Metal fusion bonding – Process – Using dynamic frictional energy
Patent
1998-06-24
2000-02-08
Ryan, Patrick
Metal fusion bonding
Process
Using dynamic frictional energy
228 21, 228102, 228103, 2281145, B23K 2012, B23K 100, B23K 3112
Patent
active
060219386
DESCRIPTION:
BRIEF SUMMARY
FIELD OF THE INVENTION
The present invention pertains to a process and a device for the friction welding of workpieces that consist of different materials or possess different material properties, especially different hardnesses and/or melting points, where the workpieces are rotated in frictional contact in relation to one another, stopped and upset.
BACKGROUND OF THE INVENTION
Various designs of friction welding processes and friction welding devices have been known in practice. The two workpieces to be welded together are, e.g., rotated relative to one another in frictional contact, while they are heated and plasticized in the friction area. The rotary drive is stopped after an intended period of time, as a result of which the relative rotation slows down with braking and comes to a standstill. The two workpieces are upset and connected during the slowing down. The friction process takes several seconds in prior-art friction welding process, using speeds of 1,000 rpm and more. This prior-art process is practical for identical material, or materials possessing very similar properties and has proved successful. This friction welding process cannot be used satisfactorily for the friction welding of workpieces that consist of different materials, e.g., aluminum and steel, but possess different material properties, e.g., soft or hard light metal alloys. The friction weld joints do not have the desired strength, nor a sufficiently reproducible quality.
SUMMARY AND OBJECTS OF THE INVENTION
The primary object of the present invention is therefore to provide a friction welding process and a corresponding device, which lead to a good weld quality even in the case of workpieces that consist of different materials or possess different material properties.
This object is accomplished by the present invention rotating the workpieces relative to each other. At least one of the workpieces is then moved toward the other workpiece to bring the workpieces into frictional contact with each other. The moving is done at a speed and with a force to cause the two workpieces to be friction welded together in less than 3 complete relative revolutions. The actual speed and force can vary within certain ranges to form the friction weld in less than 3 revolutions and the range of the speed and force can vary depending on the materials being welded.
The device for performing this process includes a rotating means for rotating one of the workpieces with respect to another of the workpieces. A feeding means feeds the relative rotating workpieces into the frictional contact with each other at or under a feed pressure to cause the friction welding of the workpieces to each other. A control means detects a beginning of said frictional contact and sets a friction time of the workpieces being in the frictional contact. The control means also) controls the rotating means and the feeding means to limit the angle of rotation between the workpieces to less than 1,080 degrees during the frictional contact.
It is very important in the present invention that the entire angle of rotation is limited to a low value during the friction process. The practical experience gained with the present invention shows that the angle of rotation should not be greater than 1,080.degree. or three complete revolutions. The angle of rotation should be between 180.degree. and 720.degree. for the frequently used material pairs consisting of steel and aluminum or soft and hard light metal alloys, and optimal results are obtained in an angle of rotation range of 290.degree. to 430.degree.. The angle of rotation ranges may vary for other material pairs. At any rate, they are substantially smaller than in the case of prior-art processes.
The process according to the present invention and the corresponding device are suitable for all applications in which the workpieces consist of materials with differences in the material properties, especially the hardness and/or the melting point. Such pairs are obtained, on the one band, from completely different materials, suc
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Metals Handbook Ninth Edition, vol. 6 (pp. 719-728), 1983.
Bock Johann
Groger Walter
Mazac Karel
Kuka Schweissanlagen GmbH
Ryan Patrick
Stoner Kiley
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