CN102049591A - Dissimilar metal spot welding system of light metal and coated steel and welding method thereof - Google Patents
Dissimilar metal spot welding system of light metal and coated steel and welding method thereof Download PDFInfo
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Abstract
The invention provides a dissimilar metal spot welding system of light metal and coated steel and a welding method thereof, wherein the system comprises a CMT (cold metal transfer) arc welding system, an air bottle, a robot control module, a robot and a clamping device; the arc welding system is connected to the robot control module and used for transmitting a welding control signal; the air bottle is communicated with the CMT arc welding system; the robot control module is connected to the robot for transmitting a control signal of the movement of the robot. In the invention, a spot melting soldering joint is formed between light metal and coated steel to realize the spot connection of the light metal and the coated steel; the serious deformation of the joint during continuous seam welding is solved while the connecting quality of dissimilar metal is ensured; traditional vehicle body part joints primarily using resistance spot welding process are not influenced; and the design and manufacture costs of vehicle bodies are greatly reduced.
Description
Technical field
What the present invention relates to is the device and method in a kind of metal welding techniques field, specifically is the dissimilar metal spot welding system and the welding method thereof of a kind of light metal and clad steel sheet.
Background technology
Be subjected to the favor of each big automobile production manufacturer much smaller than steel owing to the density of light alloy materials such as aluminium, magnesium, yet the overall mechanical property of advanced steel still is better than light alloy material, therefore adopt many materials syndeton of light-alloy and advanced high-strength steel to become the light-weighted preferred option of automobile, this xenogenesis that just relates between light-alloy and the steel connects.
Because the fusing point between the aluminum steel, thermal coefficient of expansion and electric conductivity difference are huge and easily form during melting welding hard mutually crisp---intermetallic compound, so be difficult to form well behaved joint.A kind of mechanical cold forming process-semitubular rivet self-piercing riveting that forms firm interlock between rivet and the plate, problem that this method has existed when effectively having avoided the foreign material melting of making abroad proposed.Yet joint is easy to generate crackle even embrittlement during low elongation light alloy material such as riveted joint Birmasil and magnesium alloy; And when the riveted joint steel, because the high distortion difficulty of steel strength needs bigger rivet force, need on the one hand to increase rivet value in order to avoid the thick and cracking of serious pier takes place rivet, on the other hand the every performance indications of equipment are also proposed requirements at the higher level, thereby increased the link cost of vehicle body.Laser weld aluminium alloy and steel can effectively be controlled the thickness of intermetallic compound, and strength of joint meets the demands easily, but need the energy and the plate gap of strict control laser beam, cause the technology cost very high.Friction stir welding has lower energy input, less advantages such as distortion, relatively is suitable for welding aluminium.But when adopting this method, the shape of joint is very restricted, and for complex-shaped body of a motor car, is difficult to guarantee assembly precision between the sheet part by anchor clamps, is welded in application in the body of a motor car thereby limited agitating friction greatly.
Find through retrieval prior art, Fronius company proposes a kind of cold metal transition (Cold Metal Transfer that is called, abbreviation CMT) technology of arc welding, and realized being connected between aluminium sheet and the galvanized steel plain sheet by the CMT melt-brazing method, it is aluminium sheet fusing in the welding process, and steel plate does not melt, and realizes being connected of aluminium alloy and galvanized steel by the welding wire solder.Because the CMT method realizes the transition of metal drop by the mechanical pumpback of welding wire, technology of arc welding specific heat input reduction greatly mutually with routine, therefore can effectively reduce the thickness of compound between the aluminum steel interface metal, thereby guaranteed the mechanical property of joint, become a kind of aluminium alloy and method of attachment of steel xenogenesis that has application prospect.But there is following defective in the CMT melt-brazing method: (1) this method at present only is used for the seam weldering, because the thermal expansion coefficient difference of aluminium alloy and steel is bigger, there is bigger welding deformation in joint; When (2) seam welds, be necessary for lap joint between aluminium alloy and the steel plate, this has proposed challenge to traditional vehicle body parts design, is difficult to apply.
