fastening element for fixing a first electrically conductive material to a second electrically condu

专利摘要:
APPARATUS, METHOD AND RESISTANCE WELDING FIXER. The present invention relates to an apparatus and method for fixing dissimilar materials such as steel, plastic and aluminum. A resistance welding fastener having multiple layers can be used with or without a sealant. The fastening element can be used to form an aluminum-coated steel laminate by means of a fastening sheath pattern. The fixation element can have a solid axis or have an extended range and have characteristics to interact with the welding electrode. A variety of electrode tips can be used to cooperate with the fixing element
公开号:BR112016017920B1
申请号:R112016017920-0
申请日:2015-02-02
公开日:2021-01-26
发明作者:Donald J. Spinella；Daniel Bergstrom
申请人:Arconic Inc.；
IPC主号:

专利说明:

Cross Reference to Related Orders
[001] This application claims priority benefit to US provisional application No. 61 / 934,951, filed on February 3, 2014, entitled Resistance Welding Fixing Element, Apparatus and Methods, which is hereby incorporated by reference into its wholeness. Field
[002] The present invention relates to fastening elements, fastening apparatus and methods for fixing parts and more particularly, for fixing metals, including dissimilar metals. Background
[003] Various fasteners, apparatus and methods for joining and assembling parts or subunits are known, such as welding, riveting, threaded fasteners, etc. In some cases, there is a need to join parts, subunits, layers of aluminum, etc. in a cost-effective way, to other parts, subunits, layers, etc. produced from other materials, such as steel (bare, coated, lower carbon, high strength, ultra-high strength, stainless), titanium alloys, copper alloys, magnesium, plastics, etc. Solutions to said fixing problems include mechanical fasteners / rivets in combination with an adhesive and / or a barrier layer to maintain adequate joint strength while minimizing corrosion, for example, due to the galvanic effect present in a junction of dissimilar metals. Direct welding between aluminum and other materials is not commonly used due to the intermetallics generated by aluminum and other materials, which negatively affect mechanical resistance and corrosion resistance. In cases where direct welding is employed, it is typically some type of solid state welding (friction, turning, ultrasonic, etc.) or braking / welding technology in order to minimize intermetallic, but the mechanical performance of said joints it is sometimes poor or only applicable to single joint geometries.
[004] In the automotive industry, the technology in use for the steel-to-steel joint is resistance point welding (RSW), due to cost and time cycle considerations (less than 3 seconds per individual joint and which can carried out by means of robots). Known methods for joining aluminum to steel include: the use of drilled hole riveting / conventional fastening elements, self-drilling riveting (SPR), the use of flow drilling screws (FDS or EJOTS trademark), welding agitation and friction / junction point (FSJ), friction tip junction (FBJ), and use of adhesives. Each of these processes is more challenging than steel-to-steel (RSW) resistance spot welding. For example, when high strength aluminum (above 240 MPa) is coupled to steel using SPR, the aluminum may break during the riveting process. In addition, high-strength steels (> 590 MPa) are difficult to drill, requiring the application of high magnitude forces by large, heavy-duty pistols. FSJ is not widely used in the automotive industry since the joint properties (mainly peeling and cross tension) are of low comparison to SPR. Furthermore, FSJ requires very precise alignment and fitting. As the thickness of the joint increases, the cycle times for the process can increase dramatically where the 5 mm to 6 mm joint stack may require 7 to 9 seconds of total processing time, which is well above 2 to 3 seconds of RSW cycle time when fabricating steel structures. FBJ employs a drill bit that is rotated through aluminum and is then welded to steel. This process requires very precise alignment and fitting similar to FSJ and high forging forces are required for welding steel. FDS involves turning a screw inside the workpieces, plasticizing one of the sheets, which then becomes interlocked with the screw threads. SDS is typically applied from a single side and requires alignment with a pilot hole in the steel sheet, which complicates assembly and increases costs. Alternative fastening elements, devices and methods for joining and assembling parts or subunits, therefore, still remain desired. summary
[005] The subject described refers to a method for fixing a first electrically conductive material to a second electrically conductive material using electrical resistance welding, including: putting the first and second materials together in physical and electrical contact, the first material having a lower melting point than the second material; placing an electrically conductive fastener that is capable of being welded to the second material and which has a higher melting point than the first material in physical and electrical contact with the first material to form an electrically conductive stack including the fastener , of the first material and the second material; before or after the step of placing the fastener to form the pile, apply a sealant between the fastener and the first material; apply an electrical potential through the stack, induce a current to flow through the stack and cause resistive heating, resistive heating causing the first material to soften; launching the fastening element through the first softened material towards the second material; after the fastener comes into contact with the second material, welding the fastener to the second material.
