Friction spot joining method

Abstract

A plurality of steel plates including at least one first non-coated steel plate and at least one metal-coated steel plate are prepared. The plurality of steel plates are overlaid in such a fashion that at least one of the two steel plates located on the respective sides in the overlaying direction is the first non-coated steel plate. A rotary tool is rotated and allowed to press a to-be-joined part of the plurality of overlaid steel plates from the first non-coated steel plate side to friction-spot-join the to-be-joined part in a solid state by causing plastic flow at the to-be-joined part by generated frictional heat. Whereby, both elongation of time required for joining and lowering of the corrosion resistance of the metal-coated steel plate are suppressed.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram showing a construction of a joining gun in one embodiment of the present invention.

FIG. 2 shows a process of friction-spot-joining a work piece by the joining gun, wherein FIG. 2A is a diagram showing a state in which a rotary tool starts rotating; FIG. 2B is a diagram showing a state in which the rotary tool is thrust into a second steel plate; FIG. 2C is a diagram showing a state in which the rotary tool is thrust into a third steel plate; and FIG. 2D is a diagram showing a state in which the rotary tool is pulled out from the work piece.

FIG. 3 is a list indicating compositions of a first steel plate in Working Examples and Comparative Examples.

FIG. 4 is a diagram showing a friction spot joining of a work piece by the joining gun in Working Examples.

FIG. 5 is a diagram showing a friction spot joining of a work piece by the joining gun in Comparative Examples.

FIG. 6 is a list indicating joining conditions in friction spot joining of a work piece by the joining gun, the tensile shearing strengths of joints, and evaluation results in Working Examples and Comparative Examples.

FIG. 7 is a graph showing the tensile shearing strengths of the joints in Working Examples.

FIG. 8 is a graph showing the tensile shearing strengths of the joints in Comparative Examples.

FIG. 9 is a diagram showing a modified example of the rotary tool.

FIG. 10 is a diagram showing another modified example of the rotary tool.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

FIG. 1 is a schematic diagram showing a construction of a joining gun 1 in the present embodiment. As shown in FIG. 1, the joining gun 1 includes a joining unit 2 as a friction spot joining apparatus and a gripping frame 3 mounted at, for example, a wrist of a robot (not shown). The joining gun 1 spot-joins, in a solid sate (a state in which each steel plate W1, W2 (see FIG. 2) are not melted), a plurality of steel plates W1, W2 of a work piece W used for a car body of an automobile in such a fashion that the plurality of steel plates W1, W2 are overlaid at least partially in the thickness direction. In the present embodiment, the steel plate W1 includes two first non-coated steel plates W1a, W1b, and the steel plate W2 is one second metal-coated steel plate. The first steel plates W1a, W1b are made of high-tensile steel having a tensile strength of 340 MPa or larger while the second steel plate W2 is made of mild steel having a tensile strength smaller than 340 MPa. The two first steel plates W1a, W1b are used as an inner plate and a reinforcing plate for a car body while the one second steel plate W2 is used as an outer plate for the car body.

The joining unit 2 includes an apparatus body 4, a pressing shaft motor 5, and a rotary shaft motor 6. Below the apparatus body 4, a rotary tool 7 is mounted. The rotary tool 7 includes a cylindrical shoulder part 7a and a cylindrical pin 7b protruding downward from the central part at the bottom of the shoulder part 7a and having a diameter smaller than that of the shoulder part 7a. The rotary tool 7 is rotated around the rotation axis X by the rotary shaft motor 6 and is moved up and down in the direction of the rotation axis X by the pressing shaft motor 5. The pressing shaft motor 5 and the rotary shaft motor 6 are connected to a control board (not shown) that controls them.

At the end of an arm 3a in an L-shape in section of the gripping frame 3, a metal-made (steel-made) cylindrical receiving member 8 is mounted. To-be-joined part of the work piece W is clipped between the rotary tool 7 and the receiving member 8. The diameter of the receiving member 8 is set larger than the diameter of the shoulder part 7a of the rotary tool 7.

(Process of Friction-Spot-Joining Work Piece by Joining Gun)

Description will be given below with reference to FIG. 2 to a process of friction-spot-joining the work piece W by the joining gun 1.

First, as shown in FIG. 2A, the second metal-coated steel plate W2 and the first non-coated steel plates W1b, W1a are overlaid in this order to form the work piece W, and the receiving member 8 is allowed to receive the to-be-joined part of the work piece W with the second steel plate W2 of the work piece W set against the receiving member 8. In other words, the three steel plates W1a, W1b, W2 are overlaid on the receiving member 8 in a state in which one (the upper one) of two steel plates located on the respective sides in the overlaying direction (vertical direction in FIG. 2) is the first steel plate W1a while the other (the lower one in FIG. 2) is the second plate W2.

