WO2010087508A1 - インダイレクトスポット溶接方法 - Google Patents
インダイレクトスポット溶接方法 Download PDFInfo
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- WO2010087508A1 WO2010087508A1 PCT/JP2010/051549 JP2010051549W WO2010087508A1 WO 2010087508 A1 WO2010087508 A1 WO 2010087508A1 JP 2010051549 W JP2010051549 W JP 2010051549W WO 2010087508 A1 WO2010087508 A1 WO 2010087508A1
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- electrode
- spot welding
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- metal plate
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- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/10—Spot welding; Stitch welding
- B23K11/11—Spot welding
- B23K11/115—Spot welding by means of two electrodes placed opposite one another on both sides of the welded parts
-
- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/10—Spot welding; Stitch welding
- B23K11/11—Spot 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/24—Electric supply or control circuits therefor
-
- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/30—Features relating to electrodes
-
- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/30—Features relating to electrodes
- B23K11/3009—Pressure electrodes
-
- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/30—Features relating to electrodes
- B23K11/31—Electrode holders and actuating devices therefor
- B23K11/312—Electrode holders and actuating devices therefor for several electrodes
-
- 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
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/04—Tubular or hollow articles
-
- 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
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/18—Sheet panels
-
- 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
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/02—Iron or ferrous alloys
- B23K2103/04—Steel or steel alloys
Definitions
- the present invention presses a welding electrode while pressing a welding electrode against a metal plate from one surface side against a member in which at least two metal plates are overlapped, and feed terminal at a position away from the metal plate on the other surface side And an indirect spot welding method in which welding is performed by energizing between the welding electrode and the power supply terminal.
- resistance spot welding mainly direct spot welding
- series spot welding indirect spot welding, etc.
- FIG. 1A shows the direct spot welding method.
- a current is applied while pressing a pair of electrodes 3 and 4 from above and below between the two stacked metal plates 1 and 2, and the resistance heating of the metal plates is used.
- This is a method for obtaining a spot-like welded portion 5.
- Each of the electrodes 3 and 4 includes pressurization control devices 6 and 7 and a current control device 8, so that the pressurizing force and the current value to be energized can be controlled by these.
- the two metal plates 21 and 22 are pressed against one metal plate 21 while pressing the electrode 23, and then applied to the other metal plate 22.
- direct spot welding is used when there is sufficient space and an opening that sandwiches the metal plate from above and below is obtained.
- series spot welding method or indirect spot welding method is used. It is done.
- the stacked metal plates are pressed by the electrode only from one direction, and the opposite side is a hollow with no support. It is in a state. Therefore, it is not possible to apply a high applied pressure directly under the electrodes as in the direct spot welding method in which the electrodes are sandwiched from both sides. Further, since the electrode sinks into the metal plate during energization, the contact state between the electrode-metal plate and the metal plate-metal plate changes. For these reasons, there is a problem in that the current energization path is not stable between the stacked metal plates, and a melt-bonded portion is difficult to form.
- Patent Document 1 In order to solve the above-mentioned problem, for series spot welding, in Patent Document 1, “To form a nugget at a contact point where metal plates are overlapped, a large current is passed in the initial stage of welding to form an electrode nugget. , A steady current is passed ”. Further, in Patent Document 2, “welding is sufficient without a back electrode by forming a seat surface that is one step higher than the other parts at the position where the electrode is brought into contact, and press-contacting so as to crush the seat surface. It is described that strength can be obtained.
- Patent Document 3 states, “When a series spot welding or indirect spot welding is energized, a time zone in which a current value is kept high and a current value are made low. A welding method that consists of alternately repeating the time period to maintain, and further, the time period in which the current value is kept high as the time period in which the current value is kept high and the time period in which the current value is kept low are alternately repeated. A welding method comprising “gradually increasing the current value” is disclosed.
- Patent Document 1 is considered effective for series spot welding, but has a problem that it is not always effective for indirect spot welding with different welding methods.
- Patent Document 2 is also considered effective for series spot welding, but is not necessarily effective for indirect spot welding, and is one step higher than the other parts at the position where the electrode is brought into contact. There is a problem that a process of forming the seating surface with a press or the like is required.
- Patent Document 3 “when the metal structure of the overlapped portion of the metal plates 11 and 12 is welded by the energization pattern according to the technique disclosed in the same document, the metal in the overlapped portion of the metal plates 11 and 12 is conventionally Compared to ordinary nuggets, a large number of finely melted and recrystallized items are observed, which is the case of joining in the so-called diffusion bonding state. It may be joined by different events "(paragraph [0038] of the same document 3), and it is formed into a meteorite shape in a completely melted state like a nugget seen in direct spot welding. Not exclusively.