[006] According to another aspect of the present description, the fastener has a cap portion and a stem portion that extends at right angles from the cap portion and the sealant is in the form of at least one of a account, a ring, a disc, a strip or a deposit of sealant applied to at least one of the cap portion proximal to the first material or on the surface of the first material where the fastening element will be arranged during the laying step.
[007] According to another aspect of the present description, the sealant is at least one of an adhesive, a polymer, a brazing material or a solder.
[008] According to another aspect of the present description, additionally including the step of making the sealant flowable during the resistive heating step, the sealant conforms to and covers at least a portion of an interface between the lid portion and the first material after the welding step is complete.
[009] According to another aspect of the present description, the step of placing the fastening element includes keeping the fastening element on a vehicle mat and moving the mat and fastening element over the first material to a selected position and additionally comprising the step of disassociating the web from the fixing element after the welding step.
[0010] According to another aspect of the present description, a portion of the mat is captured between the fixing element and the first material during the casting step and before the disassociation step.
[0011] According to another aspect of the present description, the portion of the captured mat is the sealant.
[0012] According to another aspect of the present description, a fastener for fixing a first electrically conductive material to a second electrically conductive material using electrical resistance welding includes: a cover portion, an extending shaft portion from the lid portion and having a distal end to the lid portion, the fixing element, when disposed in a pile including first and second electrically conductive materials positioned in electrical contact and subjected to an electrical potential applied through the pile, capable of of conducting an electrical current that passes through the stack, the current causing resistive heating and welding to the second material at the distal end for the cap portion, the first material being captured between the cap portion and the second material after the end is welded to the second material, the fastener having a plurality of layers, a first layer having a first first composition and a second layer having a different second composition from the first composition.
[0013] According to another aspect of the present description, the first layer is steel and the second layer is aluminum.
[0014] According to another aspect of the present description, the first material is steel and the second material is aluminum, the second layer that comes into contact with and joins the second aluminum material after it is extended through an opening in the first material and subjected to electrical resistance welding.
[0015] According to another aspect of the present description, the second layer is the lower layer present along the entire lower surface of the fastening element, including a underside of the cover portion, an external surface of the shaft and a outer surface of the shaft end of the fastener.
[0016] According to another aspect of the present description, the second layer is the lower layer present along the lower surface from the end of the distal axis to the lid portion.
[0017] According to another aspect of the present description, the second layer is the bottom layer present along the bottom surface of the lid portion and an outer lateral surface of the shaft, but not at the end of the distal shaft for the lid portion. .
[0018] According to another aspect of the present description, the end of the axis has a peripheral edge against which the second layer comes into contact.
[0019] According to another aspect of the present description, the first layer is compatible for welding to the second material and the second layer is compatible for welding to the first material.
[0020] According to another aspect of the present description, the first layer is steel, the first material is aluminum, the second material is steel and the second layer is selected from titanium, stainless steel and cold sprayed aluminum.
[0021] According to another aspect of the present description, the first layer is compatible for welding to the second material and the second layer is an electrical insulating element through which the first layer extends to make electrical contact with the second material.
[0022] According to another aspect of the present description, the second layer is selected from a ceramic element and a polymer.
[0023] According to another aspect of the present description, the plurality of layers includes a diffusion barrier disposed between two of the plurality of layers, the two layers being dissimilar metals, a first being a top layer and a second being a lower layer with respect to the diffusion barrier.
[0024] According to another aspect of the present description, the first layer is at least one of steel, titanium and copper, the second layer is aluminum and the diffusion barrier is at least one of high purity aluminum, titanium or zinc .
[0025] According to another aspect of the present description, the second layer is coupled to the end of the fastener.
[0026] According to another aspect of the present description, a fastening element for fixing a first electrically conductive material to a second electrically conductive material using electrical resistance welding, includes: a cap portion, a shaft portion that extends from the cap portion and having a distal end to the cap portion, the fastener, when disposed in a stack including first and second electrically conductive materials positioned in electrical contact, the first material having a lower melting point than the second material and subjected to an electrical potential applied through the stack, capable of conducting an electric current that passes through the stack, the current causing resistive heating and welding to the second material at the distal end to the cap portion, the first material being captured between the cap portion and the second material after the end is welded to the second material, the tend axis o a solid cross section between the lid portion and the distal end for the lid portion.
[0027] According to another aspect of the present description, the cap portion has a depression in it capable of receiving a projection that extends from the surface of a welding electrode, an area of surface contact between the tip of the electrode and the cap portion exceeding the tip contact surface area with the second material.
