Patent Application
20180142771
The subject invention relates to the art of metallurgical bonds and, more particularly to a system of components having a wire weld joint and a method of joining a system of components including a cast iron component.
Motor vehicles include numerous mechanical components that are joined through various techniques. Components can be joined through mechanical fasteners such as bolts, screws, clips and the like. Components may also be joined through chemical or metallurgical bonds such as those achieved through welding. Metallurgical bonds with cast iron components require special consideration. Welded joints associated with cast iron surfaces are prone to cracking.
In order to avoid cracking, a filler metal is used when welding cast iron components. Proper position of the filler metal relative to the joint is particularly important when the weld joint includes a generally J-shaped cross-section as is typically the case when laser welding cast iron. Occasionally, employing filler wire to weld cast iron will lead to less than desirable results due to wire placement and weld geometry. In some cases, the less than desirable results may include a lack of fusion between the filler wire and cast iron and/or a weak weld joint. Accordingly, it is desirable to provide a system for welding cast iron components with increased consistency in bond integrity.
In accordance with an aspect of an exemplary embodiment, a system of components includes a first component including a first joint portion, and a second component including a second joint portion abutting the first component. At least one of the first and second components is formed from cast iron. The first joint portion and the second joint portion, when aligned, form a V-Shaped groove having a groove opening, a groove bottom angle of between about 10° and about 20° and a weld nugget envelope defined therebetween. The groove opening is wider than an outer diameter of a filler wire employed to form a metallurgical bond between the first component and the second component.
In accordance with another exemplary aspect, a vehicle differential includes a differential barrel component including a first joint portion. The differential barrel component is formed from cast iron. A ring gear component is mounted to the differential barrel component. The ring gear component includes a second joint portion. The first joint portion and the second joint portion, when aligned, form a V-Shaped groove having a groove opening, a groove bottom angle of between about 10° and about 20° and a weld nugget envelope defined therebetween. The groove opening is wider than an outer diameter of a filler wire employed to form a metallurgical bond between the first component and the second component.
In accordance with yet another exemplary aspect, a method of joining a system of components includes adjoining a first component including a first joint portion with a second component having a second joint portion. At least one of the first and second components is formed from cast iron. The first joint portion is aligned with the second joint portion forming a V-Shaped groove having a groove opening, a groove bottom angle of between about 10° and about 20° and a weld nugget envelope defined therebetween. A filler wire having an outer diameter smaller than the groove opening is inserted into the V-Shaped groove. The first component is metallurgically bonded to the second component including melting the filler wire into the V-Shaped groove.
The above features and advantages and other features and advantages of the invention are readily apparent from the following detailed description of the invention when taken in connection with the accompanying drawings.
Other features, advantages and details appear, by way of example only, in the following detailed description of embodiments, the detailed description referring to the drawings in which:
The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
A vehicle, in accordance with an exemplary embodiment, is indicated generally at 10 in
In accordance with an aspect of an exemplary embodiment, rear differential 28 includes a housing portion 54 having an outer surface 58 and an inner surface 60 that defines a gear receiving zone 62 as shown in
Reference will now follow to
Ring gear component 82 may be positioned on body 84 abutting axial projecting portion 97 to establish a desired position on outer surface 86 (
In accordance with an aspect of an exemplary embodiment, V-Shaped groove 130 includes a groove opening 132 having a selected dimension 134. V-Shaped groove 130 also includes a groove bottom angle 136 defined by first angled surface 102 and second angled surface 118. First angled surface 102 and second angled surface 118 abut to form an apex 138 of groove bottom angle 136. In accordance with an aspect of an exemplary embodiment, first angled surface 102 and second angled surface 118 are substantially similarly angled such that V-Shaped groove 130 is substantially symmetrical. In accordance with an aspect of an exemplary embodiment, groove bottom angle 136 may be defined by an angle of between about 10° and about 20°. In accordance with another aspect, groove bottom angle 136 may be defined by an angle of about 15°.
A weld nugget zone 140 is defined between apex 138 and groove opening 132. In accordance with an aspect of an exemplary embodiment, weld nugget zone 140 includes a depth of between about between about 2.5 mm and about 6 mm. Weld nugget zone 140 receives metal from a filler wire 148 as well as weld metal from each of differential barrel component 80 and ring gear component 82.
In accordance with an aspect of an exemplary embodiment, filler wire 148 includes an outer diameter 150 having a dimension that is selected to be less than the selected dimension 134 of groove opening 132. In this manner, filler wire 148, when heated through a metallurgical bonding process, such as laser welding, will combine with the weld metal to substantially completely fill weld nugget zone 140 from apex 138 to groove opening 132 forming a weld 154 shown in
The terms “about” and “substantially” are intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” can include a range of ±8% or 5%, or 2% of a given value.
While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed, but that the invention will include all embodiments falling within the scope of the application.
