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CN102085598B - 摩擦搅拌接合方法 - Google Patents

摩擦搅拌接合方法 Download PDF

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Publication number
CN102085598B
CN102085598B CN200910310831.8A CN200910310831A CN102085598B CN 102085598 B CN102085598 B CN 102085598B CN 200910310831 A CN200910310831 A CN 200910310831A CN 102085598 B CN102085598 B CN 102085598B
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China
Prior art keywords
component
top layer
junction surface
joining tool
connecting method
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CN200910310831.8A
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CN102085598A (zh
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中川考一
刘庆
盐泽勇雄
中川威雄
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Hongfujin Precision Industry Shenzhen Co Ltd
FTC Corp
Hon Hai Precision Industry Co Ltd
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Hongfujin Precision Industry Shenzhen Co Ltd
FTC Corp
Hon Hai Precision Industry Co Ltd
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Application filed by Hongfujin Precision Industry Shenzhen Co Ltd, FTC Corp, Hon Hai Precision Industry Co Ltd filed Critical Hongfujin Precision Industry Shenzhen Co Ltd
Priority to CN200910310831.8A priority Critical patent/CN102085598B/zh
Priority to US12/728,387 priority patent/US8052033B2/en
Priority to JP2010090340A priority patent/JP2011115846A/ja
Publication of CN102085598A publication Critical patent/CN102085598A/zh
Priority to US13/246,982 priority patent/US8167188B2/en
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Publication of CN102085598B publication Critical patent/CN102085598B/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B23K20/1245—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding characterised by the apparatus
    • B23K20/1255—Tools therefor, e.g. characterised by the shape of the probe