[0028] According to another aspect of the present description, the cap portion has a rounded depression in it capable of receiving a rounded surface that protrudes from the tip of the welding electrode.
[0029] According to another aspect of the present description, the cap portion has a projection that extends from its surface capable of being received in a depression in the surface of a tip of the welding electrode.
[0030] According to another aspect of the present description, a fastener for fixing a first electrically conductive material to a second electrically conductive material using electrical resistance welding, includes: a cover portion, a shaft portion that extends from the lid portion and having a distal end to the lid portion, the fixing element, when disposed in a pile including first and second electrically conductive materials positioned in electrical contact and subjected to an electrical potential applied through the pile, able to conduct an electric current that passes through the stack, the current causing resistive heating and welding of the second material at the distal end to the cap portion, the first material being captured between the cap portion and the second material after the end is welded to the second material, the lid portion curving backwards towards the end of the shaft, so that after the outer periphery of the same is approximately coextensive with the end and additionally comprising an electrical insulating element attached to the outer periphery of the lid portion, the insulating element capable of preventing the electrical current from flowing through the external periphery in parallel to the electrical current flowing through the end, the lid portion capable of being flexed to accommodate the passage of the end through the first material and welding to the second material at the same time that the insulating element comes into contact against the surface of the first material.
[0031] According to another aspect of the present description, a method for fixing a plurality of adjacent layers of a first electrically conductive material to a second electrically conductive material using electrical resistance welding, includes: placing the first and second materials together in physical and electrical contact, the first material having a lower melting point than the second material; placing an electrically conductive fastener that is capable of being welded to the second material and which has a higher melting point than the first material in physical and electrical contact with the first material to form an electrically conductive stack including the fastener , of the first material and the second material; apply an electrical potential through the stack, induce a current to flow through the stack and cause resistive heating, resistive heating causing the first material to soften; launching the fastener through the plurality of softened layers of the first material towards the second material; after the fastener comes into contact with the second material, welding the fastener to the second material, the plurality of layers of the first material are welded together next to where the fastener passes through.
[0032] According to another aspect of the present description, the second material is a second fastening element and in which the plurality of layers of the first material are welded together close to at least one of the first fastening element and the second fastening element fixation.
[0033] According to another aspect of the present description, a method for fixing a first electrically conductive material to a second electrically conductive material using electrical resistance welding, includes: flexing the first material in a configuration having a shaped cross section of J; inserting the second material within the J-shaped curvature with the first and second materials in physical and electrical contact, the first material having a lower melting point than the second material; place an electrically conductive fastener that is capable of being welded to the second material and which has a higher melting point than the first material against the short side of the J shape in physical and electrical contact with the first material to form a electrically conductive cell including the fastener, the first material and the second material; apply an electric potential across the stack, induce a current to flow through the stack and cause resistive heating, resistive heating causing the first material to soften on the short side of the J shape; launching the fastening element through the first softened material towards the second material; after the fastener comes into contact with the second material, welding the fastener to the second material.
[0034] The fastening element is inserted through the short side of the J shape and welds to the second material without disturbing the outer surface of the first material on the other side of the J shape.
[0035] According to another aspect of the present description, the method is repeated for a plurality of fastening elements that form a sheath.
[0036] According to another aspect of the present description, a tip portion for an electrical resistance welding electrode for applying a resistance welding fastener, wherein the tip portion has a bottle neck shape with a larger diameter portion close to the welding electrode and a small diameter portion distal to the electrode, the small diameter portion having a rounded end to contact the fastener during welding.
[0037] According to another aspect of the present description, there is a transition from the portion of reduced diameter to the portion of larger diameter in the form of a rectilinear wall arranged at an angle with respect to an external wall of the portion of greater diameter.
[0038] According to another aspect of the present description, in which there is a transition from the small diameter portion to the larger diameter portion in the form of a double curvature.
[0039] According to another aspect of the present description, there is a transition from the small diameter portion to the larger diameter portion in the shape of the surface having a radius at least twice that of the rounded end.
[0040] According to another aspect of the present description, a method for fixing a first material to a second electrically conductive material using electrical resistance welding, includes: providing an opening in the first material; putting the first and second materials together in physical contact; providing an electrically conductive fastener having a cap portion larger than the opening in the first material and a shaft portion having at least a portion that can pass through the opening, the fastener capable of being welded to the second material; placing the axis of the fastener through the opening in the first material and in electrical contact with the second material to form an inclusive stack of the fastener, the first material and the second material; apply an electrical potential through the stack, induce a current to flow through the stack and cause resistive heating, resistive heating causing a softening of the fastener and the second material; weld the fastener to the second material and capture the first material between the cap portion and the second material.