Summary of the invention
The present invention is directed to the prior art above shortcomings, the dissimilar metal spot welding system and the welding method thereof of a kind of light metal and clad steel sheet are provided, by between light metal and clad steel sheet, forming the molten soldered fitting of point, realize that light metal is connected with the point of steel, when guaranteeing the dissimilar metal quality of connection, having solved continuous seam weldering makes joint produce the problem of gross distortion, and be connected to main vehicle body parts joint design with resistance spot welding process and do not exert an influence, thereby greatly reduce the design and the manufacturing cost of vehicle body to traditional.
The present invention is achieved by the following technical solutions:
The present invention relates to the dissimilar metal spot welding system of a kind of light metal and clad steel sheet, comprise: CMT electric arc welding system, gas cylinder, robot control module, robot and clamping device, wherein: electric arc welding system links to each other with the robot control module and transmits the welding control signal, gas cylinder is communicated with the CMT electric arc welding system, the robot control module links to each other with robot, the control signal of transferring robot motion.
Described CMT electric arc welding system comprises: welding gun, wire-feed motor, welding wire, host power supply and tank for coolant, wherein: welding gun respectively with wire-feed motor, host power supply and tank for coolant link to each other, and welding gun is fixedly set in the end of robot, wire-feed motor links to each other with host power supply and receives control instruction, welding wire is arranged in wire-feed motor and splashes into the fabrication hole of light metal plate with holes and form joint with the mother metal fusion as filling metal after the welding gun heat fused, tank for coolant is connected with host power supply and receives control instruction and be connected with the CMT electric arc welding system, cooling CMT electric arc welding system in welding process, host power supply links to each other with the robot control module with the input/output signal in the transmission welding process.
Described light metal plate with holes is provided with a fabrication hole for cylindrical or truncated cone-shaped structure.
Described steel plate is a clad steel sheet, and its parent metal is mild steel, high-strength steel, advanced high-strength steel or super-high strength steel etc., and coating is zinc, tin, copper or nickel alloy plating layer, and thickness of coating is the 5-50 micron;
Described gas cylinder built-in protective gas is for welding process provides inert protective atmosphere.
Described machine people is the industrial machinery arm that has six axles that rotatablely move, and the weight capacity and the radius of clean-up satisfy the arc welding requirement, drives the welding gun that is contained in the 6th in welding process, makes its accurately center of location light metal plate holes.
The present invention relates to the welding method of said system
1) on the light metal plate, gets some fabrication holes in advance;
2) overlapping being positioned on the clad steel sheet and by clamping device of light metal plate with holes clamped, contact between the metallic plate up and down;
3) robot drives the welding gun motion and makes welding wire in the welding gun vertical with the metallic plate face and aim at the center of the fabrication hole of light metal plate with holes;
4) robot control module sends the control signal that welding process begins and opens the logical in advance protective gas of gas cylinder to CMT arc welding host power supply, forms protective gas atmosphere on light metal plate with holes;
5) welding gun is by CMT arc welding host power supply control, under the CMT arc mode, with the striking current set and the voltage electric arc that ignites;
6) electric arc is adjusted to welding current, the weldingvoltage of setting, with wire feed rate and the welding of setting of welding wire pumpback frequency, welding is realized by border, melting process hole and upper strata aluminium sheet in wire melting fill process hole, realizes soldering by coating and lower floor's clad steel sheet;
7) after welding finished, welding current decayed to the receipts arc current, the fabrication hole on the light-alloy plate filled up fully and surfacing after arc extinction, keep feeding protective gas to prevent the joint oxidation;
8) robot drive welding gun moves to the position of next preset holes and repeats the operation of step 3) to step 7), realizes dissimilar metal spot welding.
