JP2006055898A - Resistance spot welding method - Google Patents
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本発明は、重ね抵抗溶接法の一種である抵抗スポット溶接法に係り、詳しくは、複数枚の薄肉の金属板(被溶接材)を重ね合わせた板組み、とくに板厚比(=総厚/一番薄い板の板厚)の大きな板組みを抵抗スポット溶接法により、散りの発生なく所望サイズのナゲットを形成する、抵抗スポット溶接方法に関する。 The present invention relates to a resistance spot welding method which is a kind of lap resistance welding method, and more specifically, a plate assembly in which a plurality of thin metal plates (materials to be welded) are stacked, particularly a plate thickness ratio (= total thickness / The present invention relates to a resistance spot welding method in which a nugget of a desired size is formed by a resistance spot welding method using a plate assembly having the largest thickness (thickness of the thinnest plate) without occurrence of scattering.
一般に、重ね合わせられた金属板同士の接合には、重ね抵抗溶接法の一種である抵抗スポット溶接法が用いられている。例えば、自動車の製造にあたっては1台あたり数千点ものスポット溶接がなされている。この溶接法は、2枚以上の金属板を重ね合わせ、その表面を直接、上下の電極で挟み加圧力を加えながら、上下電極間に大電流の溶接電流を短時間流して接合する方法である。大電流の溶接電流を流すことで発生する抵抗発熱を利用して、円形状の溶接部が得られる。この円形状の溶接部は、ナゲットと呼ばれ、両金属板に電流を流した際に両金属板の接触個所で両金属板が溶融し、凝固した部分であり、これにより両金属板が円形状に接合される。 In general, a resistance spot welding method, which is a kind of a lap resistance welding method, is used to join metal plates that are overlapped with each other. For example, in the manufacture of automobiles, several thousand spots are welded per vehicle. This welding method is a method in which two or more metal plates are overlapped, and the surface is directly sandwiched between the upper and lower electrodes and a large current is applied between the upper and lower electrodes for a short time to join them. . A circular weld is obtained by utilizing resistance heat generated by passing a large welding current. This circular weld is called a nugget and is the part where both metal plates melt and solidify at the contact points of both metal plates when current is passed through both metal plates. Joined in shape.
抵抗スポット溶接部の接合強度は、ナゲット径により左右されるため、自動車部品等の高い接合強度を必要とする場合にはとくに、所定の径以上のナゲット径を確保することが重要となってくる。一般に、加圧力、通電時間を一定とした場合には、ナゲット径は、溶接電流の増加にしたがって徐々に増加するが、ある値以上になると金属板間、あるいは金属板と電極との間から、溶融金属が飛散する散りという現象が生じる。なお、散りを、金属板間から溶融金属が飛散する場合を「中散り」、金属板と電極との間から溶融金属が飛散する場合を「表散り」として区別することもある。散りの発生は、危険であるうえ、溶接部周辺に散りが付着し外観を悪化させ、ナゲット径や継手引張強度にばらつきを生じさせたり、継手部の品質が不安定になる。 Since the joint strength of resistance spot welds depends on the nugget diameter, it is important to ensure a nugget diameter of a predetermined diameter or greater, especially when high joint strength is required for automobile parts and the like. . In general, when the applied pressure and energizing time are constant, the nugget diameter gradually increases as the welding current increases, but when it exceeds a certain value, from between the metal plates or between the metal plate and the electrode, A phenomenon of scattering of molten metal occurs. In addition, the case where the molten metal scatters from between the metal plates may be distinguished as “medium scatter”, and the case where the molten metal scatters between the metal plate and the electrode may be distinguished as “surface scatter”. The occurrence of scattering is dangerous, and scattering adheres to the periphery of the weld and deteriorates the appearance, causing variations in the nugget diameter and joint tensile strength, and the quality of the joint becomes unstable.
このような問題に対し、例えば、特許文献1には、棒状電極間に、2枚以上の薄鋼板を任意の圧力で挟持し一回以上の散りを発生する電流を印加通電する前期通電を行った後、任意の冷却時間を与え、引き続き、散りを発生しない電流を用いて後期通電する薄鋼板重ね抵抗点溶接方法が提案されている。特許文献1に記載された技術では、散り発生を容認し、生成した空洞を後期通電時に圧縮縮小させるとしているが、前記の散り発生による問題点は残されたままである。 In order to deal with such a problem, for example, in Patent Literature 1, two or more thin steel plates are sandwiched between rod-shaped electrodes at an arbitrary pressure, and the previous energization is performed to apply a current that causes one or more scatterings. After that, a thin steel sheet lap resistance spot welding method has been proposed in which an arbitrary cooling time is given and subsequently energized late using a current that does not cause scattering. The technique described in Patent Document 1 accepts the occurrence of scattering and compresses and shrinks the generated cavity during the latter energization, but the problems due to the occurrence of scattering remain.