[0041] According to another aspect of the present description, the first material is electrically non-conductive.
[0042] According to another aspect of the present description, the first material is plastic.
[0043] According to another aspect of the present description, the first material is a ceramic element. Brief Description of Drawings
[0044] For a more complete understanding of the present description, reference is made to the detailed description below of the exemplary modalities considered together with the attached drawings.
[0045] Figure 1 is a perspective view of a fastener according to an embodiment of the present description.
[0046] Figure 2 is a cross-sectional view of the fixing element of Figure 1 taken along section line 2-2 and looking in the direction of the arrows.
[0047] Figure 3 is a cross-sectional view of a fixation element such as that shown in figure 2, but having different dimensions.
[0048] Figure 4 is a diagrammatic view showing, in sequence, the insertion of a fastening element according to an embodiment of the present description through a first layer and being welded to a second layer.
[0049] Figure 5 is a diagrammatic view showing in sequence the insertion of a fastening element according to another embodiment of the present description through a first layer and being welded to a second layer.
[0050] Figure 6 is a diagrammatic view showing in sequence the insertion of a fastening element according to another embodiment of the present description through a first layer and being welded to a second layer.
[0051] Figure 7 is a diagrammatic view showing in sequence the insertion of a fastening element according to another embodiment of the present description through a first layer and being welded to a second layer.
[0052] Figure 8 is a diagrammatic view showing in sequence the insertion of a fastening element such as that shown in Figure 7 through a first layer and being welded to a tubular member by means of a single side access.
[0053] Figure 9 is a diagrammatic view showing in sequence the insertion of a fastening element such as that shown in Figure 7 through a first layer and being welded to a second layer in a series weld formation.
[0054] Figure 10 is a diagrammatic view showing in sequence the insertion of opposite fastening elements such as those shown in Figure 7 through the first and second layers and being welded together.
[0055] Figure 11 is a diagrammatic view showing the fixation elements such as those shown in figure 7 positioned next to different stacks of layers of material to be fixed and before insertion or welding.
[0056] Figure 12 is a side view of a spot welding cap portion according to an embodiment of the present description.
[0057] Figures 13a and 13b are plan and side views, respectively, of a fixing element according to another embodiment of the present description.
[0058] Figures 14a and 14b are side and plan views, respectively, of a fixing element according to another embodiment of the present description.
[0059] Figure 15 is a side view of a fastening tool capping tool according to an embodiment of the present description.
[0060] Figure 6 is a perspective view of two sheets of metal in the spot welding apparatus before applying a fastener in accordance with an embodiment of the present description.
[0061] Figures 17a-17d are seen in cross section of fasteners according to an alternative embodiment of the present description.
[0062] Figures 18-20 are seen in plan and in cross section, respectively, of a fixing element according to an alternative embodiment of the present description.
[0063] Figure 21 is a cross-sectional view of a fastening element according to an alternative embodiment of the present description.
[0064] Figure 22 is a diagrammatic cross-sectional view of the fixing element of Figure 21 inserted through a first layer and being welded to a second layer.
[0065] Figure 23 is a diagrammatic cross-sectional view of a fastening element according to an alternative embodiment of the present description inserted through a first layer and welded to a second layer.
[0066] Figure 24 is a cross-sectional view of a fastening element in accordance with an alternative embodiment of the present description.
[0067] Figure 25 is a diagrammatic cross-sectional view of the fixing element of Figure 24 inserted through a first layer and being welded to a second layer.
[0068] Figure 26 is a diagrammatic cross-sectional view of a fastener in two parts according to an alternative embodiment of the present description, the first part inserted through a support layer and welded to the second part.
[0069] Figure 27 is a diagrammatic cross-sectional view of a fastener in two parts according to an alternative embodiment of the present description, the first part inserted through a support layer and welded to the second part.
[0070] Figure 28 is a cross-sectional view of a fixing element with a sealant according to an alternative embodiment of the present description.
[0071] Figure 29 is a diagrammatic cross-sectional view of the fixing element of Figure 28 inserted through a first layer and being welded to a second layer.
[0072] Figure 30 is a cross-sectional view of a fastening element according to an alternative embodiment of the present description.
[0073] Figure 31 is a diagrammatic cross-sectional view of the fixing element of Figure 30 inserted through a first layer for welding to a second layer.
[0074] Figure 32 is a cross-sectional view of a fastening element according to an alternative embodiment of the present description.
[0075] Figure 33 is a cross-sectional view of a fastening element according to an alternative embodiment of the present description.
[0076] Figure 34 is a cross-sectional view of a fastening element according to an alternative embodiment of the present description.
