WO2013134112A2 - Processus de soudage par résistance et méthode de commande - Google Patents

Processus de soudage par résistance et méthode de commande Download PDF

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Publication number
WO2013134112A2
WO2013134112A2 PCT/US2013/028843 US2013028843W WO2013134112A2 WO 2013134112 A2 WO2013134112 A2 WO 2013134112A2 US 2013028843 W US2013028843 W US 2013028843W WO 2013134112 A2 WO2013134112 A2 WO 2013134112A2
Authority
WO
WIPO (PCT)
Prior art keywords
parts
resistance welding
set forth
joined
controlling
Prior art date
Application number
PCT/US2013/028843
Other languages
English (en)
Other versions
WO2013134112A3 (fr
Inventor
Kevin Arthur FEE
Joseph Allen BRIGGS
William Edward PAJAK
David Dominic FILICICCHIA
Original Assignee
Hess Industries, 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 Hess Industries, Inc. filed Critical Hess Industries, Inc.
Publication of WO2013134112A2 publication Critical patent/WO2013134112A2/fr
Publication of WO2013134112A3 publication Critical patent/WO2013134112A3/fr

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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
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/002—Resistance welding; Severing by resistance heating specially adapted for particular articles or work
    • B23K11/0026—Welding of thin 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
    • 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 pertains to a resistance welding process, and in particular, to a resistance welding process with a method of control that in one application can be used for butt welding parts together.
  • Resistance welding is a process in which a current is passed through materials to be joined, and resistance in the materials and at the weld interface generate heat to allow the materials to be joined. Resistance welding utilizes a combination of heat together with force and time .
  • the material at the interface between the parts to be joined is not heated to a melting point and joined by mixing the melted materials, but rather, the materials are heated to a forging temperature and forged together with force.
  • typically the material at the weld interface does not change from a solid to a liquid but rather, is softened until it is pliable enough to be joined by forging.
  • a resistance welding/forging temperature is approximately 2300°F.
  • resistance welding is used for a wide variety of welding applications due to the ability to quickly and economically weld parts together.
  • Some typical examples of resistance welding include spot or seam welds to weld sheet metal together in an overlapping relationship or to weld a piece of sheet metal to a thicker material.
  • Resistance welding is also commonly used for attaching studs or screws to a surface so that the stud projects from the surface in a perpendicular or angled fashion. Accordingly, the studs or screws can be used to mount other parts to the surface.
  • Resistance welding is also commonly used to form end-to-end butt welds between two Attorney Docket No. 382317-00001 mating end faces.
  • One common application of such a butt weld is in the forming of wheel rims, and in particular, for steel wheel rims.
  • a method for resistance welding parts together and method of controlling the process includes the steps of clamping the parts to be joined with electrodes; closing the gap between the parts to be joined; squeezing the parts together to deform contact surfaces on the parts to be joined defining an initial squeeze force; heating the parts to soften the material; monitoring the contact force between the parts; and forcing the parts together and upsetting material when the contact force reaches a predetermined value. It may also include the steps of holding the parts after being forced together and upset to reduce shrinkage stress and Attorney Docket No. 382317-00001 preheating the parts to increase the temperature before the heating cycle is commenced.
  • the contact force between the parts is monitored while the parts are being heated to a forging temperature, the contact force is increased in order to "upset" the parts by forcing the heated parts together and when the force while the parts are being heated to the forging temperature of the material reaches a predetermined value, for example, approximately 50% of the initial squeeze force.
  • the distance that the parts may be upset is approximately the same distance as the thickness of the parts being joined together.
  • the parts to be joined may be manufactured from steel, the steel having thickness from between 1.5 mm to 13 mm and a width of 125 mm to 500 mm.
  • the steel may be selected from a grade having a 230 MPa to 550 MPa yield strength.
  • a direct electric current can be used to heat the parts, the direct current having an approximate square wave configuration when the time and current value are graphed.
  • Fig. 1 is an isometric view of a wheel rim with an axial or longitudinal butt weld seam that was welded using conventional resistance welding parameters.
  • FIG. 2 is an isometric view of a wheel rim with a longitudinal butt weld seam welded using resistance welding parameters in accordance with the present invention.
  • Fig. 3 is a cross sectional view of parts to be resistance but welded together.
  • Fig. 4 is a cross sectional view of the parts in Fig. 3 with the faces to be joined butt against one another and squeezed together; Attorney Docket No. 382317-00001
  • Fig. 5 is a cross sectional view of the parts of Fig. 3 after being heated and upset to weld the interfaces together using conventional resistance weld parameters.
  • Fig. 6 is a front elevational view of an exemplary display of a resistance weld controller resistance welding for use with the present invention.