- the current management standards for spot welds in transportation equipment manufacturers often require that they be a meteorite-shaped nugget that has been completely melted, as obtained by direct spot welding, so that joint strength can be obtained. However, if a meteorite-shaped nugget formed in a completely molten state is not obtained, there is a problem that the management standard is not satisfied.
- the present invention has been developed in view of the above-described present situation, and the superimposed metal plates are pressurized with an electrode only from one direction, and the opposite side is melted during indirect spot welding for welding in a hollow state without support. It is an object to propose an indirect spot welding method capable of stably obtaining a meteorite-shaped nugget formed in a state.
- the energization time and the pressurization time from the start of energization are divided into two stages, respectively, and the current value and / or the electrode pressing force at each stage of the energization time and pressurization time are individually controlled, It is possible to stably form a melt-bonded portion made of a healthy meteorite-shaped nugget.
- the present invention is based on the above findings.
- the gist configuration of the present invention is as follows. 1. Pressing the welding electrode against the metal plate from one side while pressing the welding electrode against a member on which at least two metal plates are overlapped, and feeding the terminal on the other side of the metal plate at a position separated from the welding electrode
- the current value to be energized is constant from the start to the end of the energization, divided from energization start to two time periods t 1, t 2, then pressurized at the first time period t 1 the pressure force F 1, the next time slot t 2, lower pressure than the F 1 F 2
- An indirect spot welding method characterized by pressurizing with
- the applied pressure of the electrode is constant from the start to the end of the energization, After the energization start, it is divided into two time zones t 1 and t 2 , energized at the current value C 1 in the first time zone t 1 , and then at a current value C 2 higher than C 1 in the next time zone t 2.
- An indirect spot welding method characterized by energizing.
- the electrode pressing force is divided into two time zones t F1 and t F2 from the start of energization, In the first time zone t F1 , after pressurizing with the pressurizing force F 1 , in the next time zone t F2 , pressurization is performed with the pressurizing force F 2 lower than F 1 , while regarding the current value to be energized, the time zone t Independent of F1 and tF2, it is divided into two time zones t C1 and t C2 from the start of energization. In the first time zone t C1 , after energizing at the current value C 1 , in the next time zone t C2 , Energi
- FIGS. 2A and 2B show the basic relationship between energization time and applied pressure and the relationship between energization time and current value, respectively.
- the time zone from the start of energization is divided into two simultaneously or independently, and the electrode pressing force F or the current value C to be energized in each time zone. Or both the pressure F and the current value C are controlled.
- each divided time zone is set to t 1 and t 2, and both the applied pressure F and the current value C are controlled independently.
- T F1 and t F2 are time zones for dividing the applied pressure F
- t C1 and t C2 are time zones for dividing the current value C
- F 1 and F 2 are applied pressure in each time zone
- current values are Indicated by C 1 and C 2 .
- the pressure is increased with the applied pressure F 1 and the current value C 1 is energized.
- the time period t 1 while pressing under pressure to a metal plate obtained by superposing the electrodes to start the energization, the time period to begin the formation of the molten part from heat generated by contact resistance between the metal plates.
- pressure F 1 is a direct spot welding method sandwiched by electrodes from both sides can not be a higher pressure, such as, the area of contact between the pressure F 1 is too low electrode and the metal plate becomes excessively small, the current density is increased excessively to the metal plate surface melting Scattering occurs and the surface shape is significantly impaired. Therefore, the pressing force F 1 such that a Such problem does not occur, it is necessary to select appropriately.
- the current value C 1 it is necessary to the current value high enough to initiate melting by heat generated from the metal plates, too high a metal plate surface as described above is melted scattered, Not only does the appearance become poor, the appearance is significantly impaired, but the joint strength also decreases, so it is necessary to select appropriately so as not to cause such a problem.
- the current value C 2 is energized.
- the time period t 2 is the stage which will further grow the fused portion formed began at time period t 1.
- the metal plate around the electrode softens due to heat generated by energization, and when the indirect spot welding is performed in a hollow state with no support on the opposite side of the electrode, the tip of the electrode sinks into the metal plate when the metal plate softens. Since the contact area between the electrode and the metal plate or between the metal plate and the metal plate is increased and the current density is lowered, heat generation sufficient for growing the nugget cannot be obtained. Therefore, in the time period t 2, the pressure F 2 and lower pressure than the pressure F 1, the electrode tip is necessary to suppress the sink into the metal plate.