[0077] Figure 35 is a diagrammatic cross-sectional view of a fixture according to an alternative embodiment of the present description positioned adjacent to a tip of the welding electrode.
[0078] Figure 36 is a cross-sectional view of a fastening element according to an alternative embodiment of the present description.
[0079] Figure 37 is a cross-sectional view of a fastening element in accordance with an alternative embodiment of the present description.
[0080] Figure 38 is a diagrammatic cross-sectional view of a fixture according to an alternative embodiment of the present description positioned adjacent to a tip of the welding electrode.
[0081] Figure 39 is a diagrammatic cross-sectional view of a fixture according to an alternative embodiment of the present description positioned adjacent to a tip of the welding electrode.
[0082] Figure 40 is a diagrammatic cross-sectional view of a fixture according to an alternative embodiment of the present description positioned adjacent to a tip of the welding electrode.
[0083] Figure 41 is a diagrammatic cross-sectional view of a pair of fastening elements according to an alternative embodiment of the present description, each of which is inserted through an associated outer layer and welded to a common central layer.
[0084] Figure 42 is a cross-sectional view of a fastening element in accordance with an alternative embodiment of the present description.
[0085] Figure 43 is a diagrammatic cross-sectional view of a fastening element according to an alternative embodiment of the present description, inserted through a portion of a J-shaped layer and welded to the J-shaped layer.
[0086] Figures 44A and 44B are seen in cross-sectional diagrams of fastening elements and a composite structure according to an alternative embodiment of the present description being applied and after application.
[0087] Figure 45 is a diagrammatic cross-sectional view of a fastener according to an alternative embodiment of the present description, inserted through a pair of layers and welded to a third layer.
[0088] Figure 46 is a diagrammatic cross-sectional view of a pair of fastening elements according to an alternative embodiment of the present description, inserted through a pair of layers of comparable thickness and welded together.
[0089] Figure 47 is a diagrammatic cross-sectional view of a pair of fastening elements according to an alternative embodiment of the present description, inserted through a pair of layers with different thicknesses and welded together.
[0090] Figure 48 is a diagrammatic cross-sectional view of a pair of fastening elements according to an alternative embodiment of the present description, inserted through a set of three layers and welded together.
[0091] Figure 49 is a photograph of a cross section of a fastener according to an alternative embodiment of the present description, inserted through a pair of layers and welded to a third layer.
[0092] Figure 50 is a photograph of the cross section of a pair of fastening elements according to an alternative embodiment of the present description, inserted through a pair of layers and welded together.
[0093] Figure 51 is a diagrammatic cross-sectional view of a welding electrode and a fixing element according to an alternative embodiment of the present description, positioned in a pair of layers.
[0094] Figure 52 is a diagrammatic cross-sectional view of a tip of the welding electrode and a fixing element according to an alternative embodiment of the present description, positioned in a pair of layers.
[0095] Figure 53 is a diagrammatic cross-sectional view of a tip of the welding electrode and a fixing element according to an alternative embodiment of the present description, positioned in a pair of layers.
[0096] Figure 54 is a diagrammatic cross-sectional view of a tip of the welding electrode and a fixing element according to an alternative embodiment of the present description, positioned in a pair of layers.
[0097] Figure 55 is a diagrammatic cross-sectional view of a tip of the welding electrode and a fixing element according to an alternative embodiment of the present description, positioned in a pair of layers.
[0098] Figure 56 is a diagrammatic cross-sectional view of a tip of the welding electrode and a fixing element according to an alternative embodiment of the present description, positioned in a pair of layers.
[0099] Figure 57 is a diagrammatic cross-sectional view of fasteners and an associated material layer according to an alternative embodiment of the present description.
[00100] Figure 58 is a diagrammatic cross-sectional view of fasteners and an associated vehicle for positioning fasteners with respect to a portion of electrical resistance welding tip and layers of material to be fastened. Detailed Description of Exemplary Modalities
[00101] Figures 1 and 2 show a fastening element 10 having a peripheral cap portion 12 and a tapered shaft 14 having a pointed, blind end 16 opposite the cap portion 12. An internal hollow portion H extends through the cover portion 12 and into the shaft 14. The fixing element 10 can be produced from a conductive metal, for example, steel or titanium, which is capable of withstanding a resistance spot welding process. The cap portion 12 has an edge-to-top dimension CE, and diameter CD. The rod portion has an SD diameter and a length from the cap portion 12 to the end 16 of SL. As described below, said dimensions can be varied depending on the use to which the fastener 10 is placed, for example, the thickness and type of parts that the fastener 10 is used to join. In one example, the diameter CD can be in the range of about 4 mm to 16 mm, the length SL in the range of about 3 mm to 10 mm, CE in the range of about 0.5 to 3.0 mm and SD in the range of about 2 to 12 mm. Figure 3 shows a fixing element 20, like that of figure 1, but having different dimensions, that is, having a thinner axis 24 with a more severely pointed end 26.
