WO2021117209A1 - 溶接方法及び溶接構造 - Google Patents

溶接方法及び溶接構造 Download PDF

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Publication number
WO2021117209A1
WO2021117209A1 PCT/JP2019/048858 JP2019048858W WO2021117209A1 WO 2021117209 A1 WO2021117209 A1 WO 2021117209A1 JP 2019048858 W JP2019048858 W JP 2019048858W WO 2021117209 A1 WO2021117209 A1 WO 2021117209A1
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Prior art keywords
members
joined
auxiliary member
boundary
facing
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Application number
PCT/JP2019/048858
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English (en)
French (fr)
Inventor
中村　友美
Original Assignee
新電元工業株式会社
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 新電元工業株式会社 filed Critical 新電元工業株式会社
Priority to CN201980101169.7A priority Critical patent/CN114555279B/zh
Priority to DE112019007968.9T priority patent/DE112019007968T5/de
Priority to JP2020547437A priority patent/JP7003284B2/ja
Priority to PCT/JP2019/048858 priority patent/WO2021117209A1/ja
Priority to US17/782,335 priority patent/US20230039275A1/en
Publication of WO2021117209A1 publication Critical patent/WO2021117209A1/ja

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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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/18—Working by laser beam, e.g. welding, cutting or boring using absorbing layers on the workpiece, e.g. for marking or protecting purposes
    • 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
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/21—Bonding by 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
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys
    • B23K2103/12—Copper or alloys thereof

Definitions

  • the present invention relates to a welding method and a welded structure.
  • Patent Document 1 discloses a welding method in which a plurality of members to be joined are joined to each other by laser welding.
  • electricity does not pass through the member to be welded during welding, and the range affected by heat during welding can be kept small, so the effect of welding on electronic components (electrical effect, thermal effect) ) Is small.
  • the present invention has been made in view of the above circumstances, and is a welding method and a welding structure capable of easily welding a member to be welded having a low laser absorption rate even in laser welding in which the output of laser light is small.
  • the purpose is to provide.
  • an auxiliary member having a higher laser beam absorption rate than a plurality of members to be joined to each other is provided with a boundary between the plurality of members to be joined and a boundary between the plurality of members to be joined appears.
  • the auxiliary member is irradiated with a laser beam to melt the auxiliary member, and the molten portion of the auxiliary member raises the temperature of the boundary portion of the plurality of members to be joined.
  • the plurality of members to be welded are welded by shifting the boundary portion to a state in which it easily absorbs the laser beam, irradiating the boundary portion with the laser beam, and melting the boundary portion.
  • the welded structure according to one aspect of the present invention is arranged so as to face the boundary exposed surfaces of the plurality of members to be joined and the plurality of members to be joined in which the boundaries of the plurality of members to be joined appear.
  • Auxiliary members having a higher absorption rate of laser light than the joining members are provided, and the plurality of members to be joined and the auxiliary members are joined to each other by an alloy portion containing the plurality of members to be joined and the components of the auxiliary members. ing.
  • FIG. 5 is a cross-sectional view taken along the line VI-VI of FIG. 5 and 6 are cross-sectional views showing a state before the auxiliary members are attached to the three members to be joined.
  • FIG. 8 is a plan view of FIG. 9 is a cross-sectional view taken along the line XX of FIG. It is a perspective view which shows the plurality of members to be joined and auxiliary member used in the welding method which concerns on 2nd Embodiment of this invention.
  • FIG. 11 is a cross-sectional view taken along the line XII-XII of FIG. It is sectional drawing which shows the welding method and the welding structure which concerns on 2nd Embodiment of this invention. It is sectional drawing which shows the modification of the plurality of members to be joined and auxiliary member used in the welding method which concerns on 2nd Embodiment of this invention.
  • the welding method according to the present embodiment is a method of joining two members 1 to be joined to each other by using a laser beam LL.
  • auxiliary member 2 is a material having a higher absorption rate of laser light LL (hereinafter, referred to as laser absorption rate) than the member 1 to be joined. Further, the auxiliary member 2 is a material having a higher melting point than the member 1 to be joined.
  • the member 1 to be joined is copper (Cu)
  • stainless steel (SUS) can be used for the auxiliary member 2.
  • the laser beam LL is the laser beam of a fiber laser
  • the laser absorption rate of copper is about 2%
  • the laser absorption rate of stainless steel is about 25%.
  • the two members are covered so that the two members 1 are in contact with each other and the boundary exposed surface 12 of the two members 1 where the boundary 11 of the two members 1 appears is flush with each other.
  • the joining member 1 is arranged.
  • the auxiliary member 2 is arranged so that the auxiliary member 2 faces and contacts the boundary exposed surface 12 of the two members to be joined 1.
  • the facing surface 21 of the auxiliary member 2 facing the two members to be joined 1 comes into surface contact with the boundary exposed surface 12.
  • Both the boundary exposed surface 12 and the facing surface 21 of the auxiliary member 2 are formed on a flat surface.
  • the auxiliary member 2 is formed in a plate shape in which the direction in which the facing surface 21 and the opposite surface 22 facing the opposite side to the facing surface 21 are lined up is the plate thickness direction.
  • the laser beam LL is applied to the opposite surface 22 of the auxiliary member 2 to melt the auxiliary member 2.
  • the laser beam LL is the boundary 11 between the two members 1 to be joined in the direction in which the member 1 to be joined and the auxiliary member 2 are aligned (the thickness direction of the auxiliary member 2) in the opposite surface 22 of the auxiliary member 2. Is irradiated to a position overlapping with (or a region in the vicinity thereof).
  • the laser beam LL irradiates not the position overlapping the boundary 11 but another position on the opposite surface 22 of the auxiliary member 2 depending on the output of the laser beam LL, the diameter of the focal point, or the size of the member 1 to be joined. May be done.
  • the temperature of the boundary exposed surface 12 and the boundary portion 13 of the two members 1 to be joined rises due to the molten portion 23 of the auxiliary member 2, and the laser beam LL reaches the boundary exposed surface 12 of the two members 1 to be joined. As a result, the boundary portion 13 is melted.
  • the temperature of the boundary exposed surface 12 and the boundary portion 13 of the two members 1 to be joined rises due to the molten portion 23 of the auxiliary member 2, so that the boundary exposed surface 12 and the boundary portion 13 of the two members 1 to be joined are subjected to laser light LL.
  • the laser absorption rate of the boundary exposed surface 12 and the boundary portion 13 of the two members 1 to be joined becomes high. Since the boundary exposed surface 12 and the boundary portion 13 of the two members 1 to be joined have a high laser absorption rate, they are heated not only by the heat of the molten portion 23 of the auxiliary member 2 but also by the laser beam LL. As a result, the temperature of the boundary portion 13 of the two members 1 to be joined is likely to rise further, and the boundary portion 13 is likely to be melted.
  • the alloy portion 3 containing the components of the two joint members 1 and the auxiliary member 2 is formed. It is formed. Then, the two members 1 to be joined and the auxiliary member 2 are joined to each other by the alloy portion 3.
  • the welding method of the present embodiment for welding the two members 1 to be joined is completed.
  • the two members 1 to be joined may be arranged with a slight gap at the boundary 11. Further, the two members 1 to be joined may be arranged in a state where the boundary exposed surface 12 is not flush with each other and has a slight step. Further, the auxiliary member 2 may be arranged with a slight gap between the facing surface 21 of the auxiliary member 2 and the boundary exposed surface 12 of the two members to be joined 1.
  • the welded structure obtained by the welding method of the present embodiment includes two members to be joined 1 and an auxiliary member 2 arranged so as to face the boundary exposed surface 12.
  • the two members to be joined 1 and the auxiliary member 2 are joined to each other by an alloy portion 3 containing the components of the two members to be joined 1 and the auxiliary member 2.
  • the alloy portion 3 is a combination of the melted portion 23 of the auxiliary member 2 (see FIGS. 2 and 3) and the melted portion of the two members 1 to be joined.
  • three or more members to be joined may be joined to each other by using the auxiliary member 2.
  • the first embodiment is a welding method and a welding structure in which three plate-shaped members to be joined 1A are arranged so as to be stacked in the plate thickness direction and these three members to be joined 1A are welded.
  • the boundary 11A appearing on the boundary exposed surface 12A of the three members to be joined 1A is linear (particularly see FIG. 5).
  • the boundary exposed surface 12A of the three members to be joined 1A is a side surface of the members to be joined 1A extending in the arrangement direction (horizontal direction in FIGS. 6 and 7) of the three members to be joined 1A.
  • the three members to be joined 1A are arranged so that the boundary exposed surfaces 12A of the three members to be joined 1A are flat.