  • Fig. 7 shows an exemplary display of jog platten test panel which forms part of the resistance weld controller for use with the present invention wherein parameters in accordance with the subject invention may be entered;
  • Fig. 8 is another exemplary display wherein parameters for a systems welding in accordance with the subject invention can be entered;
  • Fig. 9 is a graph of time versus value curve for the parameters of force, current, position, and velocity for a resistance welding process in accordance with the present invention.
  • Fig. 10 is a flow chart of the process for resistance welding in accordance with the present invention.
  • FIG. 1 one embodiment of a wheel rim is shown, generally indicated as 10.
  • the rim is formed from a rolled sheet of material, which is often steel, wherein the ends of the sheet are resistance butt welded together to form a cylinder.
  • the wheel rim 10 has a generally cylindrical shape which includes flared ends 12a and 2b and a central portion 14.
  • the wheel rim 10 is manufactured with an axial or longitudinal butt weld seam 16 extending along the length of the central portion 14.
  • Fig. 1 is generally representative of resistance butt welds and affected zones for such a seam using conventional parameters and techniques.
  • the butt weld seam 16 is formed with a relatively large heat affected zone and upset area as a part of the manufacturing process.
  • wheel rim 110 has a generally cylindrical configuration and includes flared ends 112a and 112b and a central portion 114. Wheel rim 110 also includes a longitudinal butt weld seam 116 with a representative weld and heat affected zone shown for a weld made with the resistance welding process and method of control of the subject invention. The heat affected zone in the weld area of butt weld seam 116 is considerably smaller than that of butt weld seam 16.
  • the butt weld seam 116 is a result of using a total lower current and deformed or upset area as compared to conventional processes.
  • the process in accordance with the present invention utilizes approximately constant DC current as opposed to ramped up and down current, as commonly used in conventional methods, as well as a monitoring and control process based upon the force exerted in pushing the weld faces together, as is discussed in further detail below.
  • FIGs. 3-5 cross sections through a wheel rim 110 show the mechanical steps of the welding process to form butt weld seam 116 in accordance with the present invention.
  • ends 112a and 112b typically have not been flared yet so that the shape conforms to middle portion 114 along the length of the wheel rim 110.
  • a flat sheet of steel or other metal Prior to welding, a flat sheet of steel or other metal is rolled into a generally cylindrical shape having end faces 120a and 120b. Adjacent ends 120a and 120b of the portions 114 are clamped together by way of welding electrodes, for example, aligned copper wheels, on both the inner and outer faces of each sheet member 114.
  • a gap G exists between end faces 120a and 120b, which are to be welded to one another. From there, end faces 120a and 120b are brought together by increasing the force between the electrodes, as shown in Fig. 4 to close the gap therebetween and bring end faces 120a and 120b into contact with one another.
  • the contact position is registered as the home position with a weld controller used for the process for a particular wheel rim that is being prepared for welding.
  • Such weld controllers are known in the art and are known to include a CPU, persistent memory storage for storing one or more programs and data, input means for receiving data, such as temperature and force, as well as manually input data, and a display, as will be discussed below. Dimensional measurements for subsequent weld cycles are measured from this home position.
  • the step of closing the gap step is initiated with rim band gaps from 0 mm to 25 mm.
  • An exemplary target time for closing the gap is 0.2 seconds.
  • the target gap close is 1 mm.
  • An exemplary target time for the squeeze step is 0.5 seconds, and one target distance for horizontal movement is 1 mm.
  • the squeeze step is not optional in this particular embodiment of the process
  • the next step is an optional preheat step to increase the temperature of the materials to be joined at the joint interface.
  • This step is used under three conditions: when the temperature of the steel is below 10°C, if the thickness of the material is greater than 8 mm, or when High Strength Low Alloy (HSLA) steel material is used. If Attorney Docket No. 382317-00001 any of these conditions are present, the weld quality can be improved with a preheat step.
  • One target time for the step is 0.5 seconds, and there is no intended horizontal movement of the parts in the preheat step, if performed.
  • the next step is heating the material to be welded.
  • the materials to be joined may be uniformly heated at the joint area through the depth of any material which will be upset during the forging or upset step.
  • the material is heated to the forging temperature of the material.
  • the forging temperature of steel is approximately 2250°F.
  • the controlling variable of the step is the percentage of the maximum current required to achieve energy input into the joint and upset zone.
  • the current level needed to achieve adequate heating through the upset zone is in the range of 120 to 180 amps per mm 2 .
  • the higher the amperage the less time is required for heating. However, as heating time decreases, the depth of the heat penetration into the joint also decreases.