The present invention compared with prior art has the following advantages: the present invention changes spot welding into by stitching weldering, greatly reduces the influence because of the different thermal deformation butt joint quality that produce of two kinds of material thermal expansion coefficients.Compare with self-piercing riveting mechanical connection technology, the punching and the cost of welding wire are very low, and the vehicle body parts design method based on resistance spot welding process is not for a long time influenced, and are easy to apply.The particularly important is this method and can effectively control the thickness of compound between light metal and steel plate interface metal, joint has superior mechanical property.
Description of drawings
Fig. 1 is a process schematic diagram of the present invention.
Fig. 2 is a system schematic of the present invention.
Fig. 3 is the inventive method fundamental diagram.
Fig. 4 is a technological parameter curve map of the present invention.
The specific embodiment
Below embodiments of the invention are elaborated, present embodiment is being to implement under the prerequisite with the technical solution of the present invention, provided detailed embodiment and concrete operating process, but protection scope of the present invention is not limited to following embodiment.
As shown in Figure 2, present embodiment comprises: CMT electric arc welding system 1, welding wire 2, light metal plate 3 with holes, steel plate 4, gas cylinder 5, robot control module 6, robot 7, clamping device 8.Wherein: CMT electric arc welding system 1 links to each other with robot control module 6 and transmits the welding control signal, welding wire 2 is loaded in the CMT electric arc welding system 1, light metal plate 3 with holes, steel plate 4 are fixed on the clamping device 8, gas cylinder 5 is communicated with CMT electric arc welding system 1, robot control module 6 links to each other with robot 7, the control signal of transferring robot 7 motions.
Described CMT electric arc welding system comprises: welding gun 9, wire-feed motor 10, host power supply 11 and tank for coolant 12, and wherein: welding gun 9 links to each other with wire-feed motor 10, host power supply 11 and tank for coolant 12, and is contained in the end of robot 7; Wire-feed motor 10 is by host power supply 11 controls, and the welding wire 2 that is mounted in it splashes in the hole of light metal plate 3 as filling metal molten by welding gun 9, forms joint with the mother metal fusion; Tank for coolant 12 provides power supply and control signal by host power supply 11, cooling CMT arc welding 1 system in welding process; Host power supply 11 links to each other with robot control module 6 with input, output signal in the transmission welding process.
Described light metal plate 3 with holes, the fabrication hole on it is cylindrical, diameter is 6.5mm.
Described steel plate is a clad steel sheet 4, is zinc plated mild carbon steel.
The dress argon gas is as protective gas, for welding process provides inert protective atmosphere in the described gas cylinder 5.
Described robot 7 is the industrial machinery arm, and weight capacity is 5kg, has six axles that rotatablely move, and the radius of clean-up is 1444mm, drives the welding gun 9 that is contained in the 6th in welding process, makes its accurately center of location light metal plate 3 holes.
The upper strata light metal plate 3 of present embodiment is aluminium alloy AA6061-T6, lower floor's galvanized steel plain sheet 4 is zinc plated mild carbon steel plate HDG-GMW2, panel thickness coupling: 1mm+1.2mm, aluminium alloy plate 3 usefulness mechanical grinding modes are removed the oxide layer on surface, remove the greasy dirt of metal sheet surface with acetone reagent, welding wire 2 materials are A1Si5, and diameter is 1.2mm.
Technological parameter: welding current is 127A, voltage 15.3V, and wire feed rate 6.0m/min, arc length is modified to-30%, and welding wire pumpback frequency 70Hz adopts argon gas as protective gas, and its flow is 15L/min, and be 0.8s weld interval.