Next, when the rotary shaft motor 6 (see FIG. 1) is driven, the rotary tool 7 is rotated around the rotation axis X (see FIG. 1).

After the number of rotation of the rotary tool 7 reaches a target number of rotation, the pressing shaft motor 5 (see FIG. 1) is driven with the rotary tool 7 rotated to move the rotary tool 7 downward.

In this way, the pressing shaft motor 5 is driven to move the rotary tool 7 downward until the pin 7b is in contact with the surface of the work piece W, that is, the surface of the first non-coated steel plate W1a. Whereby, the to-be-joined part of the work piece W is clipped between the rotary tool 7 and the receiving member 8 and are pressed in the direction of the rotation axis X (downward in FIG. 2). This causes friction between the rotating rotary tool 7 and the surface of the first steel plate W1a to generate frictional heat. The thus generated frictional heat is transferred from the first steel plate W1a to the first steel plate W1b and then to the second steel plate W2 to soften the first steel plate W1b and the second steel plate W2.

When the rotation and pressing of the rotary tool 7 is continued, as shown in FIG. 2B and FIG. 2C, plastic flow is caused in the first and second steel plates W1a, W1b, and W2. The frictional heat is released from the receiving member 8 having the diameter larger than the diameter of the shoulder part 7a.

After the plastic flow is allowed to be generated in the work piece W for a predetermined period of time, the pressing shaft motor 5 is reversed to raise the rotating rotary tool 7 with the rotary tool 7 rotated, so that the rotary tool 7 is pulled out from the work W, as shown in FIG. 2D.

Thereafter, the work piece W is cooled (left for cooling) to be hardened, thereby completing joining of the work piece W.

It is noted that the pressure and the number of rotation of the rotary tool 7 and the joining period are set in the above joining process so that the to-be-joined part of the work piece W does not reach a temperature at which the steel plates W1, W2 are melted by frictional heat, for example, so that it reaches a temperature at which an austenitic structure is generated.

WORKING EXAMPLES

Working Examples of the present invention will be described below.

(Joining Unit)

A stationary pressure unit having a servo motor as the pressure shaft motor was employed as the joining unit.

A ceramic-made rotary tool was used as the rotary tool. The diameter of the shoulder part of the rotary tool was 10 mm. The diameter and the length of the pin of the rotary tool were 3 mm and 1.27 mm, respectively.

(Steel Plates)

High-tensile steel plates (JIS 3135 SPFC980Y) on a 980 MPa level having a thickness of 1.0 mm were used as the first steel plates. The compositions of the first steel plates are indicated in FIG. 3.

A mild steel plate on a 270 MPa level was used as the second steel plate. The second steel plate was zinc-coated and was subjected to an alloying process to obtain a galvaneal steel plate having a coating weight of 55 g/m² and a thickness of 0.7 mm. The melting point of the alloyed hot dip zinc coating, which depends on the content ratio of zinc to iron, is within the range between 530 and 600° C.

(Joining)

In Working Examples 1 and 2, one galvaneal steel plate (Zn—Fe coated mild steel plate) and two high-tensile steel plates (DP980) were overlaid in this order to form a work piece, as shown in FIG. 4, and the rotary tool was rotated and allowed to press the to-be-joined part of the work piece from above to friction-spot-join the to-be-joined part. The to-be-joined part of the work piece at joining was heated up to the temperature at which an austenite structure is generated by the frictional heat.

In Comparative Examples 1, 2, and 3, two high-tensile steel plates and one galvaneal steel plate were overlaid in this order to form a work piece, as shown in FIG. 5, and the rotary tool was rotated and allowed to press the to-be-joined part of the work piece from above to friction-spot-join the to-be-joined part. The to-be-joined part of the work piece at joining was heated up to the temperature at which an austenite structure is generated by the frictional heat, likewise Working Examples.

(Joining Conditions)

As indicated in FIG. 6, the pressure and the number of rotation of the rotary tool were set to 19.6 kN and 1000 rpm, respectively, and the joining period was set to 3.0 s in Working Example 1.

In Working Example 2, the pressure and the number of rotation of the rotary tool were set to 19.6 kN and 3000 rpm, respectively, and the joining period was set to 5.0 s.

In Comparative Example 1, the pressure and the number of rotation of the rotary tool were set to 19.6 kN and 1000 rpm, respectively, and the joining period was set to 5.0 s.

In Comparative Example 2, the pressure and the number of rotation of the rotary tool were set to 19.6 kN and 3000 rpm, respectively, and the joining period was set to 5.0 s.

In Comparative Example 3, the pressure and the number of rotation of the rotary tool were set to 19.6 kN and 1000 rpm, respectively, and the joining period was set to 3.0 s.