- the current value C 2 as higher current value than the current value C 1, it is important to suppress the current density from the increase in contact area due to sinking of the electrodes described above is reduced.
- the current value is too high, the molten metal scatters from the surface of the metal plate on the opposite side of the electrode and melts, resulting in a problem that not only the appearance is significantly impaired but also the joint strength is lowered.
- the present invention is not limited to this. Only one of them may be controlled, and both the pressing force F and the current value C can be controlled independently. That is, in the time period t 1, t 2 of the current value C 1, C 2 is a constant, a method for the pressure F 2 less than F 1, also pressure F 1, F 2 was constant, the current value the C 2 either method of higher than C 1, it is possible to obtain the same effect. However, as described above, in the above-described time zones t 1 and t 2 , it is possible to obtain a further effect by making the pressure F 2 lower than F 1 and making the current value C 2 higher than C 1. it can.
- the applied pressure F is divided into time zones t F1 and t F2 from the start of energization, and the applied pressure F 2 is set lower than F 1 , while the current value C is separated from the time zones t F1 and t F2. Independently, it can be divided into time zones t C1 and t C2 from the start of energization, and the current value C 2 can be made higher than C 1. In this way, the change in the applied pressure and the change in the current are independent times. Higher effects can be obtained by performing optimally with the belt.
- the energization times in the time zones t 1 and t 2 are t 1 : It is preferable that 0.02 to 0.30 s, t 2 : about 0.10 to 0.60 s.
- the applied pressure in each of the time zones t 1 and t 2 is F 1 : 300 to 2000 N, F 2 : about 100 to 1500 N, and the current values are C 1 : 2.0 to 10.0 kA, C 2 : Preferably about 2.5 to 12.0 kA.
- the current values C 1 and C 2 are constant, and the constant current value when the pressure F 2 is lower than F 1 is about 2.5 to 10 kA, and the pressure F 1 , F 2 is constant, and the constant pressure when the current value C 2 is higher than C 1 is preferably about 200 to 1500 N. Furthermore, when both the pressing force F and the current value C are controlled independently, the pressing force F is set to t F1 : 0.02 to 0.30 s and t F2 : 0.10 to 0.60 s.
- F 1 is about 300 to 2000 N and F 2 is about 100 to 1500 N
- the current value C is t C1 : 0.02 to 0.30 s
- t C2 0.10 to 0.60 s
- C 1 2.0 to 10.0 kA and C 2 : 2.5 to 12.0 kA in each of the time zones t C1 and t C2 are preferable.
- an electrode having a curved tip at the tip is preferable to use as the welding electrode.
- the tip of the electrode By making the tip of the electrode a curved surface, a sufficient contact area between the electrode and the metal plate is ensured in the initial stage of energization, the current density increases excessively, the metal plate surface is melted and scattered, and the surface shape is Problems that are significantly impaired can be avoided, and furthermore, a necessary and sufficient pressure contact state is formed between the metal plates, the current density is appropriately maintained, and sufficient heat generation is obtained to start melting.
- the tip of the electrode sinks into the metal plate, increasing the contact area between the electrode and the metal plate, and between the metal plate and the metal plate.
- heat generation sufficient for growth may not be obtained, by making the tip of the electrode a curved surface, it is possible to avoid a uniform increase in contact area with respect to the sinking of the tip of the electrode.
- the curved surface of the electrode tip can have a uniform curvature, or a relatively large curvature on the side close to the tip with a circle having a predetermined radius centered on the tip, and a relatively small curvature on the side far from the tip.
- the radius of curvature is preferably 10 to 80 mm.
- the radius of the predetermined circle centered on the tip is It is desirable that the radius of curvature on the side close to the tip is 4 to 10 mm, and the radius of curvature on the side far from the tip is 4 to 12 mm.
- the indirect spot welding method was performed with the configuration shown in FIG.
- the metal plate 21 an SPC270 steel plate having a thickness of 0.7 mm and a chemical component shown in Table 1 and having a tensile strength of 270 MPa is used, and as the metal plate 22, the plate thickness is 1.
- welding was performed according to the energizing time, applied pressure, and current value of the pattern shown in Table 2.
- a chromium copper alloy was used as the material, and an electrode having a curved surface of R40 mm at the tip and a DC inverter type power source were used.
- Table 3 shows the results of examining the nugget diameter, the nugget thickness, the nugget thickness / diameter, and the occurrence of scattering of each joint when welding with the energization pattern shown in Table 2.