Present embodiment technical process technical process such as Fig. 3 (a)～(h) and shown in Figure 4:
1) on aluminium alloy plate 3, gets the fabrication hole that cylindrical diameter is 6.5mm in advance;
2) aluminium alloy plate 3 overlapping being positioned on the clad steel sheet 4 and by clamping device are clamped, contact between the metallic plate up and down;
3) robot 7 drives welding guns 9 motions and makes welding wire 2 in the welding gun 9 vertical with the metallic plate face and aim at the center of the fabrication hole of aluminium alloy plate 3 with holes;
4) robot control module 6 sends the control signal that welding process begins and opens the logical in advance protective gas of gas cylinder 5 to CMT arc welding host power supply 11, forms protective gas atmosphere near the fabrication hole of aluminium alloy plate 3 with holes;
5) behind the logical in advance protective gas certain hour (GPr=0.1s), welding gun 9 is by 11 controls of CMT arc welding host power supply, under the CMT arc mode, with striking current (size be welding current 135%), the voltage electric arc that ignites;
6) ignite electric arc after the I-S section, electric current is through decay (SL section), welding current, weldingvoltage and wire feed rate and the welding wire pumpback frequency welding of CMT electric arc welding system 1 to set,, burning and fill process hole, the border of melt-off pore simultaneously, and realize soldering by coating with the steel plate 4 of lower floor;
7) after reaching predefined weld interval (I section), welding current decays to through the SL section and receives arc current (size is 50% of welding current), fabrication hole on the aluminium alloy plate 3 filled up fully and surfacing after (I-E section) arc extinction, the protective gas (GPo=0.5s) that continues logical certain hour is to prevent the joint oxidation;
Weld under this welding parameter condition, the zinc element on the galvanized steel plain sheet has improved the wetability of aluminium on steel, has obtained good welding point.The smooth symmetry of joint pattern, nothing is splashed, and weld defects such as pore, crackle are few.Postwelding adopts universal testing machine to stretch, and joint draws cuts that intensity is the highest can to reach 3.364KN; And self-piercing riveting technology (SPR) adopts same material and thickness of slab, draw to cut intensity and be up to 2.704KN, so this process can reach higher intensity.The zinc coat at the galvanized steel plain sheet back side does not have scaling loss simultaneously, has kept the Corrosion Protection of steel plate.
The upper strata light metal plate 3 of present embodiment is aluminium alloy AA6061-T6, lower floor's galvanized steel plain sheet 4 is high-strength steel DP780, panel thickness coupling: 1mm+2mm, the aperture is 6.5mm, centre-to-centre spacing between the Kong Yukong is 20mm, aluminium alloy plate 3 usefulness mechanical grinding modes are removed the oxide layer on surface, remove the greasy dirt of metal sheet surface with acetone reagent.
Technological parameter: welding wire 2 materials are A1Si5, and diameter is 1.2mm, and welding current is 144A, voltage 16.4V; wire feed rate 6.5m/min, arc length is modified to-30%, welding wire pumpback frequency 70Hz; adopt argon gas as protective gas, its flow is 15L/min, and be 0.8s weld interval.
Present embodiment technical process technical process such as Fig. 3 (a)～(h) and shown in Figure 4:
1) fabrication hole that to get some cylindrical diameters in advance on aluminium alloy plate 3 be 6.5mm;
2) aluminium alloy plate 3 overlapping being positioned on the clad steel sheet 4 and by clamping device are clamped, contact between the metallic plate up and down;
3) robot 7 drives welding guns 9 motions and makes welding wire 2 in the welding gun 9 vertical with the metallic plate face and aim at the center of the fabrication hole of aluminium alloy plate 3 with holes;
4) robot control module 6 sends the control signal that welding process begins and opens the logical in advance protective gas of gas cylinder 5 to CMT arc welding host power supply 11, forms protective gas atmosphere near the fabrication hole of aluminium alloy plate 3 with holes;
5) behind the logical in advance protective gas certain hour (GPr=0.1s), welding gun 9 is by 11 controls of CMT arc welding host power supply, under the CMT arc mode, with striking current (size be welding current 135%), the voltage electric arc that ignites;
6) ignite electric arc after the I-S section, electric current is through decay (SL section), welding current, weldingvoltage and wire feed rate and the welding wire pumpback frequency welding of CMT electric arc welding system 1 to set,, burning and fill process hole, the border of melt-off pore simultaneously, and realize soldering by coating with the steel plate 4 of lower floor;
7) after reaching predefined weld interval (I section), welding current decays to through the SL section and receives arc current (size is 50% of welding current), fabrication hole on the aluminium alloy plate 3 filled up fully and surfacing after (I-E section) arc extinction, the protective gas (GPo=0.5s) that continues logical certain hour is to prevent the joint oxidation;
8) robot 7 drive welding guns 9 move to the position of next preset holes and repeat the operation of step 3) to step 7), realize dissimilar metal spot welding.
