WO2000034672A1 - Improved weldable aluminum stud - Google Patents

Improved weldable aluminum stud Download PDF

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Publication number
WO2000034672A1
WO2000034672A1 PCT/US1999/028950 US9928950W WO0034672A1 WO 2000034672 A1 WO2000034672 A1 WO 2000034672A1 US 9928950 W US9928950 W US 9928950W WO 0034672 A1 WO0034672 A1 WO 0034672A1
Authority
WO
WIPO (PCT)
Prior art keywords
aluminum
titanium
acidic solution
stud
containing material
Prior art date
Application number
PCT/US1999/028950
Other languages
French (fr)
Other versions
WO2000034672B1 (en
Inventor
Klaus G. Schmitt
Michael Krengel
Original Assignee
Emhart, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Emhart, Inc. filed Critical Emhart, Inc.
Priority to AU20443/00A priority Critical patent/AU2044300A/en
Priority to EP99964138.4A priority patent/EP1151205B1/en
Priority to JP2000587094A priority patent/JP4778615B2/en
Priority to US09/830,721 priority patent/US6860687B1/en
Publication of WO2000034672A1 publication Critical patent/WO2000034672A1/en
Publication of WO2000034672B1 publication Critical patent/WO2000034672B1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/20—Stud welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
    • B23K35/0288—Welding studs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/001—Interlayers, transition pieces for metallurgical bonding of workpieces
    • B23K35/002—Interlayers, transition pieces for metallurgical bonding of workpieces at least one of the workpieces being of light metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/28—Selection of soldering or welding materials proper with the principal constituent melting at less than 950 degrees C
    • B23K35/286—Al as the principal constituent

