊接工序。
液体金属脆化是一个问题,其中液体金属渗入固体金属并因此出现晶间裂纹。该问题在如铝与镓的材料结合、可热成形的镀锌钢、不锈钢、奥氏体钢或与镀锌材料或硬钎焊材料焊接在一起的多相钢的文献中是熟知的。如果将非临界金属合金作为层来热喷涂在危险的固体金属的表面上,则锌或硬钎在焊接或硬钎焊期间不能作为液体金属渗透固体金属的表面和晶界。该工艺适用于搭接构造中的所有焊接工艺,如电弧焊、电子束焊或电阻焊以及硬钎焊。对于汽车结构应用,该该工艺可进一步与混合接合工艺结合。
混合接合工艺的特征在于以连续或同时的方式使用至少两个接合工序。此类混合接合工艺是点焊粘结,其中首先通过在处于搭接构造的两个片材之间施加未固化的粘合剂来产生第一粘结。然后在第二步骤中,进行电阻点焊,在现有粘合连接之外添加材料锁定连接。另一种类型的混合接合工艺是将粘结与机械接合(如压接、铆接或钉固)相结合。另外,可将两个热接合工艺结合为混合接合工艺:激光束焊接与GMAW工艺结合称为“GMAW-激光-混合”。例如,非临界金属合金是单相铁素体铬合金不锈钢,在与镀锌碳钢进行常规焊接之前,将其作为热喷涂层施加在奥氏体不锈钢上。
利用本发明的方法,也可能以积极的方式影响易碎金属如铁素体稳定的(Ti、Nb)不锈钢的热影响区中的晶粒生长。通常,熔融焊接期间基体材料的热影响区中的温度导致晶粒生长。由于较粗的晶粒导致较高的淬透性,热影响区的硬度显著增加,并表现出脆性、快速失效、较低的功率传输和较低的疲劳性能。
通过在此类危险金属的表面上热喷涂非危险金属合金,根据热喷涂层厚度的不同,较低的硬度可以增加直至完全避免硬度增加。此类较不易碎的金属层可为奥氏体不锈钢。
对于不稳定或未定义为ELC(超低碳)并因此易受晶间腐蚀(IC)影响的不锈钢,本发明可以使用热喷涂层来避免IC。利用稳定层,可以将未与接合伙伴直接焊接的IC危险基底材料的温度降低到350℃以下。因此,临界M23C6偏析不能以临界方式形成,因为必要的临界起始温度和时间将降低。未被稳定的铬合金钢如1.4016因此是可焊接的。1000℃以上的固溶退火以及随后的作为后处理的水淬火不再必要。此外,该热喷涂层像用于腐蚀介质的屏障一样起作用。该原理也可用于避免应力腐蚀开裂,使得例如,由于焊缝、热喷涂层的原因,必要的腐蚀介质不会侵蚀受力区域中的基体材料。
利用本发明的方法,还可以避免碳含量大于0.2%C的可硬化高碳合金钢、马氏体钢和不锈钢的冷裂纹危险。利用热喷涂层,可硬化的基材仅作为T<700℃的低温热影响区受影响。还可避免延迟的氢影响的冷裂纹。可以以相同的方式降低双相不锈钢的475℃脆化。
综合本发明的方法,可以在搭接构造中避免舍弗勒图指出的不同危险。
利用本发明的方法,还可以避免搭接构造中的焊缝不规则性或内部缺陷,如气孔、(收缩)空腔、缺乏熔合或冶金引起的微裂纹。一个示例是在对航空航天应用进行焊接过程中镁对气孔的危害。通过使用另一种金属合金或钎焊材料,可在没有不期望的气孔率的情况下实现搭接。使搭接能够适于航空航天应用的另一种可能是利用活性气体焊接钛。现有技术在焊接期间,钛与活性气体(CO2、O2)接触后会发生脆化。在用非钛金属或钎焊材料制造的钛基体材料上施加热喷涂层将解决这个问题。
对于具有异种材料的搭接构造中的腐蚀应力应用也有益处,尤其是当该异种材料的电化学电位差非常高时,例如在湿蚀环境中用于底盘汽车应用的与铝结合的不锈钢。不锈钢作为一种惰性显著更强的材料(>标准电位值E0的差0,8V)将会错误地使用铝作为牺牲阳极。这种腐蚀机制被称为接触腐蚀、电偶腐蚀或双金属腐蚀。在搭接构造期间出现间隙的情况下,缝隙腐蚀进一步加剧负面影响,因为离子(例如氯根离子)浓度增加,氧气浓度降低。在整个间隙周围使用类似的材料会显著降低腐蚀影响。在所述情况下,不锈钢合金可以作为热喷涂层施加在铝片上,以使间隙周围只有不锈钢合金。此外,越不光彩的材料应该有更大的面积来减缓接触腐蚀的影响。因此,在较大铝片的表面上结合较薄的热喷涂不锈钢合金是有意义的。