また、特許文献2には、溶接部外周部にのみナゲットが存在するドーナツ状ナゲットの発生を防止する抵抗スポット溶接方法が提案されている。特許文献2に記載された技術は、溶接後の溶接部最小板厚が、重ね合わされた鋼板の全体板厚の80%を下回らないように加圧力および通電量(溶接電流値×通電時間)を調節して抵抗スポット溶接を行うというものである。しかし、特許文献2に記載された技術によってもなお、散り発生による問題点は残されたままである。
また、近年、自動車車体の衝突安全性の向上という要求の高まりから、例えば、車体を構成する、パネルとメンバーとの間にリインフォースメントを挟み込んだ構造が採用されるようになっている。この構造では、従来の単純な二枚重ねの鋼板をスポット溶接する場合と異なり、3枚以上の鋼板を重ね合わせてスポット溶接することが要求される。さらに、最近では、車体の衝突安全性の更なる向上要求にともない、リインフォースメントなどの高強度化、厚肉化が進み、外側に板厚の薄いパネル(薄金属板)を配置し、内側に板厚の厚いメンバー、リインフォースメント(厚金属板)を組み合わせた板組みをスポット溶接することが必要となる場合が多い。なお、ここで、薄金属板とは、板組みされた金属板のうち,肉厚が相対的に小さいものをいい、厚金属板とは、肉厚の相対的に大きいものをいう。以下、薄金属板を薄板、厚金属板を厚板と略記する。なお、薄板は、重ね合わせた板組みの中で最も薄い金属板を指し、厚板はそれ以外の金属板を指すものとする。
このような板厚比(=総厚(A)/一番薄い板の板厚(B))の大きな板組みにおいて、従来のような加圧力、溶接電流を一定値としたままにするスポット溶接を行なった場合には、一番外側の薄板と厚板との間に必要なサイズのナゲットが形成されにくいことが知られている。とくに、板厚比が5を超えるような板組みでは、この傾向が強い。
Further, in recent years, due to an increasing demand for improving the collision safety of an automobile body, for example, a structure in which reinforcement is sandwiched between a panel and a member constituting the vehicle body has been adopted. In this structure, unlike the conventional simple two-ply steel plate spot-welded, it is required that three or more steel plates be superposed and spot-welded. Furthermore, recently, with the demand for further improvement in the collision safety of the car body, reinforcement and other strength have been increased, and a thin panel (thin metal plate) has been placed on the outside. In many cases, it is necessary to spot-weld a plate assembly in which thick members and reinforcements (thick metal plates) are combined. Here, the thin metal plate refers to a plate with a relatively small thickness among the assembled metal plates, and the thick metal plate refers to a plate with a relatively large thickness. Hereinafter, a thin metal plate is abbreviated as a thin plate, and a thick metal plate is abbreviated as a thick plate. Note that the thin plate refers to the thinnest metal plate in the stacked plate assembly, and the thick plate refers to the other metal plate.
Spot welding that keeps the applied pressure and welding current at a constant value in a plate assembly having such a large thickness ratio (= total thickness (A) / thickness of the thinnest plate (B)). Is known, it is difficult to form a nugget of a necessary size between the outermost thin plate and the thick plate. In particular, this tendency is strong in the plate assembly in which the plate thickness ratio exceeds 5.
これは、電極チップによる冷却によって一番外側の薄板と厚板の間では温度が上がりにくいことが原因である。ナゲットは、電極間の中央付近から材料の固有抵抗により体積抵抗発熱にて形成されるが、ナゲットが一番外側の薄板と厚板の間にまで成長するまでに、電極間中央部に近い部分に位置する厚板と厚板間でのナゲットの成長が大きく、電極による加圧では抑えきれずに散りが発生するため、散り発生なく必要なサイズのナゲットを薄板・厚板間に得ることが困難となる。 This is because the temperature hardly rises between the outermost thin plate and the thick plate due to cooling by the electrode tip. The nugget is formed by volume resistance heat generation due to the specific resistance of the material from the center between the electrodes, but it is located near the center between the electrodes until the nugget grows between the outermost thin plate and the thick plate. Nugget growth between the thick plate and the thick plate is large, and it is difficult to obtain a nugget of the required size between the thin plate and the thick plate without the occurrence of splattering, because scattering occurs without being suppressed by pressing with the electrode Become.
また、一番外側に配置される薄板がパネルの場合には、強度よりも成形性が重要となるため、使用される材料は軟鋼となることが多い。一方、厚板は強度補強部材であり高張力鋼板が使用される場合が多い。このような板組みでは、発熱する位置は、固有抵抗の高い高張力鋼板側に偏るため、厚板−薄板(軟鋼)間にはさらにナゲットが形成されにくくなる。また、使用される金属板がめっき鋼板となると、低温で溶融しためっき層が鋼板間の通電経路を拡大するため電流密度が減少し、薄板側でのナゲットの形成がさらに困難となる。 When the outermost thin plate is a panel, formability is more important than strength, so the material used is often mild steel. On the other hand, the thick plate is a strength reinforcing member, and a high-tensile steel plate is often used. In such a plate assembly, the position where heat is generated is biased toward the high-tensile steel plate having a high specific resistance, so that nuggets are more difficult to be formed between the thick plate and the thin plate (mild steel). In addition, when the metal plate used is a plated steel plate, the plating layer melted at a low temperature expands the current-carrying path between the steel plates, thereby reducing the current density and making it more difficult to form a nugget on the thin plate side.
このような問題に際し、例えば、特許文献3には、重ね合わされた2枚の厚板の少なくとも一方に薄板をさらに重ね合わせた板厚比の大きな板組みをスポット溶接する方法が提案されている。特許文献3に記載された技術は、薄板の溶接すべき部位に部分的に一般部より一段高い座面を形成するとともに、薄板に対抗する電極を、先端を球面に形成し、溶接初期は低加圧力で、薄板の座面を押しつぶすようにして、薄板とこれと隣り合う厚板とを溶接し、その後、高加圧力で2枚の厚板同士を溶接するスポット溶接方法である。この技術によれば、散りを発生することなく、薄板−厚板間にも必要サイズのナゲットを形成できるとしている。しかし、特許文献3に記載された技術では、薄板−厚板間に必要サイズのナゲットを形成することはできるが、薄板の溶接する部分に予め一般部より一段高い座面をプレスなどで形成する工程が必要となり、工程が複雑になり、生産性が低下するという問題がある。 In order to deal with such a problem, for example, Patent Document 3 proposes a method of spot welding a plate assembly having a large plate thickness ratio in which a thin plate is further overlapped on at least one of two stacked thick plates. The technique described in Patent Document 3 forms a seat surface that is one step higher than the general part at the portion to be welded of the thin plate, and forms an electrode that opposes the thin plate with a spherical tip at the initial stage of welding. This is a spot welding method in which a thin plate and an adjacent thick plate are welded so as to crush the seating surface of the thin plate with a pressing force, and then the two thick plates are welded with a high pressing force. According to this technique, a nugget of a necessary size can be formed between a thin plate and a thick plate without causing scattering. However, in the technique described in Patent Document 3, a nugget of a necessary size can be formed between a thin plate and a thick plate, but a seat surface that is one step higher than a general portion is formed in advance on a portion to be welded by a press or the like. There is a problem that a process is required, the process becomes complicated, and productivity is lowered.