[00102] Figure 4 shows the insertion of a fastening element 10a according to an embodiment of the present description through a first layer of metal 11, for example, an aluminum alloy, and being welded to a second layer of metal 13 , for example, steel alloy, to form an L1 laminated structure. This is shown in sequential stages marked A-E. As shown in stage A, said process can be conducted in a conventional spot welding station having opposite electrodes, the tip portions 15a and 17a of which are shown spaced from the metal sheets / layers 11, 13, which allows the fastener 10a to be inserted between the tip portion 15a and the layer 11. The tip portion 15a can have the surface S1 shaped to accommodate, support, shape and / or retain the fastener 10a through the welding process. In stage B, opposing forces F1, F2 exerted by the conventional welding machine (not shown) to move the tip portions 15b, 17b towards each other, capture the fastener 10b and the layers 11, 13 between the and an electric current I is applied through the conjunction of said elements. The forces F1, F2 and current I are applied through stages B-E and the magnitude and duration of each one can be varied depending on the needs at each stage. For example, the current I required to heat / laminate aluminum in stage B may be less than that required to weld steel to steel as in stages D and E. Similarly, forces F1 and F2 can be varied to accommodate changing process needs.
[00103] The current I heats each of the fastener 10b, and the layers 11, 13 to a temperature at which the aluminum layer 11 plasticizes and can be displaced / perforated by the fastener 10b. The aluminum layer 11 is resistively heated by current I and also by conduction from not only fastener 10b, but also from layer 13. Fastener 10b and layer 13 have lower electrical conductivity and heat than the aluminum layer 11, so that a low current typically achieved with suitable resistance spot welding to do steel resistance spot welding can be used to generate the heat needed to plasticize the aluminum layer, as well how to provide solder in layer 13, as described below. Since aluminum has a lower melting point than steel layer 13 or fastening element 10b, which in this example is also steel, aluminum layer 11 achieves a plastic state which allows displacement by the fastener 10b and what allows the end 16b of the fastener 10b to penetrate the aluminum layer 11. As shown in stage C, the insertion of the fastener 10c into the aluminum layer 11 causes an outcrop 11U of the aluminum displaced plastic that rises above the original top surface 11S of layer 11. As shown in stage D, the fastener 10d penetrates layer 11 completely and comes into contact with the steel layer 13 with which the end 16d of the fastener element fixation 10d begins to melt and flatten and the Pd zone of the molten metal begins to form at the interface of layer 13 and the end 16d of the fixture. The Pd zone is a welding material or "nugget" where the metal of the fastening element 10d and layer 13 liquefies and mixes. As shown in stage E, the continued application of convergent forces F1, F2 and current I results in additional dullness and fusion of the end 16e and a portion of the length of the stem portion 14e, along with the expansion of the fused zone Pe. O stage E also shows the cap portion 12e descended to the level of the upper surface 11S, covering and sealing the outcrop 11U which has been assigned to the insertion of the fastener 10e completely within the aluminum layer 11.
[00104] After having completed stage E, forces F1, F2 and current I can be removed and the tip portions 15e and 17e removed. The above process can be carried out with barrier layers, for example, a layer of surface pretreatment adhesive or paint / primer (not shown) applied to the surface 11S and / or between layers 11, 13, as long as the layer barrier does not prevent current I from flowing to create electrical resistance heating. In this way, the contact between dissimilar metals of layers 11, 13 can be reduced, along with unwanted galvanic interaction and corrosion. Partial melting of the fastener 10 during the penetration and welding phases of the process allows the fastener 10a to accommodate the layer thickness strips 11.
[00105] The cap portion 12a of the fastening element 10a defines an annular recess that can receive, capture and seal aluminum and intermetallics generated from penetration (stages B and C) and welding (stages D and E). As the cap portion 12a "reaches the bottom" on the surface 11S of the aluminum layer 11. Said aluminum and intermetallic containment can significantly improve the corrosion performance and the strength of the joint that has been attributed to the fastener 10th. The cap portion 12a can be formed on the fastener 10a before the welding process or it can be formed in situ during the welding. As more fully described below with reference to figure 8, the geometry of the fastener 10a and its interaction with / retention by the tip portion 15a and the surface S1 allows welding on one side (welding from one side without a electrode that comes into contact with the member 13 directly in opposition to the tip of the electrode 15a to provide a counter force). The tip portion 15a can be formed to be held by the fastener 10a by means of a resilience or spring load of the fastener 10a which retains the fastener 10a on the tip portion 15a during welding, but a once the weld has been completed. For example, the tip portion 15 may have a peripheral edge or hollow that an upper edge of the fastening member 10a removably and flexibly grips.