Definitions

  • the invention relates generally to weldable materials and more particularly to weldable aluminum or aluminum alloy studs having a titanium containing material on at least a portion of a surface thereof, and methods of making the same.
  • Weld-on parts are used in many areas of industrial manufacture. They enable metal connections without making holes and form a link between a basic structure and a component which is to be fastened.
  • a weld stud can serve to fasten pipe conduits, push buttons, plastic nuts or cable clips.
  • Weld-on parts e.g., studs
  • Aluminum or aluminum alloys are known which can be welded to a basic part (e.g., a piece of sheet metal) which is also made of aluminum or aluminum alloys. Under normal circumstances, freshly exposed aluminum in the
  • the oxide generally forms a layer over the entire surface and continues to grow thicker with the passage of time.
  • the oxide layer is hard, adhesive, transparent, and up to several nanometers thick.
  • the thickness of the oxide layer may vary from spot to spot.
  • the oxide layer is largely insoluble in a pH range between 4.5 and 8.5.
  • the oxide layer provides the part with protection against corrosion.
  • the oxide layer does, in some circumstances, adversely affect further processing steps to which the welded part may be subjected.
  • the thickness of the oxide layer is random and variable.
  • This condition causes problems during the welding of the studs to aluminum sheets because the energy required to release electrons from the oxide is lower than the energy to release electrons from bare aluminum.
  • the arc may initiate at the center point of a rounded weld head but, after some initial melting, the arc might jump or "blow" to an adjacent region, such as an area having a thick oxide layer. If this adjacent region is seriously off-center, the result may be an unsatisfactory weld.
  • the present invention provides a weldable part comprised of aluminum or an aluminum alloy, wherein the part has a titanium containing material on at least a portion of a surface thereof, wherein the layer of titanium containing material lowers contact resistance
  • the present invention also provides a method of forming a titanium containing material on at least a portion of at least one surface of a weldable part of aluminum or an aluminum alloy.
  • the method includes the steps of:
  • Fig. 1 is a partial cross-sectional view of a weld stud, in accordance with one aspect of the present invention.
  • Fig. 2 shows an elevational view of a weld stud having a threaded portion, in accordance with one aspect of the present invention.
  • the weld-on part is pre-treated via known etching techniques to strip away aluminum oxides and thereby expose an aluminum or aluminum
  • the titanium containing material is formed upon exposed aluminum or aluminum alloy portion of the weld-on part by immersing the part in an acidic solution including a concentration of titanium ions and, preferably, a chromium free acidic solution containing titanium ions.
  • an acidic solution including a concentration of titanium ions and, preferably, a chromium free acidic solution containing titanium ions.
  • ALODINE 2040 one suitable acidic solution believed to contain a sufficient quantity of titanium ions, initially or through sequential addition during the application step, is known as ALODINE 2040, which is commercially available from Henkel Surface Technologies (Madison Heights, Michigan).
  • ALODINE 2040 is commercially available from Henkel Surface Technologies (Madison Heights, Michigan).
  • the acidic solution utilized should provide a caustic passivation for the aluminum surface to be treated.
  • an ALODINE 2040 solution for use in accordance with the teachings of the present invention, 10-30 liters (preferably 15-20 liters) of the commercially available solution is mixed with a sufficient quantity of demineralized water to form a 1000 liter bath. At the above described ratio, the resulting bath should have a pH value of 1.25.
  • the weld-on part is preferably a weld stud such as that shown in Figs. 1 and 2, made of aluminum or an aluminum alloy.
  • the weld stud 1 has a shank 2 and a head 3 extending along one end of the shank.
  • the head 3 has a conically tapered portion which forms a welding face 4.
  • the weld-on part is dipped or otherwise coated at a temperature of about 45°C in the acidic solution containing titanium ions.
  • the treatment time particularly if the part is dipped, is generally between 30-90 seconds, wherein the solution should have a free acid count of between about 6.1 to 18.3.
  • the acidic solution is controlled by the determination of the free acid count as well as via a measure of the dissolved aluminum. For each 1.0 decrease in the free acid count, additional solution should be added to the bath.
  • the welding face of the weld stud is provided with the titanium containing material, contact resistance between the weld-on part, a pin and the supporting structure or substrate is reduced.
  • Providing the layer in the region of the welding face has a positive influence on the welding process.
  • a qualitatively high grade welded connection is achieved, enabling the energy required to weld the pin to be reduced.
  • the titanium containing material be of a sufficient thickness to prevent the formation of aluminum oxide on the weld-on part. As noted above, the thickness should be on the order of several nanometers.
  • the ALODINE 2040 causes a relatively thin and uniform thickness layer of titanium aluminum oxide crystals to be formed on the surface of the weld-on part. Although the titanium aluminum oxide layer may grow with time, which is generally undesirable, the rate of growth is much lower than for non-passivated aluminum, and the thickness of the titanium aluminum oxide layer remains relatively consistent.
  • the weld stud 1 is generally connected by means of arc welding to a structure or substrate (not shown) such as a sheet of a desired thickness.
  • a structure or substrate such as a sheet of a desired thickness.
  • the weld studs may be adhered to sheets as thin as 0.8 mm on average.
  • the sheet will also be made of aluminum or an aluminum alloy.
  • the sheet structure may be an autobody panel for a motor vehicle.
  • Fig. 2 there is shown a second embodiment of a weld stud 1 having a shank 2.
  • a Christmas-tree shaped thread 6 is formed on the shank 2.
  • a welding head 3 is formed at a free end of the shank 2.
  • the welding head 3 has a welding face 4, which comes into contact during arc welding with a substrate (not shown), such as an aluminum or aluminum alloy piece of sheet metal.
  • the welding face 4 is
  • a layer 5 of a titanium containing material is provided with a layer 5 of a titanium containing material.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Arc Welding In General (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Resistance Welding (AREA)
  • Nonmetallic Welding Materials (AREA)
  • Standing Axle, Rod, Or Tube Structures Coupled By Welding, Adhesion, Or Deposition (AREA)
  • Chemical Treatment Of Metals (AREA)

Abstract

A weld-on part made of aluminum or an aluminum alloy, such as but not limited to a stud (1), which has a surface which is at least partially provided with a layer (5) which contains a titanium containing material. The stud (1) is treated with a chrome-free passivating solution which imparts corrosion resistance while simultaneously causing a layer (5) of titanium containing material to be formed on at least a portion of the surface of the stud (1). The layer (5) of titanium containing material permits the stud (1) to be satisfactorily welded to a surface, without the occurrence of arc jumping or blowing, in part, by lowering contact resistance during the welding process.