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B23K20/128—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding making use of additional material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • B29C65/0681—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding created by a tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
    • B29C65/4815—Hot melt adhesives, e.g. thermoplastic adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5007—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like
    • B29C65/5035—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like being in thread form, i.e. in the form of a single filament, e.g. in the form of a single coated filament
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/116—Single bevelled joints, i.e. one of the parts to be joined being bevelled in the joint area
    • B29C66/1162—Single bevel to bevel joints, e.g. mitre joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/434—Joining substantially flat articles for forming corner connections, fork connections or cross connections
    • B29C66/4342—Joining substantially flat articles for forming corner connections, e.g. for making V-shaped pieces
    • B29C66/43421—Joining substantially flat articles for forming corner connections, e.g. for making V-shaped pieces with a right angle, e.g. for making L-shaped pieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/434—Joining substantially flat articles for forming corner connections, fork connections or cross connections
    • B29C66/4344—Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces
    • B29C66/43441—Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces with two right angles, e.g. for making T-shaped pieces, H-shaped pieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73115—Melting point
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/18—Sheet panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys
    • B23K2103/10—Aluminium or alloys thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/32—Measures for keeping the burr form under control; Avoiding burr formation; Shaping the burr
    • B29C66/322—Providing cavities in the joined article to collect the burr

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