[00106] The fastening element 10 can be formed from thin sheet steel, for example, from about 1 mm to 4 mm thick, but it can be produced in any given thickness as determined by the thickness of the layers 11, 13 , with greater thickness in the layers that require a greater thickness of the fastening element. Alternatively, the axis 14 of the fastener 10 can be solid or semi-solid. Regardless of the thickness / concavity of the fastener (density for a given surface area), the axis 14 can be provided to collapse when the end 16 is welded to the sheet 13, so that the cover portion comes into contact with the upper surface 11S of sheet 11 and / or seals any intermetallic and outcrop areas 11U when welding is completed (stage E).
[00107] The final dimensions of the Pe welding zone will depend on the starting and final dimensions of the axis of the fastening element 14e, that is, diameter, length and the thickness of the walls of the axis. The larger the dimensions of the axis of the fastening element 14e, the larger the dimensions of the welding zone Pe. In one example, the fastening sheet 11 composed of 0.5 mm to 4.0 mm thick aluminum and the sheet 13 composed of 0 steel , 5 mm to 3.0 mm thickness, a weld diameter in the range from 2 mm to 8 mm would exhibit beneficial properties of shear and peel strength.
[00108] In order to minimize the weight on the finished welded product produced with the fasteners 10 of the present description, the gauge of the sheet used to make the fastener 10 can be reduced. As a result, the strength of the reduced side wall of the axis of the fastener 14 can cause it to collapse prematurely during the welding process. In order to support the shaft 14, the electrode 15a can be formed to extend within the hollow member H to partially or widely engage the internal surface of the shaft 14 within the hollow member H. Figure 5 shows an alternative for the fixing element 110 in two phases in the welding process, that is, phase B5 before extruding through layer 11 and phase E5 - after welding. An electrode tip 115 having the surface S2 that supports the end 116 of the fastener 110 allows the end 116 to be pushed through the layer 11 without the end 116 or axis (side wall) 114 being deformed. The tip portion 115 has a concave annular surface S3 that can receive and form / conform a corresponding area of the periphery of the fastener 110p in response to the fastener 110 being pressed against the outflow 11U when the fastener is pressed widely through layer 11 to form the weld zone Pg as shown in step E5.
[00109] Figure 6 shows a more comprehensive sequence of steps A6-F6 in use of the fastener 110 to perform spot welding through an upper layer 11, for example, an aluminum foil, to secure the upper layer 11 to the lower layer 13, for example, the steel sheet. As can be seen, said process can also be called "resistance point fastening" or "resistance point riveting", where the fastening element 110 can be described as a rivet that is dipped through layer 11, by making a hole in layer 11 and joining layer 13 by welding, the cap portion 112 of the fastener secures layer 11 against layer 13. As the fastener 110 penetrates the top layer 11 and engages the layer At the bottom 13, the concave annular surface S3 at the tip of the electrode 115 encapsulates and seals against layer 11, in particular the outcrop 11U. In one example, stage B6 and C6 can have an associated strength FH of a magnitude of, for example, from (600 to 2000 pounds) and an IH current level of a magnitude of, for example, from 4,000 at 24,000 amps, which is suitable for laminating the first layer 11 of aluminum having a thickness of 2 mm and welding to a second layer 13 of 780 MPa galvanized coated steel with a thickness of 1.0 mm, by means of a steel fastener low carbon with a general diameter of 16 mm, a total height of 3 mm and an average wall thickness of 1.0 mm. Said magnitudes of force and current are only exemplary and are dependent on the dimensions and compositions of the fastener 110 and layers 11 and 13. The time duration for the transition from stage B6 to C6 can be in the order of 0.2 to 2.0 seconds. Continuing with this example and using the same dimensions and properties of fastener 110 and layers 11, 13, stage D6 can use an associated force FW of a magnitude of, for example, from 500 to 800 pounds and a current level IW of a magnitude of, for example, from 6,000 to 18,000 amps, which is suitable for starting the fusion of the fastener 110 and the lower level 13 to form a Pd fused weld zone. The magnitude of the FW force can be changed to an FT force of a magnitude of, for example, from (600 to 1,000 pounds) and an IT current level of a magnitude of, for example, from 3,000 to 12,000 amps in stage E6 to form an expanded weld zone to temper the weld and to make it with an average cross-sectional diameter of 4 mm to 6 mm. The completion of stage D6 can take, for example, 0.1 to 0.5 seconds. In stage F6, the first and second electrode tips 115, 117 can be removed. As can be seen, since the 11U outcrop forces the cover portion 112 to conform to the surface S3, establishing a close relative fit, there may be some resistance to the removal of the first tip portion 115 from the fixation 110f in stage F6. In some applications, it may also be preferred to use a preformed fastener to reduce withdrawal force, cycle time and to reduce the amount of FW welding force required to form the cap portion 112 to conform to the surface. S3 and the 11U outcrop.
