Electric heating – Metal heating – By arc
Reexamination Certificate
1999-02-02
2001-09-11
Dunn, Tom (Department: 1725)
Electric heating
Metal heating
By arc
C219S121850, C228S117000, C228S158000
Reexamination Certificate
active
06288361
ABSTRACT:
The invention relates to a process for joining flat products of metallic materials, more particularly in the form of strips, sheets and sheet blanks to be interconnected overlapping, which are introduced converging on one another at an acute angle into a roll nip and pressed on one another in the roll nip, after the surface of at least one of the flat products is heated by radiation energy immediately prior to its physical contact to the other flat product, although the basic material has not been melted. In contrast. low-melting coatings such as, for example, zinc, can be melted.
The invention also relates to an apparatus which is suitable for the performance of the process and which mainly comprises two rollers and a radiation source directed into the roll nip.
In one known process and known apparatus of the kind specified the radiation energy is generated by a laser beam source (DE 195 02 140 C1). During the heating a temperature can be maintained at which lower-melting coatings, such as zinc, do not yet evaporate, as any melting or vaporization of the coating material would have an adverse effect on the strength of the connection. The two rollers forming the roll nip have over their whole length a smooth cylindrical generated surface extending beyond the overlap joint on both sides. To apply the surface pressure required for the connection of the two flat products, after heating they are subjected to a shaping pass with a degree of deformation of ≦20%, which is small in comparison with rollbonded cladding. The rolling force required is considerable, since even unheated zones of the flat products alongside the overlap joint are involved in the heating. To prevent the softer flat product from being shorn off at the edge of the harder flat product, more particularly in the case of materials of different softness, the soft flat product is supported by the application of a counterpressure by means of a backing strip or by a suitably calibrated roller. In any case, the rollers also cause an undesirable reduction in the thickness of the adjacent zone of at least one flat product alongside the overlap joint. For these reasons the known process is not an optimum one.
It is an object of the invention to provide a process which can be more cheaply performed for joining flat products of metallic materials to be interconnected overlapping, more particularly different materials which can be interconnected by fusion welding only with difficulty, if at all, or materials of very different hardness, for example, steel/aluminium, or steel/copper, steel/titanium or steel/special steel, the invention providing an apparatus suitable for the performance of said process.
This problem is solved according to the invention in a process of the kind specified by the feature that the surface pressing in the roll nip is limited to the zone of the overlap joint. Preferably any flow of material of the flat product in the roll nip in the longitudinal direction of the overlap joint is prevented.
The problem is solved by an apparatus characterized in that of the two rollers one roller generated surface with its operative pressure zone in its axial extension is shorter than the total axial length of the rollers; preferably the roller generated surface with its operative pressure zone has circularly extending grooves.
The limitation of the surface pressing in the roll nip to the zone of the overlap joint, more particularly in conjunction with influencing the flow of material, enables the pressure necessary for joining to be applied with a lower rolling force than in the prior art process wherein even unheated material is involved in the reduction pass. If a comparison is made with the rolling force required for a St14Z/AlMoSi connection, a reduction is found from 60 kN, in the case of an aluminium strip 25 mm wide in the conventional process, to 5 kN for the process according to the invention with a width of overlap of 9 mm. The efficiency of shaping is therefore optimum in relation to the radiation energy introduced. This has the further consequence that the required apparatuses can be constructed substantially lighter. The limitation to a comparatively narrow zone, where surface pressing takes place, also facilitates the joining of sheet blanks of defined shape (e.g., so-called “tailored blanks”), wherein the joint frequently extends not straight, but in curves. Precisely in the case of constructional components made up of different flat products, which are differentially dimensioned in accordance with their stressing in operation, but not only in the case of such constructional components, it is important that the constructional components adjacent the overlap joint should not be adversely affected by the joining. Since in the process according to the invention the heating and shaping are limited to the overlap joint, on the one hand the heat-affected zone is as small as possible and on the other hand the full thickness of material is maintained in the adjacent zones of the flat products, something which was impossible in the prior art process with the reduction pass.
According to further features of the invention, advantageously the surfaces of the two flat products are heated. It has been found to be advantageous if the two flat products are of materials of different softness, the widths of the overlap joint is at least equal to 1.5 times the thickness of the flat product of the softer material.
The aforementioned prevention of the flow of material of the flat product longitudinally of the overlap joint can be achieved constructionally in various ways. The essential feature of these embodiments of the invention is that the material can flow into receiving spaces of the elements participating in the surface pressing. For example, in one alternative the surface at least one of the elements participating in the surface pressing (roller/flat product) is profiled. The surface profiling preferably comprises peripheral/longitudinal grooves. In that case the grooves allow adequate surface pressing, but at the same time prevent any flow of material longitudinally of the overlap joint, since the material can flow into the grooves. They also serve to guide the flat products in the direction of the overlap joint. The grooved roller preferably acts on the softer base material. One of the base materials is grooved, preferably the harder one is selected.
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Kawalla Rudolf
Pircher Hans
Polzin Ralf
Stegemann-Auhage Thomas
Sussek Gerd
Cooke Colleen P.
Dunn Tom
Proskauer Rose LLP
Thyssen Stahl Aktiengesellschaft
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