  • the time duration of the step is automatically controlled, but limited, for example, to 3 seconds maximum.
  • the electrical resistance at the joint interface is high. As the joint temperature rises, the electrical resistance of the steel increases until it reaches approximately 1850°F. Above this temperature, the electrical resistance of the steel stabilizes, and the joint materials begin to soften. Once the joint area material softens, the joint interface begins to merge together, decreasing the force necessary to remain at constant position.
  • the weld controller monitors the platten force until the value falls below a predetermined value, for example, 50% of the calculated squeeze force. Once the force falls below, for example, 50% of the squeeze force, the upset step is initiated.
  • An exemplary target time for the heating step is 1 second, and there is no intended horizontal movement of the parts relative to one another.
  • the function of the upset step is to weld the joint interface by forcing the joint U (see Fig. 5) together under high pressure. It should be noted that the operator can control current up to, for example, 60% of the current value that was input into the heating step, to aid the upsetting step and prevent the joints from becoming brittle. Current should be used during the upset step if the material thickness is greater than 7 mm and on HSLA materials.
  • the target distance to horizontally move and forge or force Attorney Docket No. 382317-00001 the parts together is the same as the material thickness being welded.
  • One exemplary target time for the upset step is 0.75 seconds.
  • a hold step may be used to reduce shrinkage stress in the weld and prevent weld cracks from forming by controlling the weld cooling rate.
  • the current can be controlled and initiated by the operator during this step for a value of , for example, up to 25% of the value used during the heating step.
  • an inverter/transformer system capable of providing nearly steady state DC weld current may be used. This can reduce energy use requirements by reducing both the peak current required and the time needed to heat the weld area to welding temperature.
  • the system may use three transformers, where typical prior art systems may require five transformers. This results in a 40% reduction in current. It should further be appreciated that forging pressures associated with the subject invention may be approximately one-sixth that used in standard resistance welding process.
  • the system can monitor and automatically respond to the process step, the horizontal position of the parts relative to one another, the force exerted pushing the parts together, the weld current, and the velocity of the movement.
  • Figs. 6-8 illustrate various displays of a weld controller. Referring now to Fig. 6, an example of an exemplary display disclosing example process values that may be used for the welding process described above and limiting values is shown, generally indicated as 200.
  • FIG. 7 an exemplary display illustrating test parameters and actual parameters for position, force, and weld current, is shown, generally indicated as 300.
  • FIG. 8 an exemplary display, generally indicated as 400, is shown illustrating the parameters of time, force, current, and distance for each of the separate steps of the process detailed above.
  • a graph is shown that depicts the values of the parameters for force, current, position, and velocity in relation to time and is generally indicated as 500.
  • the curve or graph of time versus force is indicated as 530.
  • the curve of time versus current is shown, indicated as 532, the curve of time versus horizontal position is shown, indicated as 534, and the curve of time verus velocity is shown, indicated as 536.
  • the curve of time versus the sequence or step in the process is shown, indicated as 538.
  • the current used during the heating step is basically a constant current as is shown between the exemplary times of 0.6 and 1.5 seconds.
  • a flow diagram generally indicated as 600.
  • the first step is clamping adjacent ends 120a and 120b of the portions 114 together by way of welding electrodes, for example, aligned copper wheels, on both the inner and outer faces of each sheet member 114.
  • the gap is closed between the rim parts 120a, 120b in step 620, and then, the parts are squeezed together to deform the contact surfaces in step 630.
  • a preheat sequence may be initiated as discussed above in step 640, noting that this is an optional step.
  • the parts are heated to a forging temperature while the contact force between the rim parts is monitored in step 650.
  • the upset step will commence forcing the rim parts 120a, 120b together in step 660.
  • the optional step of holding the parts in 670 may be commenced as noted to prevent weld cracking and reduce shrinkage stress.
  • the steps of gap close and squeeze may be automatic functions with no operator input.
  • the time may be entered by the operator, the Attorney Docket No. 382317-00001 current level for the heat step, the current level for the upset step, and the time and current level for the hold step. All other parameters may be automatic.
  • an optimal range of material thickness is 1.5 mm to 13 mm of steel for this process and steel strip in widths between 125 mm and 500 mm, for steel grades from 230 MPa to 550 MPa yield strength. Examples of a successful welds and parameters performed in accordance with the subject invention are set forth in the Tables 1 and 2 below.
  • Table 1 Parameters: 2 mm x 21 1 mm strip - 450 MPa steel yield strength
  • Step Time Squeeze Current Distance Weld AC Power force (kN) (kA) (mm) energy (W hr)
  • Step Time Squeeze Current Distance Weld AC Power force (kN) (kA) (mm) energy (W hr)