- the nugget diameter is the length on the overlapping line of the melted portion formed between the metal plates 21 and 22 in the cross section cut around the welded portion.
- the nugget thickness was the maximum thickness of the melted portion formed between the metal plates 21 and 22 in the cross section cut at the center of the weld.
- the nugget thickness / diameter is obtained by dividing the above-described nugget thickness by the nugget diameter.
- the nugget diameter is 4.0 mm or more and the nugget thickness / diameter is 0.35 or more, it can be determined as a suitable nugget formed in a molten state. Furthermore, the occurrence of scattering is disclosed by distinguishing between “surface scattering” occurring between the electrode and the metal plate and “medium scattering” occurring between the metal plate and the metal plate.
- Invention Examples 1 to 3 in which indirect spot welding was performed according to the present invention had a nugget diameter of 4.0 mm or more and a nugget thickness / diameter of 0.35 or more. A molten nugget having a sufficient nugget diameter and a sufficient thickness with respect to this diameter could be obtained, and no occurrence of scattering was observed. In contrast, in Comparative Example 1, surface scattering occurred, and in Comparative Example 3, medium scattering occurred. In Comparative Example 2, no scattering occurred, but the nugget diameter was smaller than 4.0 mm, and the nugget thickness / diameter was smaller than 0.3. In Comparative Example 4, no spatter occurred, but no molten nugget was obtained.
- the indirect spot welding method was performed with a configuration as shown in FIG.
- the upper steel plate has a thickness of 0.7 mm and becomes a chemical component shown in Table 1.
- Tensile strength SPC270 steel plate having a thickness of 270 MPa or more, and the lower steel plate has a thickness of 1.2 mm and the same chemical components shown in Table 1.
- the SPC270 steel plate is placed on a concave metal jig as shown in the figure, the support interval is 30 mm, a ground electrode is attached to the lower part of the jig, and the electrode is pressed from above with welding.
- Table 4 shows time zones from the start of energization of the applied pressure and current value, and the applied pressure and current value conditions in each time zone.
- the time from the start to the end of energization was 0.28 s.
- a chromium copper alloy was used as the material, and an electrode having a curved surface of R40 mm at the tip and a DC inverter type power source were used.
- Invention Examples 1 and 2 have a constant current value C, and in the time zones t 1 and t 2 , when F 2 is lower than F 1 with respect to the applied pressure F, Invention Examples 3 and 4 If force F is constant, in the time period t 1, t 2, with respect to the current value C higher C 2 from C 1, invention examples 5 and 6, in the time period t 1, t 2, pressure F 2 Is lower than F 1 and the current value C 2 is higher than C 1 , and both the applied pressure F and the current value C are controlled at the same time, the inventive examples 7 and 8 are energized with respect to the applied pressure F.
- the applied pressure F 2 is set lower than F 1
- the current value C is independent of the time zones t F1 , t F2 from the start of energization to the time zones t C1 , t F2 , t F1 , t F2 . divided into t C2, the current value C 2 and higher than C 1, independently control both the pressure force F and the current value C It is the case.
- Comparative Examples 1-6 pressure F, when carried out at a constant current value C to end the energization start, Comparative Example 7, in the time period t 1, t 2, the pressure F 2 from F 1
- the comparative example 8 is the time zone t F1 , It is divided into t F2 , the applied pressure F 2 is set lower than F 1 , and the current value C is divided into time zones t C1 and t C2 from the start of energization independently of the time zones t F1 and t F2 , a current value C 2 and lower than C 1, a case of controlling both the pressure force F and the current value C independently.
- Table 5 shows the results of examining the nugget diameter, the nugget thickness, the nugget thickness / diameter, and the appearance defect of each joint when welding with the energization pattern shown in Table 4.
- the nugget diameter is the length on the overlapping line of the melted portion formed between the upper steel plate and the lower steel plate in the cross section cut around the welded portion as in Example 1.
- the nugget thickness was the maximum thickness of the melted portion formed between the upper steel plate and the lower steel plate in the cross section cut at the center of the weld.
- the nugget thickness / diameter is obtained by dividing the above-described nugget thickness by the nugget diameter.
- the nugget diameter is 3.5 mm or more and the nugget thickness / diameter is 0.25 or more, it can be determined that the nugget-like suitable nugget formed in a molten state. Furthermore, regarding the appearance defect caused by melting and scattering of the welded portion, it has been disclosed regarding the occurrence of surface cracking that occurs between the electrode and the steel plate.