  • the number of members 1A to be joined in the first embodiment is not limited to three, and may be two or four or more, for example.
  • the auxiliary member 2A in the first embodiment is formed by bending a plate-shaped member.
  • the auxiliary member 2A has a clip shape having a facing portion 25A and a pair of wall portions 26A extending from both ends of the facing portion 25A.
  • the facing portion 25A is formed in a flat plate shape having a rectangular shape in a plan view. Both sides (opposing surface 21A, opposite surface 22A) of the facing portion 25A facing opposite sides in the plate thickness direction of the facing portion 25A are formed flat.
  • the length between the pair of wall portions 26A in the facing portion 25A (the width dimension of the facing portion 25A, more specifically, the width dimension of the facing surface 21A) is such that the three members to be joined 1A are overlapped in the plate thickness direction. It is longer than the dimensions of the three members to be joined 1A in the arrangement direction. That is, the facing surfaces 21A of the facing portions 25A are arranged to face each other in the entire arrangement direction of the boundary exposed surfaces 12A of the three members to be joined 1A.
  • the pair of wall portions 26A are bent and extend toward the facing surface 21A from both ends of the facing portion 25A.
  • the pair of wall portions 26A do not extend at right angles to the facing portions 25A, but extend from both ends of the facing portions 25A in a state where the pair of wall portions 26A are inclined in a direction approaching each other.
  • the pair of wall portions 26A are elastically flexible and deformable in a direction away from each other (and in a direction approaching each other) with a connecting portion (bending portion) with the facing portion 25A as a fulcrum.
  • the tip ends of the pair of wall portions 26A are bent and extended in directions away from each other.
  • the facing surface 21A of the facing portion 25A is arranged to face the boundary exposed surface 12A of the three joined members 1A, and the three joined members 1A are sandwiched by the pair of wall portions 26A from these arrangement directions.
  • Attached to the three members to be joined 1A In this state, the flat facing surface 21A of the facing portion 25A facing the boundary exposed surface 12A comes into surface contact with the flat boundary exposed surface 12A.
  • the three members to be joined 1A are sandwiched by the pair of wall portions 26A from the arrangement direction, whereby the three members to be joined 1A are joined. It is held in a state of being.
  • the pair of wall portions 26A function as movement limiting portions that limit the relative movement of the three members to be joined 1A.
  • the welding method of welding the three members to be joined 1A using the auxiliary members 2A is the same as the method shown in FIGS. 1 to 4 after the auxiliary members 2A are attached to the three members to be joined 1A as described above.
  • the three members to be joined 1A are welded by the method. That is, on the opposite surface 22A of the facing portion 25A of the auxiliary member 2A, the laser beam LL is irradiated to a position (or a region in the vicinity thereof) where the boundary 11A of the two adjacent members 1A and the facing portion 25A overlap in the plate thickness direction. To do.
  • the irradiation position of the laser beam LL on the auxiliary member 2 is moved along the linear boundary 11A.
  • the laser beam LL may be irradiated along the boundary 11A so as to have a predetermined width such as a spiral shape or a sawtooth shape. Since the three members to be joined 1A have two boundaries 11A on the boundary exposed surface 12A, the laser beam LL is irradiated to the positions corresponding to the two boundaries 11A, respectively.
  • the portion of the facing portion 25A that overlaps the boundary 11A of the bonded member 1A melts from the opposite surface 22A side to the facing surface 21A side, and then the two bonded members 1A including the boundary 11A. The boundary part of is melted. Then, an alloy portion composed of a melted portion of the facing portion 25A and a boundary portion between the two melted members to be joined 1A is formed, and the two bonded members 1A and the facing portion 25A are joined to each other by the alloy portion. Since the two boundaries 11A are exposed on the boundary exposed surface 12A of the three members 1A to be joined, the portions corresponding to the two boundaries 11A are irradiated with the laser beam LL and joined in the same manner as described above.
  • the pair of wall portions 26A of the auxiliary members 2A remain unmelted by the laser beam LL. Therefore, even in the welded structure, the auxiliary member 2A is kept in a state for joining the three members to be joined 1A.
  • the second embodiment is a welding method and a welding structure in which two members 1B and 1C having different shapes are arranged so as to be in contact with each other and the two members 1B and 1C to be welded are welded.
  • the first member to be joined 1B in the second embodiment is a member formed in a columnar shape extending in one direction.
  • the second member to be joined 1C is a member formed in a square columnar shape extending in one direction.
  • the first and second members 1B and 1C to be joined extend in the same direction and are arranged in a state where their outer surfaces are in contact with each other.
  • the boundary exposed surfaces 12B of the first and second members 1B and 1C are end faces of the two members 1B and 1C to be joined in the longitudinal direction.
  • the first and second members to be joined 1B and 1C are arranged so that the boundary exposed surface 12B is flat.
  • the first and second members 1B and 1C may be arranged in a state where the boundary exposed surface 12B is not flush with each other and has a slight step. Further, the number of the members 1B and 1C to be joined in the second embodiment is two, but the number is not limited to this, and may be three or more.
  • the curved side surface of the first member to be joined 1B and the flat side surface of the second member to be joined 1C are close to each other.
  • the boundary 11B appearing on the boundary exposed surface 12B of the two members 1B and 1C is point-shaped (see FIG. 9).
  • the auxiliary member 2B in the second embodiment has a cap shape having a facing portion 25B and a peripheral wall portion 26B extending from the peripheral end portion of the facing portion 25B.
  • the facing portion 25B is formed in a circular plate shape in a plan view. Both sides (opposing surface 21B, opposite surface 22B) of the opposing portion 25B facing opposite sides in the plate thickness direction of the opposing portion 25B are formed flat.
  • the area of the facing surface 21B of the facing portion 25B is substantially the same as the area of the circumscribed circle of the boundary exposed surface 12B of the first and second members 1B and 1C to be joined. That is, the facing surface 21B of the facing portion 25B is arranged to face the entire boundary exposed surface 12B of the first and second members 1B and 1C to be joined.
  • the peripheral wall portion 26B extends from the peripheral end portion of the facing portion 25B toward the facing surface 21B side and is formed in a cylindrical shape.
  • the inner peripheral surface 26B1 of the peripheral wall portion 26B is formed in a circular shape when viewed from the axial direction of the peripheral wall portion 26B.
  • the circular area of the inner peripheral surface 26B1 of the peripheral wall portion 26B is the same as the area of the facing surface 21B of the facing portion 25B, and is the circumscribed circle of the boundary exposed surfaces 12B of the first and second bonded members 1B and 1C. It is approximately the same size as the area (see FIG. 9).
  • the axial length of the peripheral wall portion 26B is shorter than the longitudinal length of the first and second joined members 1B and 1C.
  • the facing surfaces 21B of the facing portions 25B are arranged to face the boundary exposed surfaces 12B of the two joined members 1B and 1C, and the peripheral wall portion 26B surrounds the two joined members 1B and 1C. It is attached to the members 1B and 1C to be joined. In this state, the flat facing surface 21B of the facing portion 25B comes into surface contact with the flat boundary exposed surface 12B. Further, the inner peripheral surface 26B1 of the peripheral wall portion 26B is circumscribed with respect to the side surfaces of the first and second joined members 1B and 1C (closely opposed to three points on the side surfaces of the two joined members 1B and 1C). It becomes a state).
  • the peripheral wall portion 26B functions as a movement limiting portion that limits the relative movement of the two members 1B and 1C to be joined.
  • the two members 1B and 1C to be joined are welded by the same method as that shown in FIG. That is, on the opposite surface 22B of the facing portion 25B of the auxiliary member 2B, the laser beam LL is irradiated to a position (or a region in the vicinity thereof) where the boundary 11B of the two members to be joined 1B and 1C and the facing portion 25B overlap in the plate thickness direction. To do.
  • the boundary 11B of the members 1B and 1C to be joined exposed on the boundary exposed surface 12B is point-shaped, the irradiation position of the laser beam LL on the auxiliary member 2 can be irradiated with almost no movement from the position of the boundary 11B. it can.
  • the portion of the facing portion 25B that overlaps the boundary 11B of the two members 1B and 1C melts from the opposite surface 22B side to the facing surface 21B side, and then the two parts including the boundary 11B are included.
  • the boundary portion of the members 1B and 1C to be joined is melted.
  • an alloy portion composed of a molten portion of the facing portion 25B and a boundary portion between the two melted members 1B and 1C to be joined is formed, and the two welded members 1B and 1C and the facing portions 25B are mutually formed by the alloy portion. Be joined.
  • the peripheral wall portion 26B of the auxiliary member 2B remains unmelted by the laser beam LL. Therefore, even in the welded structure, the auxiliary member 2B is kept in a state for joining the two members 1B and 1C to be joined.