Other embodiment of present embodiment is identical with embodiment 1.
Under this technological parameter condition, multiple spot series spot welding joint pattern is smooth attractive in appearance, and technology stability is good, does not have weld defect such as splash.Post welding distortion is little, and upper and lower two-layer plate keeps smooth substantially, compares with the seam weldering, does not have obviously crooked.Therefore adopt this process can reduce to be connected the distortion of workpiece greatly.
Claims (6)
1. the dissimilar metal spot welding system of light metal and clad steel sheet, comprise: the CMT electric arc welding system, gas cylinder, the robot control module, robot and clamping device, it is characterized in that: electric arc welding system links to each other with the robot control module and transmits the welding control signal, gas cylinder is communicated with the CMT electric arc welding system, the robot control module links to each other with robot, the control signal of transferring robot motion, described CMT electric arc welding system comprises: welding gun, wire-feed motor, welding wire, host power supply and tank for coolant, wherein: welding gun respectively with wire-feed motor, host power supply and tank for coolant link to each other, and welding gun is fixedly set in the end of robot, wire-feed motor links to each other with host power supply and receives control instruction, welding wire is arranged in wire-feed motor and splashes into the fabrication hole of light metal plate with holes and form joint with the mother metal fusion as filling metal after the welding gun heat fused, tank for coolant is connected with host power supply and receives control instruction and be connected with the CMT electric arc welding system, cooling CMT electric arc welding system in welding process, host power supply links to each other with the robot control module with the input/output signal in the transmission welding process.
2. the dissimilar metal spot welding system of light metal according to claim 1 and clad steel sheet is characterized in that, described light metal plate with holes is provided with a described fabrication hole for cylindrical or truncated cone-shaped structure.
3. the dissimilar metal spot welding system of light metal according to claim 1 and clad steel sheet, it is characterized in that, the parent metal of described clad steel sheet is mild steel, high-strength steel, advanced high-strength steel or super-high strength steel, and coating is zinc, tin, copper or nickel alloy plating layer, and thickness of coating is the 5-30 micron.
4. the dissimilar metal spot welding system of light metal according to claim 1 and clad steel sheet is characterized in that, described gas cylinder built-in protective gas.
5. the dissimilar metal spot welding system of light metal according to claim 1 and clad steel sheet is characterized in that, described machine people is the industrial machinery arm that has six axles that rotatablely move.
6. welding method that relates to the described system of above-mentioned arbitrary claim may further comprise the steps:
1) on the light metal plate, gets some fabrication holes in advance;
2) overlapping being positioned on the clad steel sheet and by clamping device of light metal plate with holes clamped, contact between the metallic plate up and down;
3) robot drives the welding gun motion and makes welding wire in the welding gun vertical with the metallic plate face and aim at the center of the fabrication hole of light metal plate with holes;
4) robot control module sends the control signal that welding process begins and opens the logical in advance protective gas of gas cylinder to CMT arc welding host power supply, forms protective gas atmosphere on light metal plate with holes;
5) welding gun is by CMT arc welding host power supply control, under the CMT arc mode, with the striking current set and the voltage electric arc that ignites;
6) electric arc is adjusted to welding current, the weldingvoltage of setting, with wire feed rate and the welding of setting of welding wire pumpback frequency, welding is realized by border, melting process hole and upper strata aluminium sheet in wire melting fill process hole, realizes soldering by coating and lower floor's clad steel sheet;
7) after welding finished, welding current decayed to the receipts arc current, the fabrication hole on the light-alloy plate filled up fully and surfacing after arc extinction, keep feeding protective gas to prevent the joint oxidation;
8) robot drive welding gun moves to the position of next preset holes and repeats the operation of step 3) to step 7), realizes dissimilar metal spot welding.
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