- Inventive Examples 1 to 8 in which indirect spot welding was performed according to the present invention had sufficient nugget diameters even under conditions where nuggets were hardly formed directly under the intentionally set electrodes. A molten nugget having a sufficient thickness with respect to this diameter could be obtained, and no appearance defect was observed.
- surface cracking occurred in Comparative Example 1.
- the nugget diameter was smaller than 3.5 mm, and the nugget thickness / diameter was smaller than 0.25. In other comparative examples, no nugget formation was observed.
- the indirect spot welding method was performed with a configuration as shown in FIG.
- the upper steel plate has a thickness of 0.7 mm and becomes a chemical component shown in Table 1.
- Tensile strength SPC270 steel plate having a thickness of 270 MPa or more, and the lower steel plate has a thickness of 1.2 mm and the same chemical components shown in Table 1.
- the SPC270 steel plate is placed on a concave metal jig as shown in the figure, the support interval is 30 mm, a ground electrode is attached to the lower part of the jig, and the electrode is pressed from above with welding. .
- the applied pressure F 2 is set lower than F 1
- the current value C is independent of the time zones t F1 , t F2 from the start of energization to the time zones t C1 , t F2 , t F1 , t F2 . divided into t C2, the current value C 2 and higher than C 1, independently control both the pressure force F and the current value C It is the case.
- Comparative Examples 1-6 pressure F, when carried out at a constant current value C to end the energization start, Comparative Example 7, in the time period t 1, t 2, the pressure F 2 from F 1
- the comparative example 8 is the time zone t F1 , It is divided into t F2 , the applied pressure F 2 is set lower than F 1 , and the current value C is divided into time zones t C1 and t C2 from the start of energization independently of the time zones t F1 and t F2 , a current value C 2 and lower than C 1, a case of controlling both the pressure force F and the current value C independently.
- Table 7 shows the results of examining the nugget diameter, the nugget thickness, the nugget thickness / diameter, and the appearance defect of each joint when welding with the energization pattern shown in Table 6.
- the nugget diameter was the length of the melted portion formed between the upper steel plate and the lower steel plate on the overlap line in the cross section cut around the welded portion in the same manner as in Example 1.
- the nugget thickness was the maximum thickness of the melted portion formed between the upper steel plate and the lower steel plate in the cross section cut at the center of the weld.
- the nugget thickness / diameter is obtained by dividing the above-described nugget thickness by the nugget diameter.
- the nugget diameter is 2.5 mm or more and the nugget thickness / diameter is 0.1 or more, it can be determined as a suitable meteorite-shaped nugget formed in a molten state. Furthermore, regarding the appearance defect caused by melting and scattering of the welded portion, it has been disclosed regarding the occurrence of surface cracking that occurs between the electrode and the steel plate.
- inventive examples 1 to 8 in which indirect spot welding was performed according to the present invention had a sufficient nugget diameter even under a condition in which nuggets were hardly formed directly under an intentionally set electrode. As a result, a molten nugget having a sufficient thickness with respect to this diameter could be obtained, and no appearance defect was observed.
- surface cracking occurred in Comparative Example 1.
- the nugget diameter was 2.7 mm, but a sufficient nugget thickness was not obtained, and the nugget thickness / diameter was smaller than 0.1. In other comparative examples, no nugget formation was observed.
- a sufficient nugget diameter and against this diameter A meteorite-shaped molten nugget having a sufficient thickness can be stably formed.