  • the auxiliary member 2 having a laser absorption rate higher than that of the plurality of members 1 to be joined is opposed to the boundary exposed surface 12 of the plurality of members 1 to be joined.
  • the auxiliary member 2 is melted by irradiating the auxiliary member 2 with the laser beam LL.
  • the temperature of the boundary portions 13 of the plurality of members 1 to be joined can be raised by the molten portion 23 of the auxiliary member 2.
  • the boundary portion 13 shifts to a state in which it easily absorbs the laser beam LL, and the laser absorption rate of the boundary portion 13 increases.
  • the boundary portion 13 is efficiently heated by the laser beam LL, so that the boundary portion 13 can be melted and the plurality of members 1 to be joined can be welded. Therefore, when the output of the laser beam LL is small and the laser absorption rate of the plurality of members 1 to be joined is low, it is difficult to perform laser welding even if the plurality of members 1 to be joined are directly irradiated with the laser beam LL. Even if there is, the plurality of members 1 to be joined can be easily welded.
  • the melting point of the auxiliary member 2 is higher than the melting point of the plurality of members 1 to be joined. Therefore, the temperature of the molten portion 23 of the auxiliary member 2 melted by the laser beam LL is higher than the melting point of the plurality of members 1 to be joined. As a result, the boundary portions 13 of the plurality of members 1 to be joined are easily melted by the heat of the melted portions 23 of the auxiliary members 2. Therefore, the plurality of members 1 to be joined (particularly the boundary portion 13) can be easily welded without being influenced by the size of the plurality of members 1 to be joined.
  • the auxiliary member 2 is first melted by the irradiation of the laser beam LL.
  • the temperature of the plurality of members 1 to be joined can be raised by the molten portion 23 of the auxiliary member 2.
  • the plurality of members 1 to be joined are shifted to a state in which they can easily absorb the laser beam, and the laser absorption rates of the plurality of members 1 to be joined become high.
  • the plurality of members 1 to be joined are heated not only by the heat of the molten portion 23 of the auxiliary member 2 but also by the laser beam LL, so that the plurality of members 1 to be joined are more reliably melted and welded. Can be done.
  • a plurality of movement restricting portions (a pair of wall portions 26A and peripheral wall portions 26B) of the auxiliary members 2A and 2B. It limits the relative movement of the member 1 to be joined. With this movement limiting portion, it is possible to suppress the variation in the relative positions of the plurality of members 1 to be joined, which occurs when the plurality of members 1 to be joined are assembled in a state of being joined. In addition, it is possible to prevent the members 1 to be joined from being relatively moved and displaced from the state in which the plurality of members 1 are joined. Further, it is possible to prevent the gap between the adjacent members 1 to be joined from being excessively widened.
  • the auxiliary member 2A of the first embodiment sandwiches the three members to be joined 1A, the gap between the members to be joined 1A can be minimized.
  • the auxiliary member 2B of the second embodiment since the inner peripheral surface 26B1 of the peripheral wall portion 26B surrounds the side surfaces of the two members 1B and 1C so as to be close to each other, the two members 1B and 1C are to be joined. The gap between the two can be kept small. From the above, it is possible to suppress welding defects due to excessive expansion of the gap between the members to be joined 1 and to stabilize the quality of welding.
  • the facing surface 21 of the auxiliary member 2 is not limited to the boundary exposed surface 12 of the plurality of members 1 to be joined being formed on a flat surface, for example, on a curved surface, an uneven surface, or the like. May be formed.
  • the facing surface 21 of the auxiliary member 2 may be formed in a shape corresponding to at least the boundary exposed surface 12 so as to make surface contact with the boundary exposed surface 12.
  • FIGS. 11 to 13 a second embodiment of the present invention will be described with reference to FIGS. 11 to 13.
  • three flat plate-shaped members to be joined 1D, 1E, 1F are arranged so as to be overlapped in the plate thickness direction, and these three members to be joined 1D, 1E, 1F are welded by using a laser beam LL. And a welded structure.
  • three members to be joined 1D, 1E, 1F and an auxiliary member 2D are first prepared as in the first embodiment.
  • the materials and characteristics of the three members to be joined 1D, 1E, 1F and the auxiliary member 2D are the same as those in the first embodiment.
  • the three flat plate-shaped members 1D, 1E, and 1F have through holes 15D, 15E, and 15F penetrating in the plate thickness direction (vertical direction in FIGS. 11 and 12, respectively).
  • the through holes 15D, 15E, and 15F are circular through holes when viewed from the plate thickness direction of the members 1D, 1E, and 1F to be joined.
  • the auxiliary member 2D is formed in the shape of a cylindrical rod.
  • the through holes 15D and 15E of the two members 1D and 1E have substantially the same diameter dimension.
  • the diameter dimension of the through holes 15D and 15E is larger than the diameter dimension of the auxiliary member 2D.
  • the diameter dimension of the through hole 15F of the remaining one member to be joined 1F is substantially equal to the diameter dimension of the auxiliary member 2D, and the auxiliary member 2D can be fitted into the through hole 15F.
  • the three members to be joined 1D, 1E, 1F are arranged so as to communicate with each other through the three through holes 15D, 15E, 15F in the plate thickness direction.
  • the member 1F to be joined having the through hole 15F having a small hole diameter dimension is arranged at the end in the arrangement direction of the three members 1D, 1E, 1F to be joined (bottom in FIGS. 11 and 12).
  • the boundaries 11D and 11E of the three members to be joined 1D, 1E and 1F are exposed on the inner peripheral surfaces of the through holes 15D, 15E and 15F of the three members to be joined 1D, 1E and 1F. That is, the inner peripheral surfaces of the through holes 15D, 15E, and 15F are boundary exposed surfaces 12D on which the boundaries 11D, 11E of the three members to be joined 1D, 1E, and 1F appear.
  • the auxiliary member 2D is inserted into the through holes 15D, 15E, 15F of the three members to be joined 1D, 1E, 1F arranged as described above.
  • the auxiliary member 2D fits into the through hole 15F of the member 1F to be joined, which has a smaller hole diameter among the three through holes 15D, 15E, and 15F, and is fixed to the member 1F to be joined.
  • one end surface of the auxiliary member 2 is flush with the surface of the member 1F to be joined (the surface opposite to the boundary 11E), and the other end surface of the auxiliary member 2 is the surface of the member 1D to be joined (the surface of the boundary 11D). It will be in a state of slightly protruding from the opposite surface).
  • the auxiliary member 2D is a boundary formed by the inner peripheral surfaces of the through holes 15D, 15E, 15F of the three members to be joined 1D, 1E, 1F. It is arranged so as to face the exposed surface 12D.
  • the auxiliary member 2D is in a state of being fitted to the through hole 15F of the member to be joined 1F having a small hole diameter as described above.
  • the auxiliary member 2D inserted in this way is a movement limiting unit that restricts the relative movement of the three members to be joined 1D, 1E, 1F in the direction orthogonal to the arrangement direction of the three members to be joined 1D, 1E, 1F. Functions as. That is, by arranging the auxiliary member 2D so as to face the boundary exposed surface 12D, the state for joining the three members 1D, 1E, and 1F to be joined is maintained.
  • the three members to be joined 1D, 1E, 1F and the auxiliary member 2D are arranged as described above, and then shown in FIG.
  • the auxiliary member 2D is irradiated with the laser beam LL to melt the auxiliary member 2D.
  • the laser beam LL is applied to the other end face of the auxiliary member 2D located on the side of the member to be joined 1D, and the irradiation position of the laser beam LL is applied from the center to the periphery of the other end face of the auxiliary member 2D.
  • the auxiliary member 2D is melted.
  • the laser beam LL may be irradiated so as to move from the center to the peripheral edge of the other end surface of the auxiliary member 2D, for example, in a spiral shape.
  • the molten portion of the auxiliary member 2D reaches the boundary exposed surface 12D of the three members to be joined 1D, 1E, 1F.
  • the gap between the inner peripheral surfaces (boundary exposed surface 12D) of the through holes 15D and 15E and the outer peripheral surface of the auxiliary member 2D is filled by the portion of the auxiliary member 2 that protrudes from the member to be joined 1D.
  • the temperature of the boundary portion 13D of the three members 1D, 1E, and 1F to be joined rises due to the melted portion of the auxiliary member 2D, and the boundary portion 13D is melted by irradiating the boundary portion 13D with the laser beam LL. ..
  • the boundary portion 13D shifts to a state in which it easily absorbs the laser beam LL, and the laser absorption rate of the boundary portion 13D increases.
  • an alloy portion 3D containing the components of the three members to be joined 1D, 1E, 1F and the auxiliary member 2D is formed.