一种摩擦搅拌接合方法，包括以下步骤：提供一接合工具，该接合工具具有摩擦面；提供一第一部件，该第一部件具有第一表层及第一接合部，第一部件上预设第一凹部，第一凹部连接第一表层和第一接合部；提供一第二部件，该第二部件具有第二表层及与第一部件的第一接合部相接合的第二接合部；将摩擦面抵压于第一表层和第二表层上，旋转并移动接合工具，使接合工具的摩擦面于该第一表层和该第二表层上摩擦搅拌产生热量，热量传导至第一部件的第一接合部和第二部件的第二接合部，使两者材料塑性流动而接合在一起，第一表层和第二表层的材料被搅拌流入第一凹部。该摩擦搅拌接合方法使摩擦搅拌接合产品的接合线与接合部的外观良好，材料组织极少发生变化。

Description

摩擦搅拌接合方法
技术领域
本发明涉及一种摩擦搅拌接合方法，特别涉及一种无搅拌针的摩擦搅拌接合方法。
背景技术
摩擦搅拌接合法主要是在进行板材的对接接合时，采用旋转工具搅拌接合部位材料的一种摩擦压接方法。由于其简易性及优良的生产性，适用范围正在逐渐扩大。由于摩擦搅拌接合法对工具的耐久性要求较高，大多用于铝合金的接合。但是，当接合面为产品外表面时，由于会残留凹凸状的搅拌痕迹或毛刺，因而必须通过切削加工或研磨加工除去接合工件表面层。
进一步地说，即使除去上述表面层，得到平滑的接合面，但由于接合时被搅拌的部分重复发生较大的塑性流动，其金属组织会变得与母材大不相同。这使得后续进行铝合金中常用的铝阳极化处理时，会在加工面上留下痕迹。上述痕迹虽然可以通过加工消除，但无法通过铝阳极化处理消除。换句话说就是，通常的铝阳极化处理附带一种化学蚀刻效果，因而会使母材的金属组织的变化浮现出来。也就是说，由于摩擦搅拌产生的塑性流动机械性地改变了金属组织，使其变成与母材不同的金属组织，因此，一旦进行铝阳极化处理，无论如何也无法避免表面产生微妙的凹凸差异，使得接合部被看出来。
即使在后续添加退火步骤，将接合件放入炉中以再结晶温度以上的温度进行退火处理，以消除上述接合部的金属组织的局部性的差异，但若是采用一般的退火处理，再结晶时搅拌部存在的差异会使得之前加工产生的差异显现出来，无法实现全体金属组织的均匀化。
通过上述实验可以了解，对部分金属组织与周围不同的接合件进行铝阳极化处理后，金属组织的差异必然会在表面性状上表现出来。总的来说就是，即使是相同成分的金属，如果采用不同的素材制造方法（压延、挤出、锻造、铸造、烧结），金属组织就会有差异，因此不管采用什么样的方法接合，一旦进行铝阳极化处理，就会以接合部为界显现出某种表面性状的差异。更何况在摩擦搅拌接合时，接合部的金属组织与母材大不相同，因此处理后接合部与周围相较而言显得十分显眼。
如果按照这种方式思考下去，铝阳极化处理时要考虑到母材的制造方法及其金属组织，接合区域的不可视在理论上非常难以实现的。
发明内容
鉴于上述状况，有必要提供一种新的摩擦搅拌接合法使接合部的外观良好。
一种摩擦搅拌接合方法，包括以下步骤：提供一接合工具，该接合工具具有摩擦面；提供一第一部件，该第一部件具有第一表层及第一接合部，所述第一部件上预设第一凹部，所述第一凹部连接所述第一表层和所述第一接合部；提供一第二部件，该第二部件具有第二表层及与第一部件的第一接合部相接合的第二接合部；将所述接合工具的摩擦面抵压于所述第一部件的第一表层和第二部件的第二表层上，旋转并移动接合工具，使接合工具的摩擦面于该第一表层和该第二表层上摩擦搅拌产生热量，热量传导至第一部件的第一接合部和第二部件的第二接合部，使两者材料塑性流动而接合在一起，所述第一表层和第二表层的材料被搅拌流入所述第一凹部。
上述摩擦搅拌接合方法，通过接合工具仅在第一部件和第二部件的表层进行摩擦搅拌通过热量传递的方式使第一接合部和第二接合部接合，只有表层材料产生塑性流动，而其余部分的材料未发生变化，因此，第一接合部和第二接合部的材料组织极少发生变化，外观良好。
附图说明
图1是本发明实施例所采用的接合工具的结构示意图。
图2是图1所示接合工具的摩擦面的结构示意图。
图3是图1所示接合工具的摩擦面的另一结构示意图。
图4是本发明实施例一的第一部件和第二部件的结构示意图。
图5是图1所示的接合工具摩擦搅拌图4所示的第一部件和第二部件的示意图。
图6是本发明实施例二的第一部件和第二部件的结构示意图。
图7是图1所示的接合工具摩擦搅拌图6所示的第一部件和第二部件的示意图。
图8是本发明实施例三的第一部件和第二部件的结构示意图。
图9是图8所示第一部件和第二部件结合的结构示意图。
图10是图1所示的接合工具摩擦搅拌图9所示的第一部件和第二部件的示意图。
图11是本发明实施例四的第一部件和第二部件的结构示意图。
图12是图1所示的接合工具摩擦搅拌图11所示的第一部件和第二部件的示意图。
图13是本发明实施例三的第一部件和第二部件的另一结构示意图以及焊接材料的结构示意图。
图14是图13所示的第一部件和第二部件的接合示意图。
具体实施方式
下面将结合附图及具体实施方式对本发明提供的摩擦搅拌接合方法作进一步地详细说明。