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Abstract
Description
いずれのスポット溶接も、重ね合わせた少なくとも2枚の鋼板を溶接により接合する点では変わりはない。
図1(a)は、ダイレクトスポット溶接法を示したものである。この溶接は、同図に示すとおり、重ね合わせた2枚の金属板1,2を挟んでその上下から一対の電極3,4を加圧しつつ電流を流し、金属板の抵抗発熱を利用して、点状の溶接部5を得る方法である。なお、電極3,4はいずれも、加圧制御装置6,7および電流制御装置8をそなえており、これらによって加圧力と通電する電流値が制御できる仕組みになっている。
しかしながら、実際の溶接に際しては、十分なスペースがない、閉断面構造で金属板を上下から挟むことができない場合も多く、かような場合には、シリーズスポット溶接法やインダイレクトスポット溶接法が用いられる。
また、特許文献2も、シリーズスポット溶接については有効であると考えられるが、インダイレクトスポット溶接に対しては有効であるとは限らず、しかも電極を接触させる位置に他の部分よりも一段高い座面をプレスなどで形成する工程が必要になるという問題があった。
輸送機器メーカーにおける現状のスポット溶接部の管理基準では、ダイレクトスポット溶接で得られるような完全に溶融した状態を経た碁石形のナゲットであることを要求されることが多いため、接合強度が得られても完全に溶融した状態で形成された碁石形のナゲットが得られなければ管理基準を満足しないという問題がある。
a)重ね合わせた金属板を一方向からのみ電極で加圧し、その反対側は支持の無い中空の状態でインダイレクトスポット溶接を行う場合、両側から電極で挟むダイレクトスポット溶接法のように電極直下に局部的に高い加圧力を与えることができないため、電極直下の重ね合わせた金属板間で高い電流密度が得られず、また通電中に電極が鋼板に沈み込んでいくため、電極−金属板、金属板−金属板間の接触面積が増大し、電極−金属板、金属板−金属板間の電流密度が低下する。そのため、インダイレクトスポット溶接では、ダイレクトスポット溶接法のように電極直下の重ね合わせた金属板間に溶融部が形成されるのに十分な発熱が得難く、溶融接合部が形成されにくい。
b)上記の問題を解決するには、通電中の電流値およびその時間を細かく制御する、または通電中の電極の加圧力およびその時間を細かく制御する、さらには通電中の電流値と電極の加圧力およびの時間を細かく制御することが有効である。
c)特に、通電開始からの通電時間、加圧時間をそれぞれ独立に2段階に分け、通電時間、加圧時間の各段階における電流値および/または電極の加圧力を個別に制御することにより、健全な碁石形のナゲットからなる溶融接合部を安定して形成することができる。
本発明は、上記の知見に立脚するものである。
1.少なくとも2枚の金属板を重ね合わせた部材に対し、一方の面側から金属板に溶接電極を加圧しながら押し当て、他方の面側の金属板には該溶接電極と離隔した位置に給電端子を取り付け、該溶接電極と該給電端子との間で通電して溶接を行うインダイレクトスポット溶接法において、通電する電流値については通電開始から終了まで一定にする一方、電極の加圧力に関しては、通電開始から2つの時間帯t1,t2に区分し、最初の時間帯t1では加圧力F1で加圧したのち、次の時間帯t2では、F1よりも低い加圧力F2で加圧することを特徴とするインダイレクトスポット溶接方法。
図2(a)、(b)に、本発明の基本的な通電時間と加圧力の関係および通電時間と電流値の関係をそれぞれ示す。
本発明では、電極の加圧力、通電する電流値に関して、通電開始からの時間帯を同時にまたはそれぞれ独立して2つに区分し、それぞれの時間帯において電極の加圧力Fまたは通電する電流値Cの一方、または加圧力Fと電流値Cの両方を制御する。ここで、加圧力Fまたは電流値Cの一方を制御する場合には、区分した各時間帯をt1,t2とし、また加圧力Fと電流値Cの両方を独立して制御する場合には、加圧力Fを区分する時間帯をtF1,tF2、電流値Cを区分する時間帯をtC1,tC2とし、各時間帯での加圧力をF1,F2、電流値をC1,C2で示す。
この時間帯t1は、電極を重ね合わせた金属板に加圧しながら押し当てつつ、通電を開始し、金属板間の接触抵抗による発熱から溶融部の形成を始める時間帯である。重ね合わせた金属板を一方向からのみ電極により加圧し、その反対側は支持の無い中空の状態でインダイレクトスポット溶接を行う際には、加圧力F1は両側から電極で挟むダイレクトスポット溶接法のような高い加圧力とすることができないが、加圧力F1が低く過ぎると電極と金属板との間の接触面積が極度に小さくなり、電流密度が過度に上昇して金属板表面が溶融飛散し、表面形状が著しく損なわれる不具合が発生する。従って、加圧力F1はかような不具合が生じないよう、適宜選択する必要がある。