また、特許文献4には、剛性の高い2枚の厚板の上に剛性の低い薄板を重ね合わせた板組みを、一対の電極チップにより挟んでスポット溶接する際に、剛性が最も小さい薄板に当接する電極チップの先端径を、厚板と当接する電極チップの先端径よりも小さくし、薄板と電極チップとの接触面積が、厚板と電極の接触面積よりも小さくなるようにして、薄板−厚板間にもナゲットを得る方法が開示されている。
しかし、特許文献4に記載された技術では、剛性が最も小さい薄板に当接する電極チップの先端径を小さくしているため、剛性の高い2枚の厚板間で十分なサイズのナゲットを散りを発生することなく得ることが困難で、板厚比が大きい板組みの場合には効果が少ないという問題がある。 However, in the technique described in Patent Document 4, since the tip diameter of the electrode tip that contacts the thin plate having the smallest rigidity is reduced, a sufficiently large nugget is scattered between the two thick plates having high rigidity. There is a problem that it is difficult to obtain without occurrence and is less effective in the case of a plate assembly having a large plate thickness ratio.
本発明は、上記した従来技術の問題点を有利に解決し、板厚比の大きな板組みにおいても必要サイズのナゲットを散り発生なく形成できる、抵抗スポット溶接方法および抵抗スポット溶接継手の製造方法を提案することを目的とする。また、本発明は、板厚比の大きな構造を有する自動車車体を製造するに当たり、抵抗スポット溶接法を用いて、必要サイズのナゲットを散り発生なく形成し板厚比の大きな構造とすることができる、自動車車体の製造方法を提案することを目的とする。 The present invention provides a resistance spot welding method and a resistance spot welded joint manufacturing method that can advantageously solve the above-described problems of the prior art and can form a nugget of a required size without being scattered even in a plate assembly having a large thickness ratio. The purpose is to propose. In addition, when manufacturing an automobile body having a structure with a large plate thickness ratio, the present invention can form a nugget of a necessary size without scattering by using a resistance spot welding method, thereby providing a structure with a large plate thickness ratio. An object of the present invention is to propose a method for manufacturing an automobile body.
本発明者らは、上記した課題を達成するため、抵抗スポット溶接におけるナゲット形成に及ぼす各種要因について鋭意検討した。その結果、重ね合わせた2枚以上の厚板の一方に薄板を重ね合わせた板厚比の大きい板組みを一対の電極チップで挟み、抵抗スポット溶接により溶接接合するに際し、薄板とそれと隣り合う厚板との間、および厚板−厚板間ともに必要なサイズのナゲットを形成するには、溶接初期に金属板間の接触抵抗発熱を有効に活用することが必要であり、そのためには、溶接の初期には低加圧力で高い電流を短時間で流すことが有効であることを知見した。 In order to achieve the above-described problems, the present inventors diligently studied various factors affecting nugget formation in resistance spot welding. As a result, when a plate assembly having a large plate thickness ratio is sandwiched between a pair of electrode tips and is joined by resistance spot welding, a thin plate and a thickness adjacent to it are stacked. In order to form a nugget of the required size between the plates and between the thick plate and the thick plate, it is necessary to effectively utilize the contact resistance heat generation between the metal plates at the initial stage of welding. It was found that it is effective to flow a high current in a short period of time with a low applied pressure in the early stage.
さらに、使用する電極チップのうち、薄板側の電極チップの先端形状を所定曲率半径を有する曲面とし、厚板側の電極チップの先端形状を薄板側電極チップの先端曲面より大きな曲率半径を有する曲面または平面とし、溶接の初期に加圧力を低くすることにより、薄板のたわみが小さく厚板側での表散りの発生が防止でき、また、電極チップと薄板の接触面積が小さく制限され、薄板−厚板間の電流密度が高くなり、溶接初期に金属板間の接触抵抗発熱を有効に活用することができて薄板−厚板間に所望サイズのナゲットを形成できることを知見した。 Further, among the electrode tips to be used, the tip shape of the electrode tip on the thin plate side is a curved surface having a predetermined radius of curvature, and the tip shape of the electrode tip on the thick plate side is a curved surface having a larger radius of curvature than the tip curved surface of the thin plate side electrode tip. Alternatively, by using a flat surface and reducing the applied pressure at the initial stage of welding, the thin plate can be prevented from bending and the occurrence of surface scattering on the thick plate side can be prevented, and the contact area between the electrode tip and the thin plate is limited to a small size. It has been found that the current density between the thick plates is increased, the contact resistance heat generation between the metal plates can be effectively utilized at the initial stage of welding, and a nugget of a desired size can be formed between the thin plate and the thick plate.
また上記したような電極チップを使用しさらに、溶接途中で加圧力を増大させることにより、薄板側の電極チップにより加圧力を加えられる範囲が増大して、薄板−厚板間、厚板−厚板間のいずれにも中散りの発生が抑制され、厚板−厚板間にも必要な径を持つナゲットを形成することも可能になることを知見した。 Further, by using the electrode tip as described above and further increasing the pressing force during welding, the range in which the pressing force can be applied by the electrode tip on the thin plate side increases, and between the thin plate and the thick plate, between the thick plate and the thick plate It has been found that the occurrence of scattering is suppressed in any of the plates, and it becomes possible to form a nugget having a necessary diameter between the thick plates.