请同时参阅图1和图4，本发明实施例一提供的摩擦搅拌接合方法采用接合工具10对第一部件20和第二部件30进行摩擦搅拌接合。
请同时参阅图1至图3，接合工具10基本呈柱状，一端具有摩擦面11，该接合工具10的摩擦面11一端为平头，即该摩擦面11基本为平面。自该摩擦面11向接合工具10的内部凹陷形成有若干凹槽13，凹槽13的形状可以为螺旋状或以接合工具10的回转中心为共同起点的若干条圆弧。接合工具10工作时的旋转方向与凹槽13自中心向外延伸的方向相同。
请参阅图4，第一部件20包括第一表层21及第一接合部23。第一部件20的第一接合部23为平面，与第一表层21垂直。
第二部件30包括第二表层31和第二接合部33。第二部件30的第二接合部33为平面，与第二表层31垂直。
请同时参阅图4和图5，对第一部件20和第二部件30进行摩擦搅拌接合时，使第一部件20的第一接合部23和第二部件30的第二接合部33对接后，将第一部件20和第二部件30固定。其中，第一部件20的第一表层21和第二部件30的第二表层31平齐，且在第一接合部23和第二接合部33在第一表层21和第二表层31之间形成接合线29。
将接合工具10的摩擦面11抵压在第一部件20的第一表层21和第二部件30的第二表层31上，且位于接合线29的上方。然后将接合工具10相对接合线29旋转并沿接合线29延伸方向移动，使第一部件20的第一表层21和第二部件30的第二表层31被摩擦搅拌，摩擦搅拌产生的热量传递至未被搅拌的第一接合部23和第二接合部33中使两者被加热至塑性流动状态后无间隙地接合在一起。
其中，接合工具10的旋转方向与凹槽13自摩擦面11的中心向外部延伸的方向相同，且采用高速旋转，低速移动并略微插入第一部件20的第一表层21和第二部件30的第二表层31的方式对第一部件20和第二部件30进行摩擦搅拌。其中，接合工具10的旋转速度S、移动速度V以及插入的第一表层21和第二表层31的深度H根据第一部件20和第二部件30的所需接合部位的厚度、材料以及接合工具10的尺寸及材料等因素确定，能使第一部件20和第二部件30仅有部分材料塑性流动并能产生足够的热量传递至未被搅拌的部位而使第一接合部23和第二接合部33接合即可。本实施例中，旋转速度S为每分钟7000转，移动速度V为每分钟500毫米，第一表层41和第二表层51被搅拌的厚度H为0.15毫米。
请同时参阅图1和图6，本发明实施例二的摩擦搅拌接合方法对采用接合工具10对第一部件40和第二部件50进行摩擦搅拌接合。
接合工具10的结构与实施例一中相同。
第一部件40包括第一表层41和第一接合部43，在第一表层41的边角处还设置有第一凹部45。第一接合部43为平面，与第一表层41垂直。
第二部件50包括第二表层51和第二接合部53，在第二表层51的边角处还设置有第二凹部55。第二接合部53为平面，与第二表层51垂直。
对第一部件40和第二部件50进行摩擦搅拌接合时，使第一部件40的第一接合部43和第二部件50的第二接合部53对接后，将第一部件40和第二部件50固定。其中，第一部件40的第一表层41和第二部件50的第二表层51平齐，第一凹部45和第二凹部55组合为一沟槽49，在第一接合部43和第二接合部53在沟槽49的底部形成接合线59。可以理解，也可以仅在一个部件上开设凹部，且凹部可以为任意形状。
请同时参阅图1，图6和图7，将接合工具10的摩擦面11抵压在第一部件40的第一表层41和第二部件50的第二表层51上，且位于沟槽49的上方。然后使接合工具10相对接合线59旋转并沿接合线59延伸方向移动，使第一部件40的第一表层41和第二部件50的第二表层51被摩擦搅拌。摩擦搅拌产生的热量传递至未被搅拌的第一接合部43和第二接合部53中使两者被加热至塑性流动状态后无间隙地接合在一起，此外，摩擦搅拌产生的热量还使第一部件40和第二部件50产生塑性流动并流向沟槽49中，从而可以使沟槽49被填充，使第一部件40和第二部件50的接合更加牢固。
其中，接合工具10的旋转方向与凹槽13自摩擦面11的中心向外部延伸的方向相同，且采用高速旋转，低速移动并略微插入第一部件40的第一表层41和第二部件50的第二表层51的方式对第一部件40和第二部件50进行摩擦搅拌。接合工具10的旋转速度S、移动速度V以及插入的第一表层41和第二表层51的深度H根据第一部件40和第二部件50的所需接合部位的厚度、材料以及接合工具10的尺寸及材料等因素确定，能使第一部件40和第二部件50仅有部分材料塑性流动并能产生足够的热量传递至未被搅拌的部位而使第一接合部43和第二接合部53接合即可。本实施例中，旋转速度S为每分钟7000转，移动速度V为每分钟500毫米，第一表层41和第二表层51被搅拌的厚度H为0.15毫米。
请同时参阅图1，图8至图10，本发明实施例三的摩擦搅拌接合方法采用接合工具10对第一部件60和第二部件70进行摩擦搅拌接合。
接合工具10与实施例一中的相同。