(Test)

A tensile strength test was performed on each joint between the upper plates and the middle plates and each joint between the middle plates and the lower plates of the work pieces after joining, and the tensile shearing strength of each joint is measured.

(Evaluation)

Evaluation was made by comparing the tensile shearing strengths of the joints with the resistance spot welding JIS class A average values (hereinafter referred to as RSW JIS class A average values) concerning the conventional resistance spot welding.

In Working Examples 1 and 2, all the tensile shearing strengths at the respective joints were larger than the respective RSW JIS class A average values, as indicated in FIG. 6 and FIG. 7.

In contrast, as indicated in FIG. 6 and FIG. 8, though all the tensile shearing strengths at the respective joint parts were larger than the respective RSW JIS class A average values in Comparative Example 1, the tensile shearing strength of the joint between the upper plate and the middle plate was larger than but that of the joint between the middle plate and the lower plate was smaller than the respective RSW JIS class A average values in Comparative Example 2. Specifically, in Comparative Example 2, the tensile shearing strength of the to-be-joined part between the high-tensile steel plates was smaller than the corresponding RSW JIS class A average values. Similarly to Comparative Example 2, the tensile shearing strength of the to-be-joined part between the middle plate and the lower plate was smaller than the corresponding RSW JIS class A average values in Comparative Example 3.

(Effects)

As described above, in the present embodiment, the plurality of steel plates W1a, W1b, W2 are overlaid in such a fashion that at least one of the two steel plates located on the respective sides in the overlaying direction is the first steel plate W1a, and the rotary tool 7 is rotated and allowed to press the to-be-joined part of the overlaid plural steel plates W1a, W1b, W2 from the first non-coated steel plate W1a side. Accordingly, the rotary tool 7 hardly slips and frictional heat is readily generated, thereby suppressing elongation of time required for joining. Further, rotation and pressing of the rotary tool 7 from the first non-coated steel plate W1a side less melts and evaporates the low-melting-point metal coating intervening between the steel plates W1 and W2, thereby suppressing lowering of the corrosion resistance of the second metal-coated steel plate W2. Thus, both elongation of time required for joining and lowering of the corrosion resistance of the metal-coated steel plate W2 are suppressed.

Moreover, the following arrangement achieves release of the frictional heat from the receiving member 8. Namely: the receiving member 8 is prepared which has a diameter larger than the shoulder part 7a of the rotary tool 7; the plurality of steel plates W1a, W1b, W2 are overlaid in such a fashion that one of the two steel plates located on the respective sides in the overlaying direction is the first non-coated steel plate W1a while the other is the second metal-coated steel plate W2; the receiving member 8 is allowed to receive the to-be-joined part of the plurality of overlaid steel plates W1a, W1b, W2 in such a fashion that the second metal-coated steel plate W2 is set against the receiving member 8; and the rotary tool 7 is rotated and allowed to press the to-be-joined part from the first non-coated steel plate W1a side. Release of the frictional heat results in further less melting and evaporation of the metal coating of the second steel plate W2 on the side against the receiving member 8, thereby suppressing lowering of the corrosion resistance of the second metal-coated steel plate W2 definitely.

Furthermore, the rotary tool 7 is rotated and allowed to press the to-be-joined part of the plurality of overlaid steel plates W1a, W1b, W2 from the non-coated high-tensile steel plate W1a side, which has high material strength and less plastic flowability, so as to cause sufficient plastic flow at the to-be-joined part of the high-tensile steel plate W1a. This increases the joint strength between the non-coated high-tensile steel plates W1a, W1b and the metal-coated mild steel plate W2.

As well, the joint strength among the two non-coated high-tensile steel plates W1a, W1b used for a car body and the one metal-coated mild steel plate W2 used for the car body can be increased. In addition, any dimple (see FIG. 2), which has been formed by the rotation and pressing of the rotary tool 7, is not formed in the outer face of the metal-coated mild steel plate W2 used as an outer plate for a car body, thereby securing the appearance of the car body.

Other Embodiments

In the above embodiment, the work piece W is used for a car body of an automobile, but may be used for any other article.

The work piece W is composed of the two first steel plates W1a, W1b and the one second steel plate W2 in the above embodiment, but the present invention is not limited thereto. The number of the first steel plates W1 may be one or plural, and the number of the second steel plates W2 may be one or plural as well. For example, the work piece W may be composed of one first steel plate W1 and one second steel plate W2. In this case, the first steel plate W1 and the second steel plate W2 are used as an inner plate and outer plate for a car body, respectively.