本発明は、上記した知見に基づき、さらに検討を加えて完成されたものである。すなわち、本発明の要旨は以下のとおりである。
(1)重ね合わせた2枚以上の厚金属板の一方に薄金属板を重ね合わせた板組みを一対の電極チップで挟み、抵抗スポット溶接により溶接接合するにあたり、前記一対の電極チップのうちの一方の、前記薄金属板に接する電極チップを先端が所定の曲率半径R1を有する曲面である電極チップとし、他方の前記厚金属板に接する電極チップを先端が平面又は前記薄金属板に接する電極チップの先端の曲率半径R1より大きな曲率半径を有する曲面である電極チップとし、前記抵抗スポット溶接を第一段および第二段の二段階からなる溶接とし、該第二段の溶接が前記第一段の溶接に比べ高加圧力の溶接とすることを特徴とする、抵抗スポット溶接方法。
(2)重ね合わせた2枚以上の厚金属板の一方に薄金属板を重ね合わせた板組みを一対の電極チップで挟み、抵抗スポット溶接により溶接接合し抵抗スポット溶接継手を製造するにあたり、前記一対の電極チップのうちの一方の、前記薄金属板に接する電極チップを先端が所定の曲率半径R1を有する曲面である電極チップとし、他方の前記厚金属板に接する電極チップを先端が平面又は前記薄金属板に接する電極チップの先端の曲率半径R1より大きな曲率半径を有する曲面である電極チップとし、前記抵抗スポット溶接を第一段および第二段の二段階からなる溶接とし、該第二段の溶接が前記第一段の溶接に比べ高加圧力の溶接とすることを特徴とする、抵抗スポット溶接継手の製造方法。
(3)厚金属板であるメンバーと薄金属板であるパネルとの間に厚金属板であるリインフォースメントを挟む構造を有する自動車車体を製造するにあたり、前記メンバーと前記リインフォースメントを重ね合わせ、さらに該メンバー又は該リインフォースメント側に前記パネルを重ね合わせた板組みとし、該板組みを、前記パネルに接する電極チップを先端が所定の曲率半径R1を有する曲面である電極チップとし、前記メンバー又は該リインフォースメントに接する電極チップを先端が平面又は前記パネルに接する電極チップの先端の曲率半径R1より大きな曲率半径を有する曲面である電極チップとする、一対の電極チップで挟み、第一段および第二段の二段階からなり、該第二段の溶接が該第一段の溶接に比べ高加圧力の溶接とする抵抗スポット溶接により溶接接合して、前記構造とすることを特徴とする自動車車体の製造方法。
The present invention has been completed based on the above findings and further studies. That is, the gist of the present invention is as follows.
(1) When a plate assembly in which a thin metal plate is superposed on one of two or more superposed thick metal plates is sandwiched between a pair of electrode tips and welded by resistance spot welding, One electrode tip in contact with the thin metal plate is an electrode tip whose tip is a curved surface having a predetermined radius of curvature R1, and the other electrode tip in contact with the thick metal plate is a flat tip or an electrode in contact with the thin metal plate. The electrode tip is a curved surface having a radius of curvature larger than the radius of curvature R1 at the tip of the tip, and the resistance spot welding is a two-stage welding of the first stage and the second stage, and the second stage welding is the first stage. A resistance spot welding method characterized by high pressure welding compared to step welding.
(2) In manufacturing a resistance spot welded joint by sandwiching a plate assembly in which a thin metal plate is overlapped with one of two or more stacked thick metal plates between a pair of electrode tips and welding by resistance spot welding, One of the pair of electrode tips is an electrode tip that is in contact with the thin metal plate, and the tip of the electrode tip is a curved surface having a predetermined radius of curvature R1, and the other electrode tip that is in contact with the thick metal plate is flat or The electrode tip is a curved surface having a radius of curvature larger than the radius of curvature R1 of the tip of the electrode tip in contact with the thin metal plate, and the resistance spot welding is a welding consisting of two stages of a first stage and a second stage, A method of manufacturing a resistance spot welded joint, wherein the step welding is a welding with a higher pressurization than the first step welding.
(3) In manufacturing an automobile body having a structure in which a reinforcement which is a thick metal plate is sandwiched between a member which is a thick metal plate and a panel which is a thin metal plate, the member and the reinforcement are overlapped, A plate assembly in which the panel is overlapped on the member or the reinforcement side, and the plate assembly is an electrode chip whose tip is a curved surface having a predetermined radius of curvature R1 as an electrode tip in contact with the panel. The electrode chip contacting the reinforcement is sandwiched between a pair of electrode chips, and the first and second stages are sandwiched between a pair of electrode chips whose tip is a flat surface or a curved surface having a curvature radius larger than the curvature radius R1 of the tip of the electrode chip contacting the panel. There are two stages, and the second stage welding is a high pressure welding compared to the first stage welding. And welded by spot welding, a method of manufacturing an automobile body, characterized in that the said structure.
本発明によれば、重ね合わせた2枚以上の厚金属板の一方に薄金属板を重ね合わせた、板厚比が5を超えるような大きな板組みにおいても、余計な工程を付加することなく、また散りを発生することなく、必要サイズのナゲットを容易に形成でき、産業上格段の効果を奏する。また、本発明によれば、厚金属板であるメンバーと薄金属板であるパネルとの間に厚金属板であるリインフォースメントを挟む構造を有する自動車車体をも容易に作製できるという効果もある。 According to the present invention, even in a large plate assembly in which a thin metal plate is superposed on one of two or more superposed thick metal plates and the plate thickness ratio exceeds 5, no additional steps are added. In addition, a nugget of a necessary size can be easily formed without causing scatter, and an industrially significant effect is achieved. In addition, according to the present invention, an automobile body having a structure in which a reinforcement that is a thick metal plate is sandwiched between a member that is a thick metal plate and a panel that is a thin metal plate can be easily produced.
本発明は、重ね合わせた2枚以上の厚板の一方に薄板を重ね合わせた板組みを、上下一対の電極チップで挟み、加圧、通電する抵抗スポット溶接により溶接接合し、必要サイズのナゲットを形成して抵抗スポット溶接継手を得る、抵抗スポット溶接方法である。 The present invention relates to a nugget of a necessary size by sandwiching a plate assembly in which a thin plate is superposed on one of two or more thick plates that are superposed on each other, sandwiched between a pair of upper and lower electrode tips, and welded by resistance spot welding to be pressurized and energized. Is a resistance spot welding method in which a resistance spot welded joint is obtained.