  • the three members to be joined 1D, 1E, 1F and the auxiliary member 2D are joined to each other by the alloy portion 3D.
  • the welding method of the present embodiment in which the three members 1D, 1E, and 1F to be welded are welded is completed.
  • the welded structure obtained by the welding method of the present embodiment has three members to be joined 1D, 1E, 1F and three members to be joined 1D, 1E, 1F, as in the first embodiment.
  • the auxiliary member 2D is inserted into the through holes 15D, 15E, 15F and is arranged so as to face the boundary exposed surface 12D formed by the inner peripheral surfaces of the through holes 15D, 15E, 15F.
  • the three members to be joined 1D, 1E, 1F and the auxiliary member 2D are joined to each other by the alloy portion 3D containing the components of the three members to be joined 1D, 1E, 1F and the auxiliary member 2D.
  • the alloy portion 3D is a combination of the melted portion of the auxiliary member 2D and the melted portion of the three members 1D, 1E, and 1F to be joined in the above-mentioned welding method.
  • the entire auxiliary member 2D since the entire auxiliary member 2D is melted, the entire auxiliary member 2D is included in the alloy portion 3D in the welded structure.
  • the portion on one end surface side of the auxiliary member 2D (the portion of the auxiliary member 2D located on the surface side of the member to be joined 1F) may remain without melting.
  • the welding method of the second embodiment has the same effect as that of the first embodiment.
  • the auxiliary member 2D is inserted into the through holes 15D, 15E, 15F of the three members to be joined 1D, 1E, 1F. With the auxiliary member 2D inserted in this way, the variation in the relative positions of the three members to be joined 1D, 1E, 1F that occur when the three members to be joined 1D, 1E, 1F are assembled to be joined is suppressed to a small extent. be able to.
  • three or more members to be welded 1D, 1E, and 1F can be welded by irradiating a single laser beam.
  • the shapes of the through holes 15D, 15E, 15F and the auxiliary member 2D seen from the arrangement direction of the three members to be joined 1D, 1E, 1F are not limited to circular shapes but correspond to each other. It may be formed. Further, the auxiliary member 2D does not have to be fitted and fixed in the through hole 15F of the member to be joined 1F, and is held in a state of being inserted into the three through holes 15D, 15E, 15F. It should be.
  • the diameter dimensions of the three through holes 15D, 15E, and 15F may be equal to each other or different from each other.
  • the inner peripheral surfaces of the three through holes 15D, 15E, 15F may be inclined with respect to the arrangement direction of the three members to be joined 1D, 1E, 1F.
  • the inner peripheral surfaces of the three through holes 15D, 15E, and 15F communicating with each other may be formed in a V-shaped or tapered cross section.
  • the auxiliary member 2D may be formed in a shape corresponding to the inner peripheral surface of the through holes 15D, 15E, 15F, such as a conical shape.
  • the auxiliary member 2D may include a flange portion that projects radially outward of the auxiliary member 2D at one end in the longitudinal direction.
  • the flange portion of the auxiliary member 2D is located at the end in the arrangement direction. You can hook it on the 1st floor.
  • the auxiliary member 2D can be positioned with respect to the three members 1D, 1E, 1F without fitting the auxiliary member 2D into the through hole 15F of the member 1F to be joined.
  • the number of members to be joined may be two or four or more.