Description

IMPROVED WELDABLE ALUMINUM STUD
FIELD OF THE INVENTION
The invention relates generally to weldable materials and more particularly to weldable aluminum or aluminum alloy studs having a titanium containing material on at least a portion of a surface thereof, and methods of making the same.
BACKGROUND OF THE INVENTION
Weld-on parts are used in many areas of industrial manufacture. They enable metal connections without making holes and form a link between a basic structure and a component which is to be fastened. For example, a weld stud can serve to fasten pipe conduits, push buttons, plastic nuts or cable clips. Weld-on parts (e.g., studs) made of aluminum or aluminum alloys are known which can be welded to a basic part (e.g., a piece of sheet metal) which is also made of aluminum or aluminum alloys. Under normal circumstances, freshly exposed aluminum in the
presence of air immediately begins to oxidize. The oxide generally forms a layer over the entire surface and continues to grow thicker with the passage of time. The oxide layer is hard, adhesive, transparent, and up to several nanometers thick. In addition, in many circumstances, the thickness of the oxide layer may vary from spot to spot. The oxide layer is largely insoluble in a pH range between 4.5 and 8.5. Thus, the oxide layer provides the part with protection against corrosion. However, the oxide layer does, in some circumstances, adversely affect further processing steps to which the welded part may be subjected.
While this condition applies equally to sheet aluminum and to aluminum studs, the process of manufacturing aluminum studs by cold working the metal makes the condition even worse because, after cold working, the surface may be comprised of areas of freshly exposed aluminum interspersed with different areas having varying oxide layer thicknesses.
Thus, in the finished stud, the thickness of the oxide layer is random and variable.
This condition causes problems during the welding of the studs to aluminum sheets because the energy required to release electrons from the oxide is lower than the energy to release electrons from bare aluminum. For example, in arc welding a stud, the arc may initiate at the center point of a rounded weld head but, after some initial melting, the arc might jump or "blow" to an adjacent region, such as an area having a thick oxide layer. If this adjacent region is seriously off-center, the result may be an unsatisfactory weld.
Therefore, there exists a need for aluminum studs that have a relatively consistent oxide layer which is capable of being satisfactorily welded to a
surface, without the occurrence of arc jumping or blowing. There also exists a need for methods of producing such aluminum studs. SUMMARY OF THE INVENTION
It accordingly is an object of the present invention to provide an
aluminum stud that has improved weldability.
It is another object of the present invention to provide an aluminum stud having a titanium containing material on at least a portion of a surface
thereof.
It is another object of the present invention to provide a method for producing an aluminum stud that has improved weldability.
It is another object of the present invention to provide a method for producing an aluminum stud having a titanium material on at least a portion
of a surface thereof.
In order to overcome the aforementioned disadvantages and achieve many of the aforementioned objects, the present invention provides a weldable part comprised of aluminum or an aluminum alloy, wherein the part has a titanium containing material on at least a portion of a surface thereof, wherein the layer of titanium containing material lowers contact resistance
during a welding procedure.
The present invention also provides a method of forming a titanium containing material on at least a portion of at least one surface of a weldable part of aluminum or an aluminum alloy. The method includes the steps of:
(1 ) providing a solution of titanium containing materials, and (2) contacting the part with the solution for a sufficient period of time to permit the titanium containing material to be applied to the part; wherein the layer of titanium containing material lowers contact resistance during a welding procedure.
A more complete appreciation of the present invention and its scope can be obtained from an understanding the accompanying drawings, which
are briefly summarized below, the followed detailed description of the invention, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a partial cross-sectional view of a weld stud, in accordance with one aspect of the present invention; and
Fig. 2 shows an elevational view of a weld stud having a threaded portion, in accordance with one aspect of the present invention.
The same reference numerals refer to the same parts throughout the various Figures.
DETAILED DESCRIPTION OF THE INVENTION
Initially, the weld-on part is pre-treated via known etching techniques to strip away aluminum oxides and thereby expose an aluminum or aluminum
alloy surface. The titanium containing material is formed upon exposed aluminum or aluminum alloy portion of the weld-on part by immersing the part in an acidic solution including a concentration of titanium ions and, preferably, a chromium free acidic solution containing titanium ions. By way of non- limiting example, one suitable acidic solution believed to contain a sufficient quantity of titanium ions, initially or through sequential addition during the application step, is known as ALODINE 2040, which is commercially available from Henkel Surface Technologies (Madison Heights, Michigan). The acidic solution utilized should provide a caustic passivation for the aluminum surface to be treated.
To prepare an ALODINE 2040 solution for use in accordance with the teachings of the present invention, 10-30 liters (preferably 15-20 liters) of the commercially available solution is mixed with a sufficient quantity of demineralized water to form a 1000 liter bath. At the above described ratio, the resulting bath should have a pH value of 1.25.
As noted above, the weld-on part is preferably a weld stud such as that shown in Figs. 1 and 2, made of aluminum or an aluminum alloy. The weld stud 1 has a shank 2 and a head 3 extending along one end of the shank. Preferably the head 3 has a conically tapered portion which forms a welding face 4.
To provide the weld-on part with a titanium containing material, the weld-on part is dipped or otherwise coated at a temperature of about 45°C in the acidic solution containing titanium ions. The treatment time, particularly if the part is dipped, is generally between 30-90 seconds, wherein the solution should have a free acid count of between about 6.1 to 18.3. Thus, as should be understood by those skilled in the art, the acidic solution is controlled by the determination of the free acid count as well as via a measure of the dissolved aluminum. For each 1.0 decrease in the free acid count, additional solution should be added to the bath.
Once at least the welding face of the weld stud is provided with the titanium containing material, contact resistance between the weld-on part, a pin and the supporting structure or substrate is reduced. Providing the layer in the region of the welding face has a positive influence on the welding process. In particular, a qualitatively high grade welded connection is achieved, enabling the energy required to weld the pin to be reduced. It is also preferred that the titanium containing material be of a sufficient thickness to prevent the formation of aluminum oxide on the weld-on part. As noted above, the thickness should be on the order of several nanometers.
Without being bound to a particular theory of the operation of the present invention, it is believed that the ALODINE 2040 causes a relatively thin and uniform thickness layer of titanium aluminum oxide crystals to be formed on the surface of the weld-on part. Although the titanium aluminum oxide layer may grow with time, which is generally undesirable, the rate of growth is much lower than for non-passivated aluminum, and the thickness of the titanium aluminum oxide layer remains relatively consistent.
The weld stud 1 is generally connected by means of arc welding to a structure or substrate (not shown) such as a sheet of a desired thickness. For example, the weld studs may be adhered to sheets as thin as 0.8 mm on average. Preferably, the sheet will also be made of aluminum or an aluminum alloy. By way of non-limiting example, the sheet structure may be an autobody panel for a motor vehicle. Referring to Fig. 2, there is shown a second embodiment of a weld stud 1 having a shank 2. However, in this embodiment, a Christmas-tree shaped thread 6 is formed on the shank 2. A welding head 3 is formed at a free end of the shank 2. The welding head 3 has a welding face 4, which comes into contact during arc welding with a substrate (not shown), such as an aluminum or aluminum alloy piece of sheet metal. The welding face 4 is
provided with a layer 5 of a titanium containing material.
The foregoing description is considered illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and process shown as described above. Accordingly, all suitable modifications and equivalents may be resorted to falling within the scope of the invention as defined by the claims which follow.