本発明で好適に使用可能な溶接装置は、上下一対の電極チップを備え、一対の電極チップで溶接する部分を挟み、加圧、通電でき、溶接中に加圧力、溶接電流をそれぞれ任意に制御可能な加圧力制御装置および制御可能な溶接電流制御装置を有していれば、加圧機構(エアシリンダやサーボモータ等)、電流制御機構、形式(定置式、ロボットガン等)
等はとくに限定されない。
The welding apparatus that can be suitably used in the present invention includes a pair of upper and lower electrode tips, can sandwich and pressurize and energize a portion to be welded, and can arbitrarily control the pressure and welding current during welding. Pressurization mechanism (air cylinder, servo motor, etc.), current control mechanism, type (stationary, robot gun, etc.) if it has a controllable pressure control device and a controllable welding current control device
Etc. are not particularly limited.
本発明では、使用する上下一対の電極チップのうち、薄板に接する電極チップを先端が所定の曲率半径R1を有する曲面である電極チップとし、他方の厚板に接する電極チップを先端が平面、又は薄板に接する電極チップの先端の曲率半径R1より大きな曲率半径を有する曲面である電極チップとする。 In the present invention, of the pair of upper and lower electrode tips to be used, the electrode tip in contact with the thin plate is an electrode tip whose tip is a curved surface having a predetermined radius of curvature R1, and the electrode tip in contact with the other thick plate is flat on the tip, or The electrode tip is a curved surface having a radius of curvature larger than the radius of curvature R1 of the tip of the electrode tip in contact with the thin plate.
薄板に接する電極チップと厚板に接する電極チップの先端形状を同じ形状とすると、加圧したときに、薄板の方が厚板より大きく撓むため、厚板側に比べて薄板側の電極との接触面積が大きくなり、薄板−厚板間に適正なナゲットが形成されるに十分な電流を供給すると、厚板−電極間では過剰な電流が供給されることになり、厚板−電極間で表散りが発生してしまう。 If the tip shape of the electrode tip in contact with the thin plate is the same as the tip shape of the electrode tip in contact with the thick plate, when pressed, the thin plate bends more than the thick plate, so the electrode on the thin plate side is more flexible than the thick plate side. If a sufficient current is supplied to form an appropriate nugget between the thin plate and the thick plate, an excessive current will be supplied between the thick plate and the electrode. Will cause scattering.
なお、厚板−電極間での表散り発生は、薄板に接する電極チップの先端径を厚板に接する電極チップの先端径より小さくすることにより防止できるが、薄板に接する電極チップの先端径を小さくすると加圧できる面積が小さくなり、散りを発生させずに形成できるナゲット径が小さくなり、厚板−厚板間に適正な径を有するナゲットを形成できなくなる。 The occurrence of scattering between the thick plate and the electrode can be prevented by making the tip diameter of the electrode tip in contact with the thin plate smaller than the tip diameter of the electrode tip in contact with the thick plate, but the tip diameter of the electrode tip in contact with the thin plate can be reduced. If it is made smaller, the area that can be pressurized is reduced, the nugget diameter that can be formed without causing scattering is reduced, and a nugget having an appropriate diameter between thick plates cannot be formed.
このようなことから、本発明では、薄板に接する一方の電極チップを、先端が所定の曲率半径R1を有する曲面の電極チップとし、厚板に接する他方の電極チップを先端が、厚板−厚板間に必要なナゲット径程度の先端径を有する、平面又は薄板に接する電極チップの先端の曲率半径R1より大きな曲率半径を有する曲面の電極チップとした。 Therefore, in the present invention, one electrode tip in contact with the thin plate is a curved electrode tip having a predetermined radius of curvature R1, and the other electrode tip in contact with the thick plate is thick plate-thick. A curved electrode tip having a radius of curvature larger than the radius of curvature R1 of the tip of the electrode tip in contact with a flat or thin plate, having a tip diameter approximately equal to the nugget diameter required between the plates.
本発明で好適に使用できる電極チップの一例を図4に示す。 An example of an electrode tip that can be suitably used in the present invention is shown in FIG.
図4(a)は、薄板に接する電極チップとして好適な例であり、先端が曲面となっているDR型の電極チップであり、先端曲率半径R1が40mm、先端径が6mmのDR型電極の例である。DR型とはJIS C 9304(1999)に規定する電極形状で、DRはDome Radiusを表す。なお、薄板に接する電極チップの先端の曲率半径R1の値は、とくに限定する必要はないが、例えば、JIS C 9304(1999)に規定される電極形状では、先端の曲率半径は32〜100mmの例が記載されており、その中から選択することができる。しかし、本発明の効果を十分に得るためには、R1は60mm以下とすることが好ましい。 FIG. 4 (a) is a suitable example of an electrode tip in contact with a thin plate, which is a DR type electrode tip having a curved tip, and a DR type electrode having a tip radius of curvature R1 of 40 mm and a tip diameter of 6 mm. It is an example. The DR type is an electrode shape defined in JIS C 9304 (1999), and DR represents Dome Radius. Note that the value of the radius of curvature R1 of the tip of the electrode tip in contact with the thin plate is not particularly limited. For example, in the electrode shape defined in JIS C 9304 (1999), the radius of curvature of the tip is 32 to 100 mm. Examples are described from which you can choose. However, in order to sufficiently obtain the effects of the present invention, R1 is preferably 60 mm or less.
