Joints and connections – With adjunctive protector – broken parts retainer – repair,... – Position or guide means
Reexamination Certificate
1999-12-03
2001-05-29
Browne, Lynne H. (Department: 3629)
Joints and connections
With adjunctive protector, broken parts retainer, repair,...
Position or guide means
C403S271000, C403S282000, C228S114500
Reexamination Certificate
active
06238121
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to the formation of a friction-welded joint between a first and a second metallic component, in particular a friction-welded joint between a friction-welded stud and a metal plate.
DE 42 25 435 A1 discloses a process for forming a friction-welded joint and a driving mandrel with which the function-welded joint can be produced in the interior of a tubular component. The driving mandrel with its conically tapering end is driven home in the tubular component and is rotated round an axis of symmetry. The end of the tubular component expands and adapts itself to the conical shape of the driving mandrel. A joint region is created on the cone surface. The joint is reinforced by frictional contact between the driving mandrel and the component.
SUMMARY OF THE PRESENT INVENTION
It is an object of the present invention to provide a process for forming a friction-welded joint between a first and a second metallic component, with which an annular joint region can be produced at a predetermined position. A further object is to provide a metallic fastening member for forming a friction-welded joint at a predetermined point of a different component.
The invention provides a process for forming a friction-welded joint between a first and a second metallic component, in particular a friction-welded joint between a metal stud and a metal plate, wherein a guide element of the first component is introduced into a positioning bore extending substantially perpendicularly to a surface of the second component and the two components are rotated relative to one another round an axis of rotation extending in the longitudinal direction of the guide element such that an annular joint region is produced between the two components.
A metallic fastening member for forming a friction-welded joint, the member comprising a stud with an outer cylindrical surface and a central projection extending axially beyond the confines of the surface, the member configured to include a continuous annular flange radially spaced from the central projection, the flange defining a continuous welding face which is oriented substantially in an assembly direction, which direction is perpendicular to a plane formed by the surface of the welding face.
Process for forming a friction-welded joint between a first and a second metallic component, the first component comprising a stud having a central projection surrounded by and radially space from a continuous annular flange, wherein the central projection of the stud is introduced into a positioning bore within the second component, the bore extending substantially perpendicularly to a surface of the second component, and wherein the first and second components are rotated relative to each other about an axis defined by the central projection, such that an annular joint region is formed between the continuous flange and the surface of the second component.
In an embodiment of a friction-welded joint, high contact pressures or relatively high speeds of rotation can occur. Therefore, there is always the risk that the components which are rotating relative to one another will run off center. This is avoided with the process according to the invention because the interplay between the guide element and the positioning bore prevents a deviation from the proposed joint position. The process control according to the invention also reduces expenditure on apparatus when producing the friction-welded joint if the correct relative positioning of the two components is achieved by the components themselves. In particular, high forces which act transversely to the axis of rotation and could damage, for example, bearings of a device with which one of the two components is rotated round an axis of rotation, are avoided. With known processes, high bearing forces occur if the axis of rotation is not orientated perpendicular to the surface of the second component.
The process control according to the invention is particularly advantageous with an aluminum/steel pairing of material as, for forming a friction-welded joint, an aluminum oxide layer on a welding face of an aluminum component first has to be rubbed away before a material joint is created between the two components. The aluminum oxide layer can be rubbed away in this way by high contact pressures and rapid relative movements between the two components. This can also be achieved if the welding face, for example of the first component comprising the guide element, has a surface structure by means of which the coefficient of friction between the mutually rubbing faces is increased.
With the process according to the invention, it is also proposed that the guide element be introduced into the positioning bore until a welding face of the first component comes into contact with the surface of the second component round the positioning bore.
The components are, in particular, a metal stud with a guide element and a metal plate with a positioning bore. The term welding face denotes a region of a surface which is rubbed when carrying out the process or with which a welding face of the other respective component is rubbed. The shape of the welding face can change significantly while carrying out the process. In particular, the material can be liquefied at the welding face owing to frictional heat. On completion of friction welding, the joint region, i.e. the material joint between the components, exists in the region of the welding face or former welding face.
The process according to the invention also allows the first component with its guide element initially to be positioned correctly on the second component, the guide element being introduced into the positioning bore. The components to be joined are then rotated relative to one another. According to a further advantageous idea, it is proposed that the guide element be introduced into the positioning bore during a rotating procedure. The guide element can be introduced into the positioning bore at a lower speed of rotation. This method of process control results in a higher speed as the positioning procedure is integrated into the rotating procedure.
Since the first component has a guide element comprising a free end designed as a drilling tip, it is possible to form the positioning bore by the guide element itself during the rotating procedure. The first component therefore has an automatic perforating effect, so that it is not necessary to form the positioning bore in advance.
In a development of the process, the guide element is introduced further into the positioning bore during the process of rotation. A contact pressure on the welding face required for the welding procedure can therefore be achieved or maintained although material on the welding face of the surface of the second component is deformed.
In a further development, a free end of the guide element is inserted through the positioning bore designed as a through-bore. The available bore length is therefore utilized completely. For the same reason, the attainment of positioning which is as stable as possible, the external dimensions of the guide element and the internal diameter of the positioning bore are adapted as accurately as possible to one another, the frictional resistance between the guide element and the wall of the positioning bore remaining as low as possible. In an alternative development, sufficiently strong friction occurs between the guide element and the wall of the positioning bore so a joint region is also produced there.
To form a joint region between the guide element and the wall of the positioning bore, it is also proposed that the guide element should have at least one portion tapering in the assembly direction, preferably a conically tapering portion. The conically tapering portion can partially form a friction-welded joint with the wall of the positioning bore. The guide element is also automatically centered in a prefabricated positioning bore by the tapering portion of the guide element.
In an embodiment of the process, the shape and/or the dimensions
Browne Lynne H.
Cottingham John R.
Emhart Inc.
Murphy Edward D.
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