此外,当然可以使用本发明的方法,通过使焊缝或熔核与正确选择的热喷涂层有针对性地合金化来改善已建立和工作中的焊接应用的焊缝或焊点熔核质量。给出了用于汽车构造的电阻点焊的一些示例。三片材式结合已经很成熟,但是这种应用对其来说很有挑战性。这是由于物理特性(例如热传导)而引起的,这对于利用现有两个连接层将所有三个片材连接在一起至关重要,尤其是如果第一片材是较厚的奥氏体钢,中间片材是铁素体钢,第三片材也是铁素体钢,但很薄,适合外皮使用。由于三个片材的厚度比和奥氏体钢保护热量的情况,在焊接在奥氏体熔核区域中产生的飞溅物之前,只能部分地连接非常薄、处于铁素体构造的第三片材。现在,利用本发明,可以在薄的低合金铁素体钢上施加奥氏体不锈钢CrNi合金层,因此也可以在正式的两种铁素体钢区域内重新定位焊接熔核,如图1所示。
综上所述,具有两个步骤顺序的本发明的方法的总体目标是将不可焊接的材料因此降至临界温度以下。通过使该目标可获得,热喷涂层或者更确切地说,从热喷涂层内的焊接端到热喷涂层与不可焊接材料的接触区域的距离(称为层距离I),起到类似于降低特定临界温度的热降低因子的作用。因此,如前文所述,临界温度被定义为不存在焊接性的材料相关值。为了设计右层距离I,可通过使用式(1)来计算。
I=(A*λ*ΔT)/Q (1)
因此,λ是热喷涂层的热导率[W/(m*K)],Q是在第二步骤中通过焊接引入的热流[W],A是焊接面积[mm2]。对于焊缝焊接工艺,可以用式(2)来定义
A=W*L (2)
其中W为焊接宽度[mm],L为焊缝的长度[mm]。对于电阻点焊等点状焊接工艺,A可由式(3)来计算
A=Pi*r2 (3)
其中r为半径[mm]。
在式(1)中,ΔT更多地由式(4)定义为本发明的方法
ΔT=T熔融-T失效 (4)
其中T熔融是焊接[K]过程中熔池的熔点温度,而T失效是焊接失效开始时的不可焊接基底材料的临界温度。因此,计算的距离I必须大于或等于临界距离IC:
I≥IC (5)
可以用“每单位焊接长度的能量”E乘以热效率η来计算缝焊工艺的热流:
Q=E*η=(U*I*η)/v (6)
其中,U是焊接电压[V],I是焊接电流[A],V是使用的焊接速度[mm/min]。
对于电阻点焊工艺,可以使用式(7)
Q=QI-QL=(I2*R*Δt)-(QLC+QLS+QLR) (7)
其中,QA是由焊接电流I[A]、电阻总和R[μΩ]、焊接时间Δt[ms],以及热损失QL定义的引入热量,其中热损失QL是由铜电极QLC、片材QLS和辐射损失QLR引起的损耗所定义的热损耗。
下面参照附图详细描述本发明,其中
图1示出了如在本发明的现有技术中所描述的,其中前沿技术位于左侧,本发明的方法示出在右侧,
图2示出了如本发明现有技术中所述的舍弗勒图(Schaeffler)的关系,其提供了关于各种类型的微结构的焊接性能的信息,
图3示出了影响参数,
图4从侧视图示意性地示出了具有本发明的铝平片的电阻点焊热喷涂铝层的另一个优选实施方案,其中示出了另一个铝平片的焊接热喷涂层/不锈钢。
当然,本发明的方法还可以用于两个片材的结合,并改善它们在不同载荷方向下的准静态以及动态或弹道动力传递,特别是可以显著改善疲劳以及断裂现象。同样,作为示例,铁素体(或多相铁素体)钢上的奥氏体热喷涂层,应通过电阻点焊与另一种低合金钢焊接。由于奥氏体热喷涂层,产生的焊接熔核也将受到奥氏体的影响,其结果是更具延展性的断裂现象,如在疲劳过程中硬度更低、水平更高的栓塞断裂。一般来说,利用根据舍弗勒的图表,可以通过使用热喷涂层以适合应用要求的方式来影响最终的焊缝或熔核。在图2中,舍弗勒的图表提供了关于各种类型的微观结构的焊接性能的信息,因此作为它们所包含的合金元素的函数。舍弗勒图表还根据焊接问题进行分类,具有不同的热裂纹、冷裂纹、晶粒成长和脆化区域。在图2中示出了现有技术和利用本发明方法的此类构造。