また、図4(b)に示す例は、厚板に接する電極チップとして好適な例であり、先端が平面(曲率半径が無限大とみなせる)、先端径が6mmのDF型電極の例である。DFはDome Flatを表す。厚板に接する電極チップとしては、DF型と同様にDR型の電極チップも好適に使用できるが、薄板に接する電極チップの先端の曲率半径R1より大きな先端の曲率半径を有する電極チップとする必要がある。なお、本発明の効果を十分に得るためには、厚板に接する電極チップの先端の曲率半径は80mm以上とすることが好ましい。 The example shown in FIG. 4B is an example suitable as an electrode chip in contact with a thick plate, and is an example of a DF type electrode having a flat tip (which can be regarded as an infinite curvature radius) and a tip diameter of 6 mm. . DF represents Dome Flat. As an electrode tip in contact with the thick plate, a DR type electrode tip can be suitably used as in the case of the DF type, but it is necessary to make an electrode tip having a radius of curvature at the tip larger than the radius of curvature R1 at the tip of the electrode tip in contact with the thin plate. There is. In order to sufficiently obtain the effects of the present invention, it is preferable that the radius of curvature of the tip of the electrode tip in contact with the thick plate is 80 mm or more.
本発明では、上記したような一対の電極チップを使用し、抵抗スポット溶接を第一段および第二段の二段階からなる溶接とする。 In the present invention, the pair of electrode tips as described above is used, and the resistance spot welding is a two-stage welding of the first stage and the second stage.
本発明では、溶接途中に加圧力を変化し、第二段の溶接における加圧力を、第一段の溶接における加圧力より高くする。上記したような一対の電極チップを使用し溶接の初期に加圧力を低くすることにより、薄板のたわみが小さく厚板側での散り発生が防止でき、また、電極チップと薄板の接触面積が小さく制限され、薄板−厚板間の電流密度が高くなり、溶接初期に金属板間の接触抵抗発熱を有効に活用することができて薄板−厚板間に所望サイズのナゲットを形成できる。なお、ここでいう、「第一段の溶接」とは、加圧力が一定である溶接を意味し、加圧力を一定とし溶接電流と通電時間の組み合わせが一種の場合に加えて、溶接電流と通電時間の組み合わせを複数とした場合をも含むものとする。 In the present invention, the applied pressure is changed during welding, and the applied pressure in the second stage welding is made higher than the applied pressure in the first stage welding. By using a pair of electrode tips as described above and reducing the applied pressure at the beginning of welding, the deflection of the thin plate is small and the occurrence of scattering on the thick plate side can be prevented, and the contact area between the electrode tip and the thin plate is small. The current density between the thin plate and the thick plate is limited, the contact resistance heat generation between the metal plates can be effectively utilized at the initial stage of welding, and a nugget of a desired size can be formed between the thin plate and the thick plate. Here, “first stage welding” means welding in which the applied pressure is constant. In addition to the case where the applied pressure is constant and the combination of welding current and energizing time is one kind, The case where a plurality of combinations of energization times are included is also included.
また、第二段の溶接における加圧力を第一段の溶接に比べて大きくすることにより、散りの発生が抑制されるとともに、体積抵抗発熱による発熱が主体となり、電極間中央部でナゲットが形成され、厚板−厚板間にも必要サイズのナゲットが形成できる。 In addition, by increasing the applied pressure in the second stage welding compared to the first stage welding, the occurrence of scattering is suppressed, and heat generation due to volume resistance heat generation is the main cause, and nuggets are formed at the center between the electrodes. Thus, a nugget of a necessary size can be formed between the thick plate and the thick plate.
図1に示すような、重ね合わせた2枚の厚板12,13の外側に薄板11を重ね合わせた金属板板組みをスポット溶接する場合を例に、以下、さらに詳しく説明する。図1、図2には、本発明によるナゲット形成の過程を模式的に示し、図3には、本発明における好ましい加圧パターンおよび通電パターンを模式的に示す。
This will be described in more detail below, taking as an example the case of spot welding a metal plate assembly in which
まず、所望の溶接位置で板組みを上記したような先端形状を有する上下一対の電極で挟み、加圧を開始する。加圧力がかかり始めてから通電を開始する。第一段の溶接では、接触抵抗発熱が小さくならないように、加圧力、溶接電流を設定し、金属板(薄板)11−金属板(厚板)12間にナゲットN1を形成する。第一段の溶接では、低加圧力で大溶接電流を短時間で加えることが好ましい。これにより、金属板11(薄板)と金属板12(厚板)間は通電経路が狭く電流密度が高くなり、めっきの溶融等による通電経路の拡大の影響も少なく、発生する接触抵抗発熱を有効にナゲットN1形成に作用させることができるようになる。 First, the plate assembly is sandwiched between a pair of upper and lower electrodes having the tip shape as described above at a desired welding position, and pressurization is started. Start energization after pressure is applied. In the first stage of welding, a pressing force and a welding current are set so that contact resistance heat generation does not become small, and a nugget N1 is formed between the metal plate (thin plate) 11 and the metal plate (thick plate) 12. In the first stage welding, it is preferable to apply a large welding current in a short time with a low pressure. As a result, the current path between the metal plate 11 (thin plate) and the metal plate 12 (thick plate) is narrow and the current density is high, and there is little influence of expansion of the current path due to melting of the plating, etc., and the generated contact resistance heat is effective. Can act on nugget N1 formation.
そして、本発明では、上記した第一段の溶接に続いて第二段の溶接を行なう。第二段の溶接は、第一段の溶接に比べ、高加圧力の溶接とする。第二段の溶接における加圧力を第一段の溶接に比べて大きくすることにより、散りの発生が抑制されるとともに、体積抵抗発熱による発熱が主体となり、電極間中央部でナゲットが形成され、図2に示すように金属板12,13間にも所定サイズのナゲットN2を形成できる。
In the present invention, the second stage welding is performed following the first stage welding described above. The second stage welding is a high pressure welding compared to the first stage welding. By increasing the applied pressure in the second stage welding compared to the first stage welding, the occurrence of scattering is suppressed, heat generation mainly due to volume resistance heat generation, nuggets are formed at the center between the electrodes, As shown in FIG. 2, a nugget N2 having a predetermined size can be formed between the
なお、図1、図2では、金属板(厚板)を2枚重ね合わせた場合について説明したが、図5に示すように金属板(厚板)12,13,14を3枚重ね合わせた場合にも、本発明における第二段の溶接で金属板12,13間に所定サイズのナゲットN2とともに、金属板13,14間にも所定サイズのナゲットN3(図示せず)が形成できる。
1 and 2, the case where two metal plates (thick plates) are overlapped has been described. However, as shown in FIG. 5, three metal plates (thick plates) 12, 13, and 14 are overlapped. Even in this case, the nugget N3 (not shown) of a predetermined size can be formed between the
また、本発明は、厚金属板であるメンバーと薄金属板であるパネルとの間に厚金属板であるリインフォースメントを挟む構造を有する自動車車体を製造するにあたり、上記した本発明の抵抗スポット溶接方法、または抵抗スポット溶接継手の製造方法を適用する自動車車体の製造方法である。 Further, the present invention provides the above-described resistance spot welding according to the present invention in manufacturing an automobile body having a structure in which a reinforcement that is a thick metal plate is sandwiched between a member that is a thick metal plate and a panel that is a thin metal plate. A method for manufacturing an automobile body, or a method for manufacturing a resistance spot welded joint.