In the above embodiment, the three steel plates W1a, W1b, W2 are overlaid in such a fashion that one of the two steel plates located on the respective sides in the overlaying direction is the first steel plate W1a while the other is the second steel plate W2. The present invention only requires an arrangement in which the plurality of steel plates W1, W2 are overlaid in such a fashion that at least one of the two steel plates located on the respective sides in the overlaying direction is the first steel plate W1 so that the rotating rotary tool 7 presses the to-be-joined part of the plurality of overlaid steel plates W1, W2 from the first steel plate W1 side.

Further, the diameter of the receiving member 7 is set larger than the diameter of the shoulder part 7a of the rotary tool 7 in the above embodiment, but may be set equal to or smaller than that of the shoulder part 7a thereof.

In the above embodiment, the rotary tool 7 includes the shoulder part 7a and the pin 7b. The present invention is not limited thereto, and the shoulder part 7a may have two stages as shown in FIG. 9 or may be formed in a helical form as shown in FIG. 10.

The present invention is not limited to the embodiments, and any other different embodiments may be made without departing from the spirit and scope of the present invention.

The above embodiments are mere preferred examples in every aspect and should not be construed definitely. The scope of the invention is to be determined by the following claims, and the description imposes no constraint on the present invention. In addition, any modifications and variations belonging to the scope equivalent to the claims may be made within the scope of the present invention.

INDUSTRIAL APPLICABILITY

As described above, the friction spot joining method in accordance with the present invention is applicable to fields necessitating suppression of both elongation of time required for joining and lowering of the corrosion resistance of a metal-coated steel plate.

Claims

1. A friction spot joining method in which a plurality of steel plates are overlaid and a to-be-joined part of the plurality of overlaid steel plates is friction-spot-joined in a solid state by causing plastic flow at the to-be-joined part by frictional heat generated by rotating a rotary tool and allowing it to press the to-be-joined part, comprising the steps of: preparing, as the plurality of steel plates, at least one first non-coated steel plate and at least one second metal-coated steel plate;overlaying the plurality of steel plates in such a fashion that at least one of two steel plates located on respective sides in an overlaying direction is the first non-coated steel plate; androtating the rotary tool and allowing it to press the to-be-joined part of the plurality of overlaid steel plates from the first non-coated steel plate side.

2. The friction spot joining method of claim 1, wherein in the overlaying step, the plurality of steel plates are overlaid in such a fashion that one of the two steel plates located on the respective sides in the overlaying direction is the first non-coated steel plate while the other is the second metal-coated steel plate,the method further comprising the steps of:preparing a receiving member having a diameter larger than a diameter of a shoulder part of the rotary tool; andallowing the receiving member to receive the to-be-joined part of the plurality of overlaid steel plates in such a fashion that the second metal-coated steel plate is set against the receiving member.

3. The friction spot joining method of claim 1, wherein the first steel plate is a high-tensile steel plate, andthe second steel plate is a mild steel plate.

4. The friction spot joining method of claim 2, wherein the first steel plate is a high-tensile steel plate, andthe second steel plate is a mild steel plate.

5. The friction spot joining method of claim 3, wherein in the steel plates preparing step, one non-coated high-tensile steel plate and one metal-coated mild steel plates are prepared as the plurality of steel plates.

6. The friction spot joining method of claim 4, wherein in the steel plates preparing step, one non-coated high-tensile steel plate and one metal-coated mild steel plates are prepared as the plurality of steel plates.

7. The friction spot joining method of claim 5, wherein the non-coated high-tensile steel plate is used as an inner plate for a car body, andthe metal-coated mild steel plate is used as an outer plate for the car body.

8. The friction spot joining method of claim 6, wherein the non-coated high-tensile steel plate is used as an inner plate for a car body, andthe metal-coated mild steel plate is used as an outer plate for the car body.

9. The friction spot joining method of claim 3, wherein in the steel plates preparing step, two non-coated high-tensile steel plates and one metal-coated mild steel plate are prepared as the plurality of metal plates, andin the overlaying step, the two non-coated high-tensile plates and the one metal-coated mild steel plate are overlaid in this order.

10. The friction spot joining method of claim 4, wherein in the steel plates preparing step, two non-coated high-tensile steel plates and one metal-coated mild steel plate are prepared as the plurality of metal plates, andin the overlaying step, the two non-coated high-tensile plates and the one metal-coated mild steel plate are overlaid in this order.

11. The friction spot joining method of claim 9, wherein the two non-coated high-tensile steel plates are used as an inner plate and a reinforcing plate for a car body, respectively, andthe one metal-coated mild steel plate is used as an outer plate for the car body.

12. The friction spot joining method of claim 10, wherein the two non-coated high-tensile steel plates are used as an inner plate and a reinforcing plate for a car body, respectively, andthe one metal-coated mild steel plate is used as an outer plate for the car body.