Claims

CLAIMSWhat is claimed is:
1. A part attachable to a substrate via a welding process, comprised of aluminum or an aluminum alloy, wherein a surface of the part to be welded to the substrate is provided with a titanium containing material capable of lowering the contact resistance between the part and the substrate during a welding process.
2. The part according to Claim 1 , wherein the titanium containing material is formed by contacting the part with an acidic solution containing titanium ions.
3. The part according to Claim 3, wherein the acidic solution is a passivating solution.
4. The part according to Claim 3, wherein the acidic solution is chromium-free.
5. The part according to Claim 1 , wherein said acidic solution includes ALODINE 2040.
6. The part according to Claim 1 , wherein the part is a weld stud having a welding face.
7. The part according to Claim 6, wherein at least a portion of the welding face is provided with a titanium aluminum oxide layer.
8. The part according to Claim 7 wherein said part is applied to a substrate having an average thickness of as little as 0.8 mm.
9. A method of producing a weldable aluminum part having titanium dispersed along a surface thereof, said method comprising the steps of: providing an acidic solution containing titanium ions; and contacting the weldable aluminum part with the acidic solution for a sufficient period of time to permit the application of titanium along a surface of the part.
10. The method according to Claim 9, wherein the acidic solution is a passivating solution.
11. The method according to Claim 9, wherein the acidic solution is chromium-free.
12. The method according to Claim 9, wherein said acidic solution includes ALODINE 2040.
13. The method according to Claim 9, wherein the part is a weld stud having a welding face.
14. The method according to Claim 9, wherein at least a portion of the welding face is provided with a titanium aluminum oxide layer.
15. The method according to Claim 15 wherein said part is applied to a substrate having an average thickness of as little as 0.8 mm.
PCT/US1999/028950 1998-12-08 1999-12-07 Improved weldable aluminum stud WO2000034672A1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
AU20443/00A AU2044300A (en) 1998-12-08 1999-12-07 Improved weldable aluminum stud
EP99964138.4A EP1151205B1 (en) 1998-12-08 1999-12-07 Improved weldable aluminum stud
JP2000587094A JP4778615B2 (en) 1998-12-08 1999-12-07 Weldable aluminum studs
US09/830,721 US6860687B1 (en) 1998-12-08 1999-12-07 Weldable aluminum stud