本発明の自動車車体の製造方法では、厚金属板(厚板)であるメンバーとリインフォースメントを重ね合わせ、さらにメンバー又はリインフォースメント側に薄金属板(薄板)であるパネルを重ね合わせた板組みとし、パネルに接する電極チップを先端が所定の曲率半径R1を有する曲面である電極チップとし、メンバー又はリインフォースメントに接する電極チップを先端が平面又はパネルに接する電極チップの先端の曲率半径R1より大きな曲率半径を有する曲面である電極チップとする一対の電極チップで、この板組みを挟み、第二段の溶接が第一段の溶接に比べ高加圧力の溶接とする二段階からなる抵抗スポット溶接により溶接接合して、メンバーとパネルとの間にリインフォースメントを挟む構造を構成する。 In the method for manufacturing an automobile body of the present invention, a member that is a thick metal plate (thick plate) is superimposed on a reinforcement, and a panel that is a thin metal plate (thin plate) is superimposed on the member or the reinforcement side. The electrode tip in contact with the panel is a curved electrode tip whose tip has a predetermined radius of curvature R1, and the electrode tip in contact with the member or reinforcement is a curvature larger than the curvature radius R1 of the tip of the electrode tip in contact with the flat surface or panel. A pair of electrode tips that are electrode tips that are curved surfaces having a radius, sandwiching this plate assembly, by resistance spot welding consisting of two stages in which the second stage welding is a higher pressure welding than the first stage welding. A structure is formed in which the reinforcement is sandwiched between the member and the panel by welding.
この自動車車体の製造における第一段の溶接では、加圧力P1は0.7〜2kN、溶接電流I1は、8.0〜9.5kA、通電時間TIは交流100V、50サイクルで3〜4 cyclesとすることが好ましい。なお、P1、I1、TIは、電極の大きさ、板組みにより適宜調整することが好ましい。また、第二段の溶接では、加圧力P2は3.5〜5.0kN、溶接電流I2は、7.0〜9.5kA、通電時間T2は交流100V、50サイクルで15〜20 cyclesとすることが好ましい。なお、P2、I2、T2は、第一段の溶接条件や、電極の大きさ、板組みにより適宜調整することができる。この自動車車体の製造においても、第二段の溶接で使用する電極チップの先端の曲率半径は、第一段の溶接で使用する電極チップの先端の曲率半径R1より大きくすることはいうまでもない。 In the welding of the first stage in this automobile body manufacture, pressure P 1 is 0.7~2KN, the welding current I 1 is, 8.0~9.5KA, the energization time T I is set to 3 to 4: cycles in AC 100 V, 50 cycles It is preferable. Note that P 1 , I 1 , and T I are preferably adjusted as appropriate depending on the size of the electrode and the plate assembly. In the second stage welding, it is preferable that the pressure P 2 is 3.5 to 5.0 kN, the welding current I 2 is 7.0 to 9.5 kA, the energization time T 2 is 100 V AC, and 15 to 20 cycles in 50 cycles. . Note that P 2 , I 2 , and T 2 can be appropriately adjusted according to the first stage welding conditions, the size of the electrodes, and the plate assembly. In manufacturing the automobile body, it goes without saying that the radius of curvature of the tip of the electrode tip used in the second stage welding is larger than the radius of curvature R1 of the tip of the electrode tip used in the first stage welding. .
本発明は、被溶接材である金属板の強度レベル(軟鋼、高張力鋼板)の違いやめっき等の表面処理の有無などによらず適用可能であり、また、その板組みも、単純な2枚重ねはもちろん、板厚比が5を超えるような板組みの場合でも同様に適用可能である。 The present invention can be applied regardless of the difference in the strength level (soft steel, high-tensile steel plate) of the metal plate that is the material to be welded or the presence or absence of surface treatment such as plating. In addition to stacking sheets, the present invention can be similarly applied to a plate assembly having a thickness ratio exceeding 5.
表1に示す3枚または4枚の薄鋼板を図5に示すように積み重ねた板組みについて、表2に示す溶接条件で抵抗スポット溶接を行い、抵抗スポット溶接継手を作製した。なお、この板組みは、自動車車体に用いられる、パネルとメンバーとの間にリインフォースメントを挟みこむ構造を模擬したものである。 Resistance spot welding was performed on the plate assembly in which three or four thin steel plates shown in Table 1 were stacked as shown in FIG. 5 under the welding conditions shown in Table 2 to produce resistance spot welded joints. In addition, this board assembly simulates the structure which sandwiches reinforcement between a panel and a member used for a vehicle body.