第一部件60包括第一表层61和第一接合部63。第一接合部63为平面，相对第一表层61倾斜。
第二部件70包括第二表层71和第二接合部73。第二接合部73为平面，相对第二表层71倾斜。
对第一部件60和第二部件70进行摩擦搅拌接合时，使第一部件60的第一接合部63和第二部件70的第二接合部73对接后，将第一部件60和第二部件70固定。其中，第一部件60的第一表层61和第二部件70的第二表层71之间具有夹角，该夹角可以为任意角度，本实施例中，夹角为90度，即第一部件60和第二部件70垂直。第一接合部63和第二接合部73在第一表层61和第二表层71之间形成接合线69，该接合线69为第一部件60和第二部件70连接拐角的边缘。
进一步地，该摩擦搅拌接合方法还包括对摩擦搅拌接合产品300进行后处理加工。可以理解，本发明实施例一、实施例二中，也可以在第一部件20，40和第二部件30，50接合后，将组织发生变化的部分去除，使组织未发生变化的材料露于外面，即使后续的处理，如阳极氧化后，也可以获得良好的外观。此外，因为接合线69设置在边角处，与物体本身的边缘线重合，因此，不易被看出。
其中，接合工具10的旋转方向与凹槽13自摩擦面11的中心向外部延伸的方向相同，且采用高速旋转，低速移动并略微插入第一部件60的第一表层61的方式对第一部件60和第二部件70进行摩擦搅拌。接合工具10的旋转速度S、移动速度V以及插入的第一表层61的深度H根据第一部件60和第二部件70的所需接合部位的厚度、材料以及接合工具10的尺寸及材料等因素确定，能使第一部件60和第二部件70仅有部分材料塑性流动并能产生足够的热量传递至未被搅拌的部位而使第一接合部63和第二接合部73接合即可。本实施例中，旋转速度S为每分钟7000转，移动速度V为每分钟500毫米，第一表层41被搅拌的厚度H为0.15毫米。
进一步地，接合时还可将一个抵压第二部件70的辅助件200。该辅助件200包括相邻的第一端面201和第二端面203，将辅助件200的第一端面201抵持第二部件70的第二表层71，第二端面203与第一部件60的第一表层61基本平齐。
这样，因为增加了辅助件200，可以增加摩擦面积，进而增加摩擦所产生的热量，并将部分热量传递给第一部件60和第二部件70，使其二者的材料接合更为充分。在后处理加工中，可以将第一部件60和第二部件70中组织发生变化的部分通过机械加工的方式去除，使组织未发生变化的材料露于外面，即使后续的处理，如阳极氧化后，也可以获得良好的外观。
请同时参阅图1，图11和图12，本发明实施例四的摩擦搅拌接合方法采用接合工具10对第一部件80和第二部件90进行摩擦搅拌接合。
接合工具10与实施例一中的相同。
第一部件80包括第一表层81、第一接合部83和连接第一表层81和第一接合部83的第一侧面85。第一接合部83为平面，相对第一表层81和第一侧面85倾斜。
第二部件90包括第二表层91和第二接合部93。第二接合部93为平面，相对第二表层91倾斜。
对第一部件80和第二部件90进行摩擦搅拌接合时，使第一部件80的第一接合部83和第二部件90的第二接合部93对接后，将第一部件80和第二部件90固定。其中，第一部件80的第一侧面85和第二部件90的第二表层91平齐，第一侧面85和第一表层81之间具有夹角，该夹角可以为任意角度，本实施例中，夹角为90度，即第一部件80和第二部件90垂直。第一接合部83和第二接合部93在第一侧面85和第二表层91之间形成接合线89。
将接合工具10的摩擦面11抵压在第一部件80的第一表层81上，且位于靠近第一侧面85的边缘。然后使接合工具10相对第一表层81旋转并沿接合线89延伸方向移动，使第一部件80的第一表层81被摩擦搅拌。摩擦搅拌产生的热量传递至未被搅拌的第一接合部83和第二接合部93中使第一部件80和第二部件90被加热至塑性流动状态后无间隙地接合在一起。
其中，接合工具10的旋转方向与凹槽13自摩擦面11的中心向外部延伸的方向相同，且采用高速旋转，低速移动并略微插入第一部件80的第一表层81的方式对第一部件80和第二部件90进行摩擦搅拌。接合工具10的旋转速度S、移动速度V以及插入的第一表层81和第二表层91的深度H根据第一部件80和第二部件90的所需接合部位的厚度、材料以及接合工具10的尺寸及材料等因素确定，能使第一部件80仅有部分材料塑性流动并能产生足够的热量传递至未被搅拌的部位而使第一接合部83和第二接合部93接合即可。
可以理解，本发明实施例四中，也可以在第一部件80和第二部件90接合后，将组织发生变化的部分去除。
第一部件20，40，60，80和第二部件30，50，70，90的材料可以为铝、铝合金、铜合金、橡胶等熔点较低的材料，形状也不局限于固定形状，可以为任何结构。第一接合部23，43，63，83及第二接合部33，53，73，93可以是面，可以是线，也可以是点。