此外,本发明的方法中还使用的材料是碳当量(CEV)大于0.65%的钢,其中,CEV使用式(8)计算(元素含量以重量%计):
CEV=C+Mn/6+(Cu+Ni)/15+(Cr+Mo+V)/5。 (8)
与基体材料、脆化、冷裂纹和临界断裂现象相比,利用特征在于低碳(LC,C≤0.25%)或更优选地极低碳含量(ELC,C≤0.03%)和韧性奥氏体合金的热喷涂层,可以避免临界硬度增加超过50HV。
对于金属与非金属(玻璃,木材)的结合,可以使用螺钉或螺栓连接以及粘接,但不能进行热接合。
对于金属与金属的结合:还可以进行粘合,机械接合(铆接、压接),对于某些金属(铝、镁)则采用摩擦搅拌焊接,但仅在对接状态下进行。
相反,如果使用/建立的焊接方法不适用于该材料,则不使用该材料。一个示例:我们的可压硬化马氏体等级,如1.4034,可在1850MPa以上进行硬化,适用于结构车身部件,但不可焊接。因此,原始设备制造商未使用1.4034。
本发明的想法是通过以明确限定的厚度、表面粗糙度和过渡电阻在不可焊接的材料的表面上施加热喷涂层使不可焊接的材料结合,如非金属(玻璃、木材、碳纤维、塑料)或金属(铜、镁、钛)与(不锈)钢或一般不可焊接的材料如高碳合金化(不锈)钢,变得可焊接。然后在第二步中,接着进行电阻焊接、电弧焊接或电子束焊接。所用的焊接参数必须选择成只有热喷涂层与可焊接材料之间的接触区域熔化,而在不可焊接材料中避免不可避免的焊接影响现象。
点焊的典型层厚度大于或等于15μm。图1示出了影响参数:不可焊接材料(1)具有取决于特定的材料/合金的临界温度TC,不得超过该温度。然后(1)施加热喷涂层(2),其中(2)对于相应的材料结合和应用具有特定的合适的热导率λ2,其影响从焊缝/熔核到不可焊接基体材料(1)的热传递。现在使用焊接方法(4)或(5)将(1)+(2)与第二材料(本文称为可焊接材料(3))焊接在一起,由此焊缝/熔核仅位于(3)和(2)及其接触表面/区域中,而不在(3)中。相应的焊接方法将特定的焊接温度TW引入到材料结合中。因此,焊缝/熔核在(4)/(5)和(1)之间有一个限定的距离,称为tW。
利用该信息,可以定义以下关系,由此T实际是通过本发明引入(1)的温度:
TC≥T实际(TW,tW,λ2) (9)
根据本发明,基材表面(1)可以通过清洗或脱脂、喷砂或喷丸处理进行预处理。在这种情况下,用于喷砂或喷丸的喷砂磨料也可以由刚玉、钢丝、碳化硅和硬铸造砾石或玻璃珠组成。图4显示了三层具有不同厚度情况下的各层。
关于本发明的热机械涂覆方法可以包括火焰喷涂、电弧喷涂、等离子喷涂、激光喷涂、冷气喷涂、***喷涂、高速氧气燃料喷涂或熔池喷涂。在喷涂过程中,材料或喷涂消耗品以线、棒、条、绳、粉末或熔池的形式供应。
下面参照附图更详细地描述本发明,其中
图1从侧视图示意性地示出了两个步骤的顺序的一个优选实施方案,其中在第一步骤期间,热机械或机械表面保护层(2)被施加在不可焊接材料(1)的表面上。在接下来的第二步骤中,使用热接合工艺,通过使用电阻焊接方法将喷涂层(2)与作为焊接熔核或焊缝(4)的施加层片材(3)接合,或者通过使用电子束焊方法(5)与焊缝(5)接合。例如,热喷涂层(2)的厚度与点焊(4)的直径所达到的比率小于或等于0.25mm。
图2示出了舍弗勒图表,其为合金钢的奥氏体和铁素体形成体关系的理论背景。对于一个具体的示例,球内的数字代表所使用的不可焊接材料(1)、热机械或机械表面保护层(2)和施加层片材(3)的位置。虚线指出了它们之间的关系,其中黑球显示了最终的焊接结构。可以看出,由于具有热机械或机械表面保护层(2),对不可焊接材料(1)和施加层片材(3)的焊接现在处于舍弗勒图表的临界区域。