抵抗スポット溶接は、定置式のサーボモータ加圧式の単相交流抵抗スポット溶接機を用いて行なった。なお、使用した一対の電極チップは、薄板11に接する電極チップを表2に示す先端の曲率半径R1、先端径を有するDR型電極とし、厚板13(又は14)に接する電極チップを表2に示す先端径を有するDF型電極とした。一部では、厚板13(又は14)に接する電極チップを表2に示す先端の曲率半径、先端径を有するDR型電極とした。
Resistance spot welding was performed using a stationary servo motor pressurization type single-phase AC resistance spot welding machine. The pair of electrode tips used is a DR type electrode having the tip radius of curvature R1 and tip diameter shown in Table 2 as the electrode tip in contact with the
得られた各溶接継手について、溶接部を切断し、断面をエッチングしたのち、光学顕微鏡により観察し、ナゲットN1,N2、あるいはさらにN3(N3は厚板13,14間に形成されるナゲット)についてナゲット径d(mm)を測定し、全てのナゲット径dが4√t以上(t:隣り合う2枚の鋼板のうち薄い方の鋼板の板厚(mm))である場合を、良好(○)として評価した。ナゲット径dが4√t未満を不良(×)とした。得られた結果を表2に併記する。
For each of the obtained welded joints, the welded portion was cut and the cross section was etched, and then observed with an optical microscope, and nuggets N1, N2 or even N3 (N3 is a nugget formed between
本発明例はいずれも、散りの発生がなく、4√t以上の径を有するナゲットが得られ、良好なスポット溶接継手が得られている。本発明例では、板厚比が5を超えるめっき鋼板の板組みの場合であっても散りを発生させることなく、必要なサイズのナゲットを有するスポット溶接が可能となる。一方、本発明の範囲を外れる比較例では、散りが発生するか、あるいは十分なサイズのナゲットが形成されていない。 In all of the examples of the present invention, there is no occurrence of scattering, a nugget having a diameter of 4√t or more is obtained, and a good spot welded joint is obtained. In the example of the present invention, spot welding having a nugget of a necessary size can be performed without generating scattering even when the plate thickness ratio is 5 or more. On the other hand, in the comparative example outside the scope of the present invention, scattering occurs or a nugget having a sufficient size is not formed.
11 金属板(薄板)
12、13、14 金属板(厚板)
11 Metal plate (thin plate)
12, 13, 14 Metal plate (thick plate)
Claims (3)
前記一対の電極チップのうちの一方の、前記薄金属板に接する電極チップを先端が所定の曲率半径R1を有する曲面である電極チップとし、他方の前記厚金属板に接する電極チップを先端が平面又は前記薄金属板に接する電極チップの先端の曲率半径R1より大きな曲率半径を有する曲面である電極チップとし、
前記抵抗スポット溶接を第一段および第二段の二段階からなる溶接とし、該第二段の溶接が前記第一段の溶接に比べ高加圧力の溶接とすることを特徴とする、抵抗スポット溶接方法。 When sandwiching a plate assembly in which a thin metal plate is superimposed on one of two or more stacked thick metal plates with a pair of electrode tips, and welding by resistance spot welding,
One of the pair of electrode tips is an electrode tip in contact with the thin metal plate, and the tip of the electrode tip is a curved surface having a predetermined radius of curvature R1, and the other electrode tip in contact with the thick metal plate has a flat tip. Or an electrode tip that is a curved surface having a radius of curvature larger than the radius of curvature R1 of the tip of the electrode tip in contact with the thin metal plate,
The resistance spot welding is a two-stage welding of a first stage and a second stage, and the second stage welding is a welding with a higher pressurization than the first stage welding. Welding method.
前記一対の電極チップのうちの一方の、前記薄金属板に接する電極チップを先端が所定の曲率半径R1を有する曲面である電極チップとし、他方の前記厚金属板に接する電極チップを先端が平面又は前記薄金属板に接する電極チップの先端の曲率半径R1より大きな曲率半径を有する曲面である電極チップとし、
前記抵抗スポット溶接を第一段および第二段の二段階からなる溶接とし、該第二段の溶接が前記第一段の溶接に比べ高加圧力の溶接とすることを特徴とする、抵抗スポット溶接継手の製造方法。 When manufacturing a resistance spot welded joint by sandwiching a plate assembly in which a thin metal plate is overlapped with one of two or more thick metal plates overlapped with a pair of electrode tips and welding by resistance spot welding,
One of the pair of electrode tips is an electrode tip in contact with the thin metal plate, and the tip of the electrode tip is a curved surface having a predetermined radius of curvature R1, and the other electrode tip in contact with the thick metal plate has a flat tip. Or an electrode tip that is a curved surface having a radius of curvature larger than the radius of curvature R1 of the tip of the electrode tip in contact with the thin metal plate,
The resistance spot welding is a two-stage welding of a first stage and a second stage, and the second stage welding is a welding with a higher pressurization than the first stage welding. A method for manufacturing a welded joint.
前記メンバーと前記リインフォースメントを重ね合わせ、さらに該メンバー又は該リインフォースメント側に前記パネルを重ね合わせた板組みとし、該板組みを、前記パネルに接する電極チップを先端が所定の曲率半径R1を有する曲面である電極チップとし、前記メンバー又は該リインフォースメントに接する電極チップを先端が平面又は前記パネルに接する電極チップの先端の曲率半径R1より大きな曲率半径を有する曲面である電極チップとする、一対の電極チップで挟み、第一段および第二段の二段階からなり、該第二段の溶接が該第一段の溶接に比べ高加圧力の溶接とする抵抗スポット溶接により溶接接合して、前記構造とすることを特徴とする自動車車体の製造方法。 In manufacturing an automobile body having a structure in which a reinforcement that is a thick metal plate is sandwiched between a member that is a thick metal plate and a panel that is a thin metal plate,
The member and the reinforcement are overlapped, and the panel is formed by overlapping the panel on the member or the reinforcement side. The plate assembly has an electrode tip in contact with the panel having a predetermined radius of curvature R1. A pair of electrode tips that are curved surfaces, and the electrode tips that are in contact with the member or the reinforcement are electrode tips that are curved surfaces having a curvature radius larger than the curvature radius R1 of the tip of the electrode tip that is in contact with the flat surface or the panel The electrode tip is sandwiched between two stages, a first stage and a second stage, and the welding of the second stage is welded by resistance spot welding, which is a welding with a higher pressure than the welding of the first stage, A method of manufacturing an automobile body, characterized by having a structure.
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