  • the members 1F to be joined arranged at one end of the three members 1D, 1E, 1F in the arrangement direction have through holes 15F, for example, as shown in FIG. May also have a recess 15Fb that opens to the boundary 11E side and into which the auxiliary member 2D can be inserted. That is, the hole of the member to be joined 1F into which the auxiliary member 2D is inserted does not have to penetrate. With such a configuration, it is possible to prevent the melted portion of the auxiliary member 2D from being exposed on the opposite side of the boundary 11E of the member to be joined 1F.
  • the auxiliary member may be made of a material having the same or lower melting point as the member to be joined.
  • the type of laser used for irradiating the laser beam is not limited to the one illustrated in the above embodiment, and may be appropriately selected depending on the material of the auxiliary member 2 and the member to be joined 1.

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Abstract

互いに接合する複数の被接合部材（１）よりもレーザ光（ＬＬ）の吸収率が高い補助部材（２）を、前記複数の被接合部材の境界（１１）が現れる前記複数の被接合部材の境界露出面（１２）に対向するように配置し、レーザ光を前記補助部材に照射して前記補助部材を溶融し、前記補助部材の溶融部分（２３）により前記複数の被接合部材の境界部分（１３）の温度を上昇させて当該境界部分がレーザ光を吸収しやすい状態に移行させ、当該境界部分にレーザ光を照射して当該境界部分を溶融することにより前記複数の被接合部材を溶接する。

Description

溶接方法及び溶接構造
本発明は、溶接方法及び溶接構造に関する。
特許文献１には、複数の被接合部材をレーザ溶接によって互いに接合する溶接方法が開示されている。レーザ溶接は、溶接時に被接合部材に電気が通らないため、また、溶接時に熱が影響する範囲を小さく抑えることができるため、電子部品などに対する溶接の影響（電気的な影響、熱的な影響）が小さいという利点がある。
特開平１０－３３４９５７号公報
しかしながら、レーザ溶接に用いるレーザ光の出力が小さい場合、銅などのようにレーザ光の吸収率（レーザ吸収率）が低い被接合部材をレーザ溶接によって接合することは難しい。
本発明は、上述した事情に鑑みたものであって、レーザ光の出力が小さいレーザ溶接であっても、レーザ吸収率が低い被接合部材を容易に溶接することが可能な溶接方法及び溶接構造を提供することを目的とする。
本発明の一態様に係る溶接方法は、互いに接合する複数の被接合部材よりもレーザ光の吸収率が高い補助部材を、前記複数の被接合部材の境界が現れる前記複数の被接合部材の境界露出面に対向するように配置し、レーザ光を前記補助部材に照射して前記補助部材を溶融し、前記補助部材の溶融部分により前記複数の被接合部材の境界部分の温度を上昇させて当該境界部分がレーザ光を吸収しやすい状態に移行させ、当該境界部分にレーザ光を照射して当該境界部分を溶融することにより前記複数の被接合部材を溶接する。
本発明の一態様に係る溶接構造は、複数の被接合部材と、前記複数の被接合部材の境界が現れる前記複数の被接合部材の境界露出面に対向するように配置され、前記複数の被接合部材よりもレーザ光の吸収率が高い補助部材と、を備え、前記複数の被接合部材及び前記補助部材は、前記複数の被接合部材及び前記補助部材の成分を含む合金部によって互いに接合されている。
本発明によれば、レーザ光の出力が小さいレーザ溶接であっても、レーザ吸収率が低い被接合部材を容易に溶接することが可能となる。
本発明の第一実施形態に係る溶接方法を示す断面図である。 本発明の第一実施形態に係る溶接方法を示す断面図である。 本発明の第一実施形態に係る溶接方法を示す断面図である。 本発明の第一実施形態に係る溶接方法及び溶接構造を示す断面図である。 本発明の第一実施形態に係る溶接方法及び溶接構造の第一実施例を示す斜視図である。 図５のVI－VI矢視断面図である。 図５，６において、補助部材を三つの被接合部材に取り付ける前の状態を示す断面図である。 本発明の第一実施形態に係る溶接方法及び溶接構造の第二実施例を示す斜視図である。 図８の平面図である。 図９のX－X矢視断面図である。 本発明の第二実施形態に係る溶接方法に用いる複数の被接合部材及び補助部材を示す斜視図である。 図１１のXII－XII矢視断面図である。 本発明の第二実施形態に係る溶接方法及び溶接構造を示す断面図である。 本発明の第二実施形態に係る溶接方法に用いる複数の被接合部材及び補助部材の変形例を示す断面図である。
〔第一実施形態〕
以下、図１～図１０を参照して本発明の第一実施形態について説明する。図１～図４に示すように、本実施形態に係る溶接方法は、二つの被接合部材１をレーザ光ＬＬを用いて互いに接合させる方法である。
図１に示すように、本実施形態の溶接方法では、はじめに二つの被接合部材１及び補助部材２を用意する。二つの被接合部材１の材質は、例えば同じであってもよいし、異なっていてもよい。補助部材２は、被接合部材１よりもレーザ光ＬＬの吸収率（以下、レーザ吸収率と呼ぶ）が高い材質である。また、補助部材２は、被接合部材１よりも融点が高い材質である。例えば、被接合部材１が銅（Ｃｕ）である場合、補助部材２にはステンレス鋼（ＳＵＳ）を用いることができる。レーザ光ＬＬがファイバーレーザのレーザ光である場合、銅のレーザ吸収率は約２％であり、ステンレス鋼のレーザ吸収率は約２５％である。
次いで、二つの被接合部材１が互いに接触するように、且つ、二つの被接合部材１の境界１１が現れる二つの被接合部材１の境界露出面１２が面一となるように、二つの被接合部材１を配置する。また、補助部材２が二つの被接合部材１の境界露出面１２に対向且つ接触するように補助部材２を配置する。この状態では、二つの被接合部材１に対向する補助部材２の対向面２１が、境界露出面１２に面接触する。境界露出面１２及び補助部材２の対向面２１は、いずれも平坦な面に形成されている。また、補助部材２は、その対向面２１と対向面２１に対して反対側に向く反対面２２とが並ぶ方向を板厚方向とする板状に形成されている。
その後、レーザ光ＬＬを補助部材２の反対面２２に照射して補助部材２を溶融する。具体的に、レーザ光ＬＬは、補助部材２の反対面２２のうち、被接合部材１と補助部材２とが並ぶ方向（補助部材２の板厚方向）において二つの被接合部材１の境界１１と重なる位置（或いはその近傍領域）に照射される。なお、レーザ光ＬＬは、レーザ光ＬＬの出力や焦点の径、或いは被接合部材１のサイズに応じて、当該境界１１と重なる位置ではなく、補助部材２の反対面２２における他の位置に照射されても良い。
レーザ光ＬＬを補助部材２の反対面２２に照射した際には、図２に示すように、はじめに補助部材２の反対面２２側の部分が溶融する。図２における符号２３は、補助部材２の溶融部分を示している。その後、図３に示すように、補助部材２の対向面２１側の部分も溶融し、補助部材２の溶融部分２３が補助部材２の対向面２１及び対向面２１に接している二つの被接合部材１の境界露出面１２に到達する。そして、補助部材２の溶融部分２３によって二つの被接合部材１の境界露出面１２及び境界部分１３の温度が上昇するとともに、レーザ光ＬＬが二つの被接合部材１の境界露出面１２に到達することにより、当該境界部分１３が溶融する。
補助部材２の溶融部分２３によって二つの被接合部材１の境界露出面１２及び境界部分１３の温度が上昇することにより、二つの被接合部材１の境界露出面１２及び境界部分１３がレーザ光ＬＬを吸収しやすい状態に移行され、二つの被接合部材１の境界露出面１２及び境界部分１３のレーザ吸収率が高くなる。二つの被接合部材１の境界露出面１２及び境界部分１３は、レーザ吸収率が高くなっているため、補助部材２の溶融部分２３の熱だけではなく、レーザ光ＬＬによっても加熱される。これにより、二つの被接合部材１の境界部分１３の温度がさらに上昇しやすくなり、当該境界部分１３が溶融しやすくなる。