图3示出了与前沿技术工艺(图3中的左图)相比的两个步骤的顺序的另一个优选实施方案(图3的右图),其示意性地从侧视图中示出了利用电阻点焊方法焊接不可焊接的三片材的构造。对于所谓的黑白结合,其中薄的铁素体钢板,例如作为外层部件,必须在中间应用另一个较厚的片材,在另一个外侧应用具有奥氏体微观结构的最厚的片材,由于不同的物理性质(左侧),前沿技术不可能将薄的铁素体片材连接其他片材上。在该实施方案中,薄铁素体片材是不可焊接材料(1)。在本发明的两个步骤的顺序的第一步骤中,热机械或机械表面保护层(2)被施加在不可焊接材料(1)的表面上。在这种情况下,该第二步骤由传统的电阻点焊代表。在该第二步骤中,现在也可以通过在中间添加焊接熔核(4)来将中间片材连接到喷涂层(2),在这种情况下,中间片材代表施加层片材(3)。上部厚奥氏体片材和中部片材之间的焊接熔核(5)将照常进行。包括基材(1)、热喷涂层(2)、施加片材(3)的总片材厚度的示例可以达到1.5mm至6.0mm之间的值。
图4从侧视图示意性地示出了两个步骤的顺序的另一个优选实施方案,其中热机械或机械表面保护层(2)仅用于在两步顺序的第二步骤期间施加后续电阻点焊(4)的区域。热机械或机械表面保护层(2)的这种定位使用一方面增加了经济效率,另一方面保护层(2)增加了对搭接构造的间隙内的缝隙腐蚀的抵抗力。作为示例,热喷涂层(2)的厚度可以具有从0.25mm到1.5mm的值。
Claims (12)
1.一种用于以搭接构造利用热接合工艺将彼此不可直接焊接的至少两种不可焊接材料接合的方法,其特征在于,使用两个步骤的顺序,包括在不可焊接材料(1)的表面上施加热机械或机械表面保护层的第一步骤以及使用热接合工艺将所述喷涂层(2)与施加层片材(3)接合的第二步骤。
2.根据权利要求1所述的方法,其特征在于,所述表面保护层是通过热喷涂方法实施的。
3.根据前述权利要求1-2中任一项所述的方法,其特征在于,所述热喷涂层(2)是基于金属的合金或者金属与碳化物的结合。
4.根据前述权利要求1-3中任一项所述的方法,其特征在于,所述热喷涂层(2)通过像粘合焊接、点焊、凸焊或滚缝焊接之类的电阻焊接方法与所述施加片材(3)焊接在一起。
5.根据前述权利要求1-4中任一项所述的方法,其特征在于,所述热喷涂层(2)的厚度与达到的点焊(4)直径之比小于或等于0.25mm。
6.根据前述权利要求1-5中任一项所述的方法,其特征在于,包括基材(1)、热喷涂层(2)、施加片材(3)的总片材厚度介于1.5mm至6.0mm之间。
7.根据前述权利要求1-6中任一项所述的方法,其特征在于,所述热喷涂层(2)的厚度为0.25mm至1.5mm。
8.根据前述权利要求1-7中任一项所述的方法,其特征在于,通过清洁和喷砂对所述基材(1)表面进行预处理。
9.根据前述权利要求1-8中任一项所述的方法,其特征在于,所述层(2)具有与金属材料相关的类似合金。
10.根据前述权利要求1-9中任一项所述的方法,其特征在于,所述混合接合工艺是粘接和机械接合的组合。
11.根据前述权利要求1-10中任一项所述的方法,其特征在于,所述热喷涂层像用于腐蚀介质的屏障一样起作用。
12.以搭接构造利用热接合工艺的至少两种彼此不可直接焊接的不可焊接材料的用途,其特征在于,使用两个步骤的顺序,包括在不可焊接材料(1)的表面上施加热机械或机械表面保护层的第一步骤以及使用热接合工艺将所述喷涂层(2)与施加层片材(3)接合的第二步骤。
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