すなわち、上記の時間帯t1,t2において、電流値C1,C2は一定とし、加圧力F2をF1より低くする方法、また加圧力F1,F2は一定とし、電流値C2をC1より高くする方法のどちらでも、同様の効果を得ることができる。
しかしながら、前述したとおり、上記の時間帯t1,t2において、加圧力F2をF1より低くし、かつ電流値C2をC1より高くすることによって、より一層の効果を得ることができる。
なお、時間帯t1,t2において、電流値C1,C2は一定とし、加圧力F2をF1より低くする場合の一定電流値は2.5~10kA程度、また加圧力F1,F2は一定とし、電流値C2をC1より高くする場合の一定加圧力は200~1500N程度とすることが好ましい。
さらに、加圧力Fと電流値Cの両方を独立して制御する場合には、加圧力Fに関しては、tF1:0.02~0.30s、tF2:0.10~0.60s程度とし、各時間帯tF1,tF2においてそれぞれF1:300~2000N、F2:100~1500N程度とすることが、また電流値Cに関しては、tC1:0.02~0.30s、tC2:0.10~0.60s程度とし、各時間帯tC1,tC2においてそれぞれC1:2.0~10.0kA、C2:2.5~12.0kA程度とすることが好ましい。
溶接に際しては、クロム銅合金を材質とし、先端にR40mmの曲面を持つ形状の電極および直流インバータ式の電源を使用した。
なお、表2においてナゲット径は、溶接部を中心で切断した断面において、金属板21、22間で形成される溶融部の重ね線上での長さとした。ナゲット厚さは、溶接部を中心で切断した断面において、金属板21、22間に形成される溶融部の最大厚さとした。また、ナゲット厚さ/径は、上述したナゲット厚さをナゲット径で除したものである。ここに、ナゲット径が4.0mm以上で、かつナゲット厚さ/径が0.35以上であれば、溶融した状態で形成された好適ナゲットと判断することができる。
さらに、散りの発生状況は、電極と金属板間で起こる「表面散り」と、金属板と金属板との間で起こる「中散り」とに区別して開示した。
これに対し、比較例1では、表面散りが発生し、また比較例3では、中散りが発生した。比較例2においては、散りの発生はなかったが、ナゲット径が4.0mmより小さくなり、ナゲット厚さ/径が0.3より小さくなった。また、比較例4は、散りは発生しなかったものの、溶融ナゲットが得られなかった。
溶接に際しては、クロム銅合金を材質とし、先端にR40mmの曲面を持つ形状の電極および直流インバータ式の電源を使用した。
なお、比較例1~6は、加圧力F、電流値Cを通電開始から終了まで一定で実施した場合、比較例7は、時間帯t1,t2において、加圧力F2をF1より低くし、かつ電流値C2をC1より低くして、加圧力Fと電流値Cの両方を同時に制御した場合、比較例8は、加圧力Fに関しては、通電開始から時間帯tF1,tF2に区分し、加圧力F2をF1より低くし、電流値Cに関しては、時間帯tF1,tF2とは独立して、通電開始から時間帯tC1,tC2に区分し、電流値C2をC1より低くして、加圧力Fと電流値Cの両方を独立に制御した場合である。
なお、表4においてナゲット径は、実施例1と同様に溶接部を中心で切断した断面において、上鋼板、下鋼板間で形成される溶融部の重ね線上での長さとした。ナゲット厚さは、溶接部を中心で切断した断面において、上鋼板、下鋼板間に形成される溶融部の最大厚さとした。また、ナゲット厚さ/径は、上述したナゲット厚さをナゲット径で除したものである。ここに、ナゲット径が3.5mm以上で、かつナゲット厚さ/径が0.25以上であれば、溶融した状態で形成された碁石形の好適なナゲットと判断することができる。
さらに、溶接部が溶融飛散しておこる外観不具合に関しては、電極と鋼板間で起こる表面えぐれの発生に関して開示した。
これに対し、比較例1では、表面えぐれが発生した。また、比較例2,3,6~8はいずれも、ナゲット径が3.5mmより小さくなり、ナゲット厚さ/径が0.25より小さくなった。その他の比較例では、ナゲットの形成は観察されなかった。
溶接に際しては、クロム銅合金を材質とし、先端にR40mmの曲面を持つ形状の電極および直流インバータ式の電源を使用した。
なお、比較例1~6は、加圧力F、電流値Cを通電開始から終了まで一定で実施した場合、比較例7は、時間帯t1,t2において、加圧力F2をF1より低くし、かつ電流値C2をC1より低くして、加圧力Fと電流値Cの両方を同時に制御した場合、比較例8は、加圧力Fに関しては、通電開始から時間帯tF1,tF2に区分し、加圧力F2をF1より低くし、電流値Cに関しては、時間帯tF1,tF2とは独立して、通電開始から時間帯tC1,tC2に区分し、電流値C2をC1より低くして、加圧力Fと電流値Cの両方を独立に制御した場合である。