上記のように、補助部材２及び二つの被接合部材１の境界部分１３が溶融することで、図４に示すように、二つの被接合部材１及び補助部材２の成分を含む合金部３が形成される。そして、二つの被接合部材１及び補助部材２が、合金部３によって互いに接合される。以上により、二つの被接合部材１を溶接する本実施形態の溶接方法が完了する。なお、この溶接方法において、二つの被接合部材１は境界１１に多少の隙間がある状態で配置されていても良い。また、境界露出面１２が面一ではなく多少の段差がある状態で二つの被接合部材１が配置されていても良い。また、補助部材２の対向面２１と、二つの被接合部材１の境界露出面１２との間に多少の隙間がある状態で補助部材２が配置されていても良い。
本実施形態の溶接方法によって得られる溶接構造は、図４に示すように、二つの被接合部材１と、これらの境界露出面１２に対向するように配置される補助部材２と、を備える。溶接構造において、二つの被接合部材１及び補助部材２は、二つの被接合部材１及び補助部材２の成分を含む合金部３によって互いに接合されている。合金部３は、前述した溶接方法において、補助部材２の溶融部分２３（図２，３参照）と二つの被接合部材１の溶融部分とが合わさったものである。
上記した溶接方法及び溶接構造では、三つ以上の被接合部材を補助部材２を用いて互いに接合させてもよい。
次に、本実施形態の第一実施例について図５～図７を参照して説明する。第一実施例は、三つの板状の被接合部材１Ａを板厚方向に重ねて配置し、これら三つの被接合部材１Ａを溶接する溶接方法及び溶接構造である。
第一実施例における三つの被接合部材１Ａは板厚方向に重なるため、三つの被接合部材１Ａの境界露出面１２Ａに現れる境界１１Ａは線状となる（特に図５参照）。三つの被接合部材１Ａの境界露出面１２Ａは、三つの被接合部材１Ａの配列方向（図６，７において左右方向）に延びる被接合部材１Ａの側面である。三つの被接合部材１Ａは、三つの被接合部材１Ａの境界露出面１２Ａが平坦になるように配置されている。なお、第一実施例における被接合部材１Ａの数は三つに限らず、例えば二つでも四つ以上であってもよい。
第一実施例における補助部材２Ａは、板状部材に折り曲げ加工を施すことで形成されている。補助部材２Ａは、対向部２５Ａと、対向部２５Ａの両端部から延びる一対の壁部２６Ａと、を有するクリップ状になっている。対向部２５Ａは、平面視矩形の平板状に形成されている。対向部２５Ａの板厚方向において互いに逆側に向く対向部２５Ａの両面（対向面２１Ａ、反対面２２Ａ）は、平坦に形成されている。対向部２５Ａにおける一対の壁部２６Ａの間の長さ（対向部２５Ａの幅寸法、より具体的には対向面２１Ａの幅寸法）は、三つの被接合部材１Ａをこれらの板厚方向に重ねた三つの被接合部材１Ａの配列方向の寸法よりも長くなっている。すなわち、対向部２５Ａの対向面２１Ａが、三つの被接合部材１Ａにおける境界露出面１２Ａの配列方向全体に対向配置されるようになっている。
一対の壁部２６Ａは、対向部２５Ａの両端部から対向面２１Ａ側に屈曲されて延びている。一対の壁部２６Ａは、対向部２５Ａに対して直角に延びているのではなく、一対の壁部２６Ａが互いに近づく方向に傾斜した状態で、対向部２５Ａの両端部から延びている。一対の壁部２６Ａは、対向部２５Ａとの接続部（屈曲部）を支点として、互いに離れる方向（及び互いに近づく方向）に弾性的に撓み変形可能になっている。一対の壁部２６Ａの先端部側はそれぞれ、互いに離れる方向に屈曲されて延びている。
補助部材２Ａは、対向部２５Ａの対向面２１Ａを三つの被接合部材１Ａの境界露出面１２Ａに対向配置させ、一対の壁部２６Ａによって三つの被接合部材１Ａをこれらの配列方向から挟むように、三つの被接合部材１Ａに対して取り付けられる。この状態において、境界露出面１２Ａに対向する対向部２５Ａの平坦な対向面２１Ａは、平坦な境界露出面１２Ａに面接触する。また、一対の壁部２６Ａが互いに離れる方向に弾性的に撓み変形することで、三つの被接合部材１Ａを一対の壁部２６Ａによって配列方向から挟み、これにより三つの被接合部材１Ａが接合される状態で保持される。また、三つの被接合部材１Ａが一対の壁部２６Ａによって挟持されることにより、三つの被接合部材１Ａが互いに動くことを防ぎ、三つの被接合部材１Ａを接合するための状態に固定する。一対の壁部２６Ａは、三つの被接合部材１Ａの相対的な移動を制限する移動制限部として機能する。
補助部材２Ａを用いて三つの被接合部材１Ａを溶接する溶接方法では、上記のように補助部材２Ａを三つの被接合部材１Ａに取り付けた後に、図１～図４で示した方法と同様の方法で三つの被接合部材１Ａを溶接する。すなわち、補助部材２Ａの対向部２５Ａの反対面２２Ａにおいて、隣り合う二つの被接合部材１Ａの境界１１Ａと対向部２５Ａの板厚方向に重なる位置（或いはその近傍領域）に、レーザ光ＬＬを照射する。なお、境界露出面１２Ａに露出する被接合部材１Ａの境界１１Ａは線状であるため、補助部材２に対するレーザ光ＬＬの照射位置を線状の境界１１Ａに沿って移動させる。このとき、境界１１Ａに沿って、例えば螺旋状や鋸歯状等のように所定の幅を持たせるようにレーザ光ＬＬを照射するようにしてもよい。三つの被接合部材１Ａでは境界露出面１２Ａにおいて二つの境界１１Ａを有しているため、二つの境界１１Ａに対応する位置にそれぞれ、レーザ光ＬＬを照射する。
このようにレーザ光ＬＬを照射すると、対向部２５Ａにおいて被接合部材１Ａの境界１１Ａと重なる部分が反対面２２Ａ側から対向面２１Ａ側まで溶融し、その後、境界１１Ａを含む二つの被接合部材１Ａの境界部分が溶融する。そして、対向部２５Ａの溶融部分と、溶融した二つの被接合部材１Ａの境界部分とからなる合金部が形成され、当該合金部によって二つの被接合部材１Ａ及び対向部２５Ａが互いに接合される。三つの被接合部材１Ａでは境界露出面１２Ａにおいて二つの境界１１Ａが露出するため、二つの境界１１Ａにそれぞれ対応する部分において、レーザ光ＬＬを照射して上記と同様に接合される。
三つの被接合部材１Ａを溶接した後の溶接構造において、補助部材２Ａの一対の壁部２６Ａは、レーザ光ＬＬによって溶融されずに残る。このため、溶接構造においても、補助部材２Ａは三つの被接合部材１Ａを接合するための状態に保つ。
次に、本実施形態の第二実施例について図８～図１０を参照して説明する。第二実施例は、形状が異なる二つの被接合部材１Ｂ，１Ｃを互いに接触させるように配置し、これら二つの被接合部材１Ｂ，１Ｃを溶接する溶接方法及び溶接構造である。
第二実施例における第一被接合部材１Ｂは、一方向に延びる円柱状に形成された部材である。第二被接合部材１Ｃは、一方向に延びる四角柱状に形成された部材である。第一及び第二被接合部材１Ｂ，１Ｃは、同じ方向に延びて互いの外面を接触させた状態で配置される。第一及び第二被接合部材１Ｂ，１Ｃの境界露出面１２Ｂは、長手方向における二つの被接合部材１Ｂ，１Ｃの端面である。第一及び第二被接合部材１Ｂ，１Ｃは、境界露出面１２Ｂが平坦になるように配置されている。なお、境界露出面１２Ｂが面一ではなく多少の段差がある状態で第一及び第二被接合部材１Ｂ，１Ｃが配置されてもよい。また、第二実施例における被接合部材１Ｂ，１Ｃの数は二つであるが、これに限らず、三つ以上であってもよい。
上記のように第一及び第二被接合部材１Ｂ，１Ｃが配置されると、第一被接合部材１Ｂの曲面形状の側面と、第二被接合部材１Ｃの平坦な側面とが近接するため、二つの被接合部材１Ｂ，１Ｃの境界露出面１２Ｂに現れる境界１１Ｂは、点状となる（図９参照）。
第二実施例における補助部材２Ｂは、対向部２５Ｂと、対向部２５Ｂの周端部から延びる周壁部２６Ｂと、を有するキャップ状になっている。対向部２５Ｂは、平面視円形の板状に形成されている。対向部２５Ｂの板厚方向において互いに逆側に向く対向部２５Ｂの両面（対向面２１Ｂ、反対面２２Ｂ）は、平坦に形成されている。対向部２５Ｂの対向面２１Ｂの面積は、第一及び第二被接合部材１Ｂ，１Ｃの境界露出面１２Ｂの外接円の面積と略同じ大きさになっている。すなわち、対向部２５Ｂの対向面２１Ｂが、第一及び第二被接合部材１Ｂ，１Ｃの境界露出面１２Ｂの全体に対向配置されるようになっている。
周壁部２６Ｂは、対向部２５Ｂの周端部から対向面２１Ｂ側に延びて円筒状に形成されている。周壁部２６Ｂの内周面２６Ｂ１は、周壁部２６Ｂの軸方向から見て円形に形成されている。周壁部２６Ｂの内周面２６Ｂ１の円形の面積は、対向部２５Ｂの対向面２１Ｂの面積と同じ大きさであり、第一及び第二被接合部材１Ｂ，１Ｃの境界露出面１２Ｂの外接円の面積と略同じ大きさになっている（図９参照）。周壁部２６Ｂの軸方向の長さは、第一及び第二被接合部材１Ｂ，１Ｃの長手方向の長さよりも短くなっている。