此种摩擦搅拌接合方法主要应用于外观产品的接合中，而外观产品对接合的强度要求不高，因此，只对表层21，31，41，51，61，81进行摩擦搅拌而进行接合的方式一般情况下可以满足外观产品的要求强度。若为了得到更高的强度，还可以在位于产品内部的接合处增设沟槽，并在沟槽内填补熔点较低的焊接材料，如焊锡等。该焊接材料的熔点应当低于第一部件及第二部件的熔点。此外，因为本发明实施例中的摩擦搅拌接合方法采用热量传递的方式进行接合，在远离摩擦搅拌的部位的热量较低，为此可以将容纳焊接材料的沟槽设置在远离摩擦搅拌的部位，以得到较好的强度，下面以本发明实施例三的第一部件60和第二部件70为例进行说明。
请同时参阅图13和图14，第三实施例的第一部件60还可包括自第一接合部63向第一部件60内部凹陷的第一沟槽67，第一沟槽97位于远离第一表层61的一端。第二部件70还包括自第二接合部73向第二部件70内部凹陷的第二沟槽77，第一沟槽67和第二沟槽77可以组合形成一凹槽。接合第一部件60和第二部件70时，可以在凹槽中放入熔点较低的焊接材料400，当第一部件60的第一表层61被摩擦搅拌产生的热量传递至第一沟槽67和第二沟槽77处时，因为焊接材料400的熔点较低，因此可以较容易地出现塑性流动状态，而使第一部件60和第二部件70具有更好的接合强度。可以理解，也可以仅在第一部件60和第二部件70其中之一上设置沟槽。另外，也可以在第一部件60和第二部件70内分别设置焊接材料。
本发明实施例的摩擦搅拌接合方法所需要接合的产品尺寸较小，所采用的接合工具10的尺寸也较小，而且多是对产品进行部分的连续加工，加工动力及加工力较小，因此加工设备简单且比较廉价。
进一步地，本发明实施例中的接合工具10可应用于常见的机械加工中心（图未示）中，以对第一部件20，40，60和第二部件30，50，70进行预处理，不需要专用设备，通用性很好，而在摩擦搅拌接合后，可在同一台加工中心上对摩擦搅拌接合产品进行后续处理，只需一次装夹，生产效率较高。
此外，因为采用具有平面状摩擦面的接合工具10，只要在物体表面作业，即使结合部是曲面或者曲线结构也可以良好接合。
本领域技术人员还可在本发明精神内做其它变化，当然，这些依据本发明精神所做的变化，都应包含在本发明所要求保护的范围内。

Claims (9)

1.一种摩擦搅拌接合方法，包括以下步骤：
提供接合工具，该接合工具具有摩擦面；
提供第一部件，该第一部件具有第一表层及第一接合部，所述第一部件上预设第一凹部，所述第一凹部连接所述第一表层和所述第一接合部；
提供第二部件，该第二部件具有第二表层及与第一部件的第一接合部相接合的第二接合部；及
将所述第一接合部和所述第二接合部对接，将所述接合工具的摩擦面抵压于所述第一部件的第一表层和第二部件的第二表层上，旋转并移动所述接合工具，使所述接合工具的摩擦面于该第一表层和该第二表层上摩擦搅拌产生热量，所述热量传导至所述第一部件的第一接合部和第二部件的第二接合部，使两者材料塑性流动而接合在一起，所述第一表层和第二表层的材料被搅拌流入所述第一凹部。
2.如权利要求1所述的摩擦搅拌接合方法，其特征在于：所述摩擦搅拌接合方法还包括在所述第二部件上预设第二凹部，所述第二凹部分别连接所述第二表层和第二接合部，所述第一凹部和第二凹部组合形成沟槽，所述第一表层和第二表层的材料被搅拌流入所述沟槽。
3.如权利要求1所述的摩擦搅拌接合方法，其特征在于：使所述第一部件和第二部件之间具有一定的夹角的接合，所述接合工具的摩擦面抵压于第一部件的第一表层，且与第二部件的第二表层之间的夹角大于0°且小于180°。
4.如权利要求3所述的摩擦搅拌接合方法，其特征在于：所述第一部件的第一接合部为相对所述第一表层倾斜的斜面，所述第二部件的第二接合部为与所述第一接合部贴合的斜面。
5.如权利要求1所述的摩擦搅拌接合方法，其特征在于：所述摩擦搅拌接合方法还包括在第一部件的第一接合部上远离所述第一表层的一端设置第一沟槽，并于所述第一沟槽内填充熔点低于第一部件的焊接材料。
6.如权利要求5所述的摩擦搅拌接合方法，其特征在于：所述第二部件的第二接合部上设置有与所述第一沟槽对应的第二沟槽，所述焊接材料的一部分位于所述第二沟槽内。
7.如权利要求1至6任意一项所述的摩擦搅拌接合方法，其特征在于：所述摩擦搅拌接合方法还包括在所述第一部件和第二部件结合后，于所述第一部件的第一表层及第二部件的第二表层去除一定厚度的材料。
8.如权利要求4所述的摩擦搅拌接合方法，其特征在于：所述第一部件还包括与第一表层及第一接合部相连且倾斜的第一侧面，所述摩擦搅拌接合方法还包括在所述第一部件和第二部件结合后，于所述第一部件的第一表层去除一定厚度的材料。
9.如权利要求1所述的摩擦搅拌接合方法，其特征在于：所述接合工具自摩擦面向其内部凹陷形成有凹槽，所述凹槽的形状为螺旋状或以接合工具的回转中心为共同起点的若干条圆弧，所述接合工具工作时的旋转方向与所述凹槽自中心向外延伸的方向相同。
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