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE19856613.1 1998-12-08
DE1998156613 DE19856613A1 (en) 1998-12-08 1998-12-08 Weld-on part made of aluminum or an aluminum alloy with a coating

Publications (2)

Publication Number Publication Date
WO2000034672A1 true WO2000034672A1 (en) 2000-06-15
WO2000034672B1 WO2000034672B1 (en) 2000-07-20

Family

ID=7890390

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1999/028950 WO2000034672A1 (en) 1998-12-08 1999-12-07 Improved weldable aluminum stud

Country Status (5)

Country Link
EP (2) EP1008416A1 (en)
JP (1) JP4778615B2 (en)
AU (1) AU2044300A (en)
DE (1) DE19856613A1 (en)
WO (1) WO2000034672A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7879157B2 (en) 2003-12-12 2011-02-01 Newfrey Llc Method for pretreating the surfaces of weld parts of aluminum or alloys thereof and corresponding weld parts

Families Citing this family (3)

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DE10035351C2 (en) * 2000-07-20 2002-06-06 Nelson Bolzenschweis Technik G Aluminum welded part, in particular aluminum studs for stud welding, and method for welding the same
DE102009015915B4 (en) * 2009-03-25 2023-06-29 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Motor vehicle with a body structure and at least one ground bolt welded to the body structure
DE102017203984A1 (en) * 2017-03-10 2018-09-13 Bayerische Motoren Werke Aktiengesellschaft Bolt for fastening components or grounding electrical or electronic components to a vehicle body, bolted bolt assembly, and method of forming the bolt assembly

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US2858414A (en) * 1953-05-18 1958-10-28 Dash Edward Aluminum coated stud
US5584946A (en) * 1993-05-24 1996-12-17 Henkel Kommanditgesellschaft Auf Aktien Chromium-free conversion coating treatment of aluminum

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JPS63313675A (en) * 1987-06-12 1988-12-21 Toyota Motor Corp Stud parts and its welding method
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JPH07100651A (en) * 1993-10-05 1995-04-18 Mitsubishi Chem Corp Stud welding method
DE4401881A1 (en) * 1994-01-23 1995-07-27 Trw Nelson Bolzenschweisstechn Welding stud made of aluminum
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US2858414A (en) * 1953-05-18 1958-10-28 Dash Edward Aluminum coated stud
US5584946A (en) * 1993-05-24 1996-12-17 Henkel Kommanditgesellschaft Auf Aktien Chromium-free conversion coating treatment of aluminum

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7879157B2 (en) 2003-12-12 2011-02-01 Newfrey Llc Method for pretreating the surfaces of weld parts of aluminum or alloys thereof and corresponding weld parts

Also Published As

Publication number Publication date
EP1151205B1 (en) 2013-08-14
JP2002531276A (en) 2002-09-24
EP1151205A1 (en) 2001-11-07
WO2000034672B1 (en) 2000-07-20
AU2044300A (en) 2000-06-26
EP1151205A4 (en) 2003-01-29
JP4778615B2 (en) 2011-09-21
EP1008416A1 (en) 2000-06-14
DE19856613A1 (en) 2000-06-15

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