補助部材２Ｂは、対向部２５Ｂの対向面２１Ｂを二つの被接合部材１Ｂ，１Ｃの境界露出面１２Ｂに対向配置させ、周壁部２６Ｂによって二つの被接合部材１Ｂ，１Ｃを囲むように、二つの被接合部材１Ｂ，１Ｃに対して取り付けられる。この状態において、対向部２５Ｂの平坦な対向面２１Ｂは、平坦な境界露出面１２Ｂに面接触する。また、周壁部２６Ｂの内周面２６Ｂ１が、第一及び第二被接合部材１Ｂ，１Ｃの側面に対して外接する（二つの被接合部材１Ｂ，１Ｃの側面における三箇所に対して近接対向した状態となる）。これにより、二つの被接合部材１Ｂ，１Ｃが接合される状態で保持され、二つの被接合部材１Ｂ，１Ｃが互いに動くことが抑制又は防止される。周壁部２６Ｂは、二つの被接合部材１Ｂ，１Ｃの相対的な移動を制限する移動制限部として機能する。
第二実施例の補助部材２Ｂを用いて二つの被接合部材１Ｂ，１Ｃを溶接する溶接方法では、上記のように補助部材２Ｂを二つの被接合部材１Ｂ，１Ｃに取り付けた後に、図１～図４で示した方法と同様の方法で二つの被接合部材１Ｂ，１Ｃを溶接する。すなわち、補助部材２Ｂの対向部２５Ｂの反対面２２Ｂにおいて、二つの被接合部材１Ｂ，１Ｃの境界１１Ｂと対向部２５Ｂの板厚方向に重なる位置（或いはその近傍領域）に、レーザ光ＬＬを照射する。なお、境界露出面１２Ｂに露出する被接合部材１Ｂ，１Ｃの境界１１Ｂは点状であるため、補助部材２に対するレーザ光ＬＬの照射位置を境界１１Ｂの位置からほとんど移動させずに照射することができる。
このようにレーザ光ＬＬを照射すると、対向部２５Ｂにおいて二つの被接合部材１Ｂ，１Ｃの境界１１Ｂと重なる部分が反対面２２Ｂ側から対向面２１Ｂ側まで溶融し、その後、境界１１Ｂを含む二つの被接合部材１Ｂ，１Ｃの境界部分が溶融する。そして、対向部２５Ｂの溶融部分と、溶融した二つの被接合部材１Ｂ，１Ｃの境界部分とからなる合金部が形成され、当該合金部によって二つの被接合部材１Ｂ，１Ｃ及び対向部２５Ｂが互いに接合される。
二つの被接合部材１Ｂ，１Ｃを溶接した後の溶接構造において、補助部材２Ｂの周壁部２６Ｂは、レーザ光ＬＬによって溶融されずに残る。このため、溶接構造においても、補助部材２Ｂは二つの被接合部材１Ｂ，１Ｃを接合するための状態に保つ。
以上説明したように、第一実施形態の溶接方法によれば、複数の被接合部材１よりもレーザ吸収率が高い補助部材２を、複数の被接合部材１の境界露出面１２に対向するように配置した状態で、レーザ光ＬＬを補助部材２に照射して補助部材２を溶融する。そして、補助部材２の溶融部分２３によって複数の被接合部材１の境界部分１３の温度を上昇させることができる。境界部分１３の温度が上昇することで、境界部分１３がレーザ光ＬＬを吸収しやい状態に移行され、境界部分１３のレーザ吸収率が高くなる。これにより、境界部分１３がレーザ光ＬＬによって効率良く加熱されることで、境界部分１３を溶融して複数の被接合部材１を溶接することができる。したがって、レーザ光ＬＬの出力が小さく、且つ複数の被接合部材１のレーザ吸収率が低いために、複数の被接合部材１に直接レーザ光ＬＬを照射してもレーザ溶接することが難しい場合であっても、当該複数の被接合部材１を容易に溶接することが可能となる。
また、第一実施形態の溶接方法及び溶接構造によれば、補助部材２の融点が、複数の被接合部材１の融点よりも高い。このため、レーザ光ＬＬによって溶融した補助部材２の溶融部分２３の温度は、複数の被接合部材１の融点よりも高くなる。これにより、複数の被接合部材１の境界部分１３が補助部材２の溶融部分２３の熱によって溶融しやすくなる。したがって、複数の被接合部材１の大きさ（サイズ）に左右されることなく、複数の被接合部材１（特に境界部分１３）を容易に溶接することができる。
また、第一実施形態の溶接方法では、複数の被接合部材１と反対側に向く補助部材２の反対面２２にレーザ光ＬＬを照射するため、レーザ光ＬＬの照射によって先ず補助部材２が溶融し、補助部材２の溶融部分２３によって複数の被接合部材１の温度を上昇させることができる。複数の被接合部材１の温度が上昇することにより、複数の被接合部材１がレーザ光を吸収しやすい状態に移行され、複数の被接合部材１のレーザ吸収率が高くなる。これにより、複数の被接合部材１が補助部材２の溶融部分２３の熱だけではなく、レーザ光ＬＬによっても加熱されることで、複数の被接合部材１をより確実に溶融して溶接することができる。
第一実施例の補助部材２Ａや第二実施例の補助部材２Ｂを用いた溶接方法及び溶接構造では、補助部材２Ａ，２Ｂの移動制限部（一対の壁部２６Ａ、周壁部２６Ｂ）が複数の被接合部材１の相対的な移動を制限する。この移動制限部により、複数の被接合部材１を接合させる状態に組み付ける際に生じる複数の被接合部材１の相対的な位置のばらつきを小さく抑えることができる。また、複数の被接合部材１を接合させる状態から相対的に移動してずれることを抑えることができる。さらに、隣り合う被接合部材１の隙間（ギャップ）が過度に広がることを抑えることができる。特に、第一実施例の補助部材２Ａでは、三つの被接合部材１Ａを挟むため、被接合部材１Ａ同士の隙間を最小限に抑えることができる。また、第二実施例の補助部材２Ｂでは、その周壁部２６Ｂの内周面２６Ｂ１が二つの被接合部材１Ｂ，１Ｃの側面に対して近接対向して囲むため、二つの被接合部材１Ｂ，１Ｃの隙間を小さく抑えることができる。以上のことから、被接合部材１同士の隙間の過度な広がりに基づく溶接不良を抑制し、溶接の品質安定化を図ることができる。
第一実施形態において、補助部材２の対向面２１は、複数の被接合部材１の境界露出面１２は平坦な面に形成されることに限らず、例えば湾曲した面、凹凸のある面などに形成されてよい。この場合、補助部材２の対向面２１は、境界露出面１２に面接触するように、少なくとも境界露出面１２に対応する形状に形成されればよい。
〔第二実施形態〕
次に、図１１～図１３を参照して本発明の第二実施形態について説明する。本実施形態は、三つの平板状の被接合部材１Ｄ，１Ｅ，１Ｆを板厚方向に重ねて配置し、これら三つの被接合部材１Ｄ，１Ｅ，１Ｆをレーザ光ＬＬを用いて溶接する溶接方法及び溶接構造である。
図１１及び図１２に示すように、本実施形態の溶接方法では、第一実施形態と同様に、はじめに三つの被接合部材１Ｄ，１Ｅ，１Ｆ及び補助部材２Ｄを用意する。三つの被接合部材１Ｄ，１Ｅ，１Ｆ及び補助部材２Ｄの材質や特性は第一実施形態と同様である。
三つの平板状の被接合部材１Ｄ，１Ｅ，１Ｆはそれぞれ、板厚方向（図１１及び図１２において上下方向）に貫通する貫通孔１５Ｄ，１５Ｅ，１５Ｆを有している。貫通孔１５Ｄ，１５Ｅ，１５Ｆは、被接合部材１Ｄ，１Ｅ，１Ｆの板厚方向から見て円形状の貫通孔である。補助部材２Ｄは、円柱棒状に形成されている。二つの被接合部材１Ｄ，１Ｅの貫通孔１５Ｄ，１５Ｅは、互いに直径の寸法が略等しくなっている。貫通孔１５Ｄ，１５Ｅの直径寸法は、補助部材２Ｄの直径寸法よりも大きくなっている。残り一つの被接合部材１Ｆの貫通孔１５Ｆの直径寸法は、補助部材２Ｄの直径寸法と略等しく、貫通孔１５Ｆに補助部材２Ｄが嵌合可能になっている。
三つの被接合部材１Ｄ，１Ｅ，１Ｆは、板厚方向に三つの貫通孔１５Ｄ，１５Ｅ，１５Ｆが連通するように重ねて配置される。孔径寸法が小さい貫通孔１５Ｆを有する被接合部材１Ｆが、三つの被接合部材１Ｄ，１Ｅ，１Ｆの配列方向の端（図１１，１２において一番下）に配置される。この状態では、三つの被接合部材１Ｄ，１Ｅ，１Ｆの境界１１Ｄ，１１Ｅが、三つの被接合部材１Ｄ，１Ｅ，１Ｆの貫通孔１５Ｄ，１５Ｅ，１５Ｆの内周面に露出する。すなわち、貫通孔１５Ｄ，１５Ｅ，１５Ｆの内周面が、三つの被接合部材１Ｄ，１Ｅ，１Ｆの境界１１Ｄ，１１Ｅが現れる境界露出面１２Ｄとなる。
上記のように配置された三つの被接合部材１Ｄ，１Ｅ，１Ｆの貫通孔１５Ｄ，１５Ｅ，１５Ｆに、補助部材２Ｄが挿入される。補助部材２Ｄは、三つの貫通孔１５Ｄ，１５Ｅ，１５Ｆのうち孔径が小さい被接合部材１Ｆの貫通孔１５Ｆに嵌まり、当該被接合部材１Ｆに固定される。この状態において、補助部材２の一方の端面が被接合部材１Ｆの表面（境界１１Ｅの反対側の面）と面一となり、補助部材２の他方の端面が被接合部材１Ｄの表面（境界１１Ｄの反対側の面）から少し突出した状態となる。
補助部材２Ｄが三つの貫通孔１５Ｄ，１５Ｅ，１５Ｆに挿入された状態において、補助部材２Ｄは、三つの被接合部材１Ｄ，１Ｅ，１Ｆの貫通孔１５Ｄ，１５Ｅ，１５Ｆの内周面からなる境界露出面１２Ｄに対向するように配置される。補助部材２Ｄは、孔径が小さい被接合部材１Ｆの貫通孔１５Ｆに対しては、上記のように嵌合された状態となる。残りの二つの被接合部材１Ｄ，１Ｅの貫通孔１５Ｄ，１５Ｅに対しては、貫通孔１５Ｄ、１５Ｅの内周面（境界露出面１２Ｄ）と補助部材２Ｄの外周面との間に隙間を有している。このように挿入された補助部材２Ｄは、三つの被接合部材１Ｄ，１Ｅ，１Ｆの配列方向に直交する方向において三つの被接合部材１Ｄ，１Ｅ，１Ｆが相対移動することを制限する移動制限部として機能する。すなわち、補助部材２Ｄが境界露出面１２Ｄに対向するように配置されることにより、三つの被接合部材１Ｄ，１Ｅ，１Ｆを接合するための状態に保つ。