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

L'invention concerne une méthode de soudage par résistance de pièces consistant à serrer les pièces à joindre grâce à des électrodes ; éliminer l'interstice entre les pièces à joindre ; comprimer les pièces ensemble afin de déformer les surfaces de contact sur les pièces à joindre ; chauffer les pièces pour ramollir le matériau ; surveiller la force de contact entre les pièces ; et forcer les pièces ensemble et effectuer le refoulement du matériau lorsque la force de contact atteint une valeur prédéterminée. Elle peut aussi consister à maintenir les pièces après les avoir forcées ensemble et refoulées afin de réduire les contraintes de retrait et préchauffer les pièces afin d'augmenter la température avant de commencer le cycle de chauffage.
PCT/US2013/028843 2012-03-05 2013-03-04 Processus de soudage par résistance et méthode de commande WO2013134112A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201261606760P 2012-03-05 2012-03-05
US61/606,760 2012-03-05

Publications (2)

Publication Number Publication Date
WO2013134112A2 true WO2013134112A2 (fr) 2013-09-12
WO2013134112A3 WO2013134112A3 (fr) 2015-06-18

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Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4912295A (en) * 1987-08-27 1990-03-27 Sumitomo Metal Industries, Ltd. Butt welding method
US5880425A (en) * 1997-04-29 1999-03-09 Board Of Regents, The University Of Texas System Method and apparatus for joining metals
JP4528089B2 (ja) * 2003-10-22 2010-08-18 新日本製鐵株式会社 耐脆性破壊発生特性を有する船体用大入熱突合せ溶接継手
US9044818B2 (en) * 2007-11-08 2015-06-02 Lincoln Global, Inc. Method of welding two sides of a joint simultaneously
US8592722B2 (en) * 2008-11-03 2013-11-26 Illinois Tool Works Inc. Weld parameter interface

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