なお、表6においてナゲット径は、実施例1と同様に溶接部を中心で切断した断面において、上鋼板、下鋼板間で形成される溶融部の重ね線上での長さとした。ナゲット厚さは、溶接部を中心で切断した断面において、上鋼板、下鋼板間に形成される溶融部の最大厚さとした。また、ナゲット厚さ/径は、上述したナゲット厚さをナゲット径で除したものである。ここに、ナゲット径が2.5mm以上で、かつナゲット厚さ/径が0.1以上であれば、溶融した状態で形成された碁石形の好適なナゲットと判断することができる。
さらに、溶接部が溶融飛散しておこる外観不具合に関しては、電極と鋼板間で起こる表面えぐれの発生に関して開示した。
これに対し、比較例1では、表面えぐれが発生した。また、比較例3はナゲット径が2.7mmとなったが、十分なナゲット厚さが得られず、ナゲット厚さ/径が0.1より小さくなった。その他の比較例では、ナゲットの形成は観察されなかった。
Claims (5)
- 少なくとも2枚の金属板を重ね合わせた部材に対し、一方の面側から金属板に溶接電極を加圧しながら押し当て、他方の面側の金属板には該溶接電極と離隔した位置に給電端子を取り付け、該溶接電極と該給電端子との間で通電して溶接を行うインダイレクトスポット溶接法において、通電する電流値については通電開始から終了まで一定にする一方、電極の加圧力に関しては、通電開始から2つの時間帯t1,t2に区分し、最初の時間帯t1では加圧力F1で加圧したのち、次の時間帯t2では、F1よりも低い加圧力F2で加圧することを特徴とするインダイレクトスポット溶接方法。
- 少なくとも2枚の金属板を重ね合わせた部材に対し、一方の面側から金属板に溶接電極を加圧しながら押し当て、他方の面側の金属板には該溶接電極と離隔した位置に給電端子を取り付け、該溶接電極と該給電端子との間で通電して溶接を行うインダイレクトスポット溶接法において、電極の加圧力については通電開始から終了まで一定にする一方、通電する電流値に関しては、通電開始から2つの時間帯t1,t2に区分し、最初の時間帯t1では電流値C1で通電したのち、次の時間帯t2では、C1よりも高い電流値C2で通電することを特徴とするインダイレクトスポット溶接方法。
- 少なくとも2枚の金属板を重ね合わせた部材に対し、一方の面側から金属板に溶接電極を加圧しながら押し当て、他方の面側の金属板には該溶接電極と離隔した位置に給電端子を取り付け、該溶接電極と該給電端子との間で通電して溶接を行うインダイレクトスポット溶接法において、電極の加圧力および通電する電流値に関して、通電開始から2つの時間帯t1,t2に区分し、最初の時間帯t1では、加圧力F1で加圧しかつ電流値C1で通電したのち、次の時間帯t2では、F1よりも低い加圧力F2で加圧しかつC1よりも高い電流値C2で通電することを特徴とするインダイレクトスポット溶接方法。
- 少なくとも2枚の金属板を重ね合わせた部材に対し、一方の面側から金属板に溶接電極を加圧しながら押し当て、他方の面側の金属板には該溶接電極と離隔した位置に給電端子を取り付け、該溶接電極と該給電端子との間で通電して溶接を行うインダイレクトスポット溶接法において、電極の加圧力に関しては、通電開始から2つの時間帯tF1,tF2に区分し、最初の時間帯tF1では、加圧力F1で加圧したのち、次の時間帯tF2では、F1よりも低い加圧力F2で加圧する一方、通電する電流値に関しては、時間帯tF1,tF2とは独立して、通電開始から2つの時間帯tC1,tC2に区分し、最初の時間帯tC1では、電流値C1で通電したのち、次の時間帯tC2では、C1よりも高い電流値C2で通電することを特徴とするインダイレクトスポット溶接方法。
- 請求項1~4のいずれかにおいて、前記溶接電極として、先端が曲面形状になる電極を使用することを特徴とするインダイレクトスポット溶接方法。
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Also Published As
Publication number | Publication date |
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US9089924B2 (en) | 2015-07-28 |
US20110272384A1 (en) | 2011-11-10 |
KR20110091592A (ko) | 2011-08-11 |
KR101562484B1 (ko) | 2015-10-22 |
JP5415896B2 (ja) | 2014-02-12 |
CN102300667A (zh) | 2011-12-28 |
JP2010194609A (ja) | 2010-09-09 |
EP2392428A1 (en) | 2011-12-07 |
CN102300667B (zh) | 2016-10-26 |
EP2392428A4 (en) | 2017-06-28 |
KR20140021079A (ko) | 2014-02-19 |
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