補助部材２Ｄを用いて三つの被接合部材１Ｄ，１Ｅ，１Ｆを溶接する溶接方法では、上記のように三つの被接合部材１Ｄ，１Ｅ，１Ｆ及び補助部材２Ｄを配置した後に、図１２に示すように、レーザ光ＬＬを補助部材２Ｄに照射して補助部材２Ｄを溶融する。具体的には、レーザ光ＬＬを被接合部材１Ｄ側に位置する補助部材２Ｄの他方の端面に照射し、且つ、当該レーザ光ＬＬの照射位置を補助部材２Ｄの他方の端面の中心から周縁まで移動させることで補助部材２Ｄを溶融する。このとき、補助部材２Ｄの他方の端面の中心から周縁まで、例えば渦巻き状に移動させるようにレーザ光ＬＬを照射するようにしてもよい。補助部材２Ｄの溶融部分は、三つの被接合部材１Ｄ，１Ｅ，１Ｆの境界露出面１２Ｄに到達する。このとき、補助部材２における被接合部材１Ｄから突出していた部分により、貫通孔１５Ｄ、１５Ｅの内周面（境界露出面１２Ｄ）と補助部材２Ｄの外周面との間の隙間が埋められる。
そして、補助部材２Ｄの溶融部分によって三つの被接合部材１Ｄ，１Ｅ，１Ｆの境界部分１３Ｄの温度が上昇するとともに、レーザ光ＬＬが境界部分１３Ｄに照射されることにより、境界部分１３Ｄが溶融する。補助部材２Ｄの溶融部分によって境界部分１３Ｄの温度が上昇することにより、境界部分１３Ｄがレーザ光ＬＬを吸収しやすい状態に移行され、境界部分１３Ｄのレーザ吸収率が高くなる。そして、図１３に示すように、三つの被接合部材１Ｄ，１Ｅ，１Ｆ及び補助部材２Ｄの成分を含む合金部３Ｄが形成される。そして、三つの被接合部材１Ｄ，１Ｅ，１Ｆ及び補助部材２Ｄが、合金部３Ｄによって互いに接合される。以上により三つの被接合部材１Ｄ，１Ｅ，１Ｆが溶接する本実施形態の溶接方法が完了する。
図１３に示すように、本実施形態の溶接方法によって得られる溶接構造は、第一実施形態と同様に、三つの被接合部材１Ｄ，１Ｅ，１Ｆと、三つの被接合部材１Ｄ，１Ｅ，１Ｆの貫通孔１５Ｄ，１５Ｅ，１５Ｆに挿入されて、これらの貫通孔１５Ｄ，１５Ｅ，１５Ｆの内周面からなる境界露出面１２Ｄに対向するように配置される補助部材２Ｄと、を備える。溶接構造において、三つの被接合部材１Ｄ，１Ｅ，１Ｆ及び補助部材２Ｄは、三つの被接合部材１Ｄ，１Ｅ，１Ｆ及び補助部材２Ｄの成分を含む合金部３Ｄによって互いに接合されている。合金部３Ｄは、前述した溶接方法において、補助部材２Ｄの溶融部分と、三つの被接合部材１Ｄ，１Ｅ，１Ｆの溶融部分とが合わさったものである。ただし、本実施形態では、補助部材２Ｄの全体が溶融するため、溶接構造においては、補助部材２Ｄの全体が合金部３Ｄに含まれる。なお、この溶接構造において、補助部材２Ｄの一方の端面側の部分（被接合部材１Ｆの表面側に位置する補助部材２Ｄの部分）は溶融せずに残っていてもよい。
以上説明したように、第二実施形態の溶接方法によれば、第一実施形態と同様の効果を奏する。また、第二実施形態の溶接方法及び溶接構造によれば、補助部材２Ｄが三つの被接合部材１Ｄ，１Ｅ，１Ｆの貫通孔１５Ｄ，１５Ｅ，１５Ｆに挿入される。このように挿入された補助部材２Ｄにより、三つの被接合部材１Ｄ，１Ｅ，１Ｆを接合させる状態に組み付ける際に生じる三つの被接合部材１Ｄ，１Ｅ，１Ｆの相対的な位置のばらつきを小さく抑えることができる。また、本実施形態の溶接方法によれば、一回のレーザ光の照射で、三つ以上の被接合部材１Ｄ，１Ｅ，１Ｆを溶接することができる。
第二実施形態の溶接方法において、三つの被接合部材１Ｄ，１Ｅ，１Ｆの配列方向から見た貫通孔１５Ｄ，１５Ｅ，１５Ｆ及び補助部材２Ｄの形状は、円形に限らず、互いに対応する形状に形成されればよい。また、補助部材２Ｄは、被接合部材１Ｆの貫通孔１５Ｆに嵌合されて固定される構成ではなくてもよく、三つの貫通孔１５Ｄ，１５Ｅ，１５Ｆに挿入された状態で保持されるようになっていればよい。三つの貫通孔１５Ｄ，１５Ｅ，１５Ｆの直径寸法は、互いに等しい寸法であっても、或いは互いに異なる寸法であってもよい。
第二実施形態の溶接方法において、三つの貫通孔１５Ｄ，１５Ｅ，１５Ｆの内周面は、三つの被接合部材１Ｄ，１Ｅ，１Ｆの配列方向に対して傾斜してもよい。例えば、互いに連通する三つの貫通孔１５Ｄ，１５Ｅ，１５Ｆの内周面が、断面Ｖ字状あるいは先細り状に形成されてよい。この場合には、補助部材２Ｄは、例えば円錐形状等のように、貫通孔１５Ｄ，１５Ｅ，１５Ｆの内周面に対応する形状に形成されてもよい。
第二実施形態において、補助部材２Ｄは、長手方向の一端部において補助部材２Ｄの径方向外側に突出する鍔部を備えてもよい。この場合には、補助部材２Ｄを三つの被接合部材１Ｄ，１Ｅ，１Ｆの貫通孔１５Ｄ，１５Ｅ，１５Ｆに挿入した状態で、補助部材２Ｄの鍔部を配列方向の端に位置する被接合部材１Ｆに引っ掛けることができる。これにより、補助部材２Ｄを被接合部材１Ｆの貫通孔１５Ｆに嵌め入れなくても、補助部材２Ｄを三つの被接合部材１Ｄ，１Ｅ，１Ｆに対して位置決めすることができる。第二実施形態において、被接合部材の数は、二つであっても、或いは四つ以上であってもよい。
第二実施形態の溶接方法において、三つの被接合部材１Ｄ，１Ｅ，１Ｆの配列方向の一方の端に配される被接合部材１Ｆは、貫通孔１５Ｆを有する代わりに、例えば図１４に示すように、境界１１Ｅ側に開口して補助部材２Ｄが挿入可能な凹部１５Ｆｂを有してもよい。すなわち、補助部材２Ｄが挿入される被接合部材１Ｆの孔は、貫通しなくてもよい。このような構成とすれば、補助部材２Ｄの溶融部分が被接合部材１Ｆの境界１１Ｅの反対側に露出することを防ぐことができる。
以上、本発明の詳細について説明したが、本発明は上述した実施形態に限定されるものではなく、本発明の主旨を逸脱しない範囲において種々の変更を加えることができる。例えば、本発明において、補助部材は、被接合部材に対して融点が同じ又は低い材質であってもよい。また、レーザ光の照射に用いるレーザの種類は、上記実施形態で例示したものに限らず、補助部材２や被接合部材１の材質に応じて適宜選択されてよい。
１，１Ａ，１Ｂ，１Ｃ，１Ｄ，１Ｅ，１Ｆ　被接合部材
２，２Ａ，２Ｂ，２Ｃ，２Ｄ　補助部材
３，３Ｄ　合金部
１１，１１Ａ，１１Ｂ，１１Ｄ，１１Ｅ　境界
１２，１２Ａ，１２Ｂ，１２Ｄ　境界露出面
１３，１３Ｄ　境界部分
１５Ｄ，１５Ｅ，１５Ｆ　貫通孔
２１，２１Ａ，２１Ｂ　対向面
２２，２２Ａ，２２Ｂ　反対面
２３　溶融部分
２５Ａ，２５Ｂ　対向部
２６Ａ　壁部（移動制限部）
２６Ｂ　周壁部（移動制限部）
ＬＬ　レーザ光

Claims (9)

  1. 互いに接合する複数の被接合部材よりもレーザ光の吸収率が高い補助部材を、前記複数の被接合部材の境界が現れる前記複数の被接合部材の境界露出面に対向するように配置し、
    レーザ光を前記補助部材に照射して前記補助部材を溶融し、
    前記補助部材の溶融部分により前記複数の被接合部材の境界部分の温度を上昇させて当該境界部分がレーザ光を吸収しやすい状態に移行させ、
    当該境界部分にレーザ光を照射して当該境界部分を溶融することにより前記複数の被接合部材を溶接する溶接方法。
  2. 前記補助部材の融点が、前記複数の被接合部材の融点よりも高い請求項１に記載の溶接方法。
  3. 前記境界露出面に対向するように配置された前記補助部材により、前記複数の被接合部材を接合するための状態に保つ請求項１又は２に記載の溶接方法。
  4. 前記複数の被接合部材に対向する前記補助部材の対向面に対して反対側に向く前記補助部材の反対面に、前記レーザ光を照射する請求項１から３のいずれか一項に記載の溶接方法。
  5. 前記補助部材は、前記境界露出面に対向配置される板状の対向部と、前記対向部の両端部から延びて前記複数の被接合部材を前記複数の被接合部材の配列方向から挟む一対の壁部と、を有する請求項１から４のいずれか一項に記載の溶接方法。
  6. 前記補助部材は、前記境界露出面に対向配置される板状の対向部と、前記対向部の周端部から延びて前記複数の被接合部材を囲む周壁部と、を有する請求項１から４のいずれか一項に記載の溶接方法。
  7. 前記複数の被接合部材は、前記複数の被接合部材の配列方向で互いに連通する孔を有し、
    前記補助部材が、棒状に形成されて複数の前記孔に挿入される請求項１から３のいずれか一項に記載の溶接方法。
  8. 複数の被接合部材と、前記複数の被接合部材の境界が現れる前記複数の被接合部材の境界露出面に対向するように配置され、前記複数の被接合部材よりもレーザ光の吸収率が高い補助部材と、を備え、
    前記複数の被接合部材及び前記補助部材は、前記複数の被接合部材及び前記補助部材の成分を含む合金部によって互いに接合されている溶接構造。
  9. 前記補助部材は、前記境界露出面に対向するように配置されて前記複数の被接合部材を接合するための状態に保つ請求項８に記載の溶接構造。
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