[00110] Figure 7 shows a sequence of steps A7-F7 using a fastener 210 to perform spot welding through an upper layer 11, for example, an aluminum foil, to secure the upper layer 11 to the layer bottom 13, for example, the steel sheet. The fastener 210 is pre-formed to have a shape similar to that of the fastener 110 after it has been formed by the welding force shown in stages D6 and E6 of figure 6, so that the upper section can encapsulate and seal the top surface without the need to be formed by the electrode during the welding process. Since the fastener 210 is preformed, the tip of the electrode 215 does not require the concave annular surface S3 to form the cap portion 212 to accommodate and seal against the outcrop 11U of the first layer 11 near where it is penetrated by fastener 210. As a result, the tip of electrode 215 can taper (be rounded on surfaces S4, S5) to the surface S2 that supports end 216 of fastener 210. This allows the concentration of heating, welding, and quenching forces FH, FW, FT as well as heating, welding, and quenching currents IH, IW, IT over a smaller area, which allows a reduced force and current to carry out the penetration, welding and tempering tasks.
[00111] Figures 4-7 illustrate direct access welding in which the resistance welding electrodes, for example, 15a, 17a, hold the workpieces / welding pile 10a, 11, 13 from opposite sides. As shown in figure 8, spot welding using a fastener 10, 20, 110, 210, according to the present description can be conducted from one side using indirect welding. The S8 structure, such as a steel beam or any other type of structure, can be connected to a pole of a source of electrical potential to conduct the welding. The other pole provides electrical energy for the welding tip portion 215 with an electrical energy supply to heat in stages B8 and C8, welding to D8 and tempering in E8. Indirect welding is commonly performed on steel, but it is difficult to conduct aluminum-to-aluminum joints. Since the present description allows welding with a fastener made from materials other than aluminum, it facilitates the joining of an aluminum layer 11, for example, an aluminum sheet, to an S8 steel structure, such as a steel tube.
[00112] In series welding, two or more electrodes are approached from a single side. Multiple welds are then produced as the welding current flows between the multiple guns in a series mode. Figure 9 shows that the welding process and the apparatus of the present description can be used to conduct series welding of fasteners 210a and 210b to join layers / members 11, 13 in a single welding operation. The current IH passes through electrode 215a, of layers 11, 13, through a conductive support bar S9, then back through layers 11, 13 to electrode 215b. As before, the current IH heats layer 11 which allows penetration by the fasteners 210a, 210b, the welding of the fasteners in contact with layer 13. The process in general is similar to that explained above, but only the stages B9, D9 and F9 are shown. Series welding is not typically conducted on aluminum, but is usually carried out using steel materials. Since the present description allows welding with a fastener made from materials other than aluminum, this facilitates the joining of an aluminum layer 11, for example, an aluminum sheet, to a steel layer / sheet 13 or structure, such as a steel tube or box structure by means of series welding.
[00113] Although the previous examples refer to a fastener 10, 20, 110, 210 made from steel, the fastener 10, 20, 110, 210 can be produced from any material and the first layer 11 and the layer (s) (second) that follow (m) 13 can also be varied in composition and in number. In order to penetrate an intermediate layer such as layer 11, the fastening element 10 ... 210 must be produced from a material with a higher melting point than the intermediate layer (s) ( s) 11 penetrated during the penetration / heating phase, for example, B6, C6 (figure 6). In order to conduct the welding phase, for example, D6, the material of the fastener 110 must be compatible with the layer to which it will be welded resistance, for example, layer 13. For example, if layer 13 is produced from high-strength galvanized steel (> 590 MPa), then fastener 110 can be produced, for example, from standard low-carbon steels, high-strength steels (> 590 MPa) or stainless steel .
[00114] Figure 10 shows that a fastener 210c can be used with an opposite fastener 210d to join a pair of layers 11a, 11b, for example made from aluminum or magnesium, by spot welding one to another, so that cover portions 212c, 212d capture layers 11a, 11b between them. The procedure shown in stages A10 to F10 mimics the procedure described above, for example, as described with reference to figures 4-7, in which electrical resistance is used in heating, penetration of layers and welding, but instead of the elements of fasteners 210c, 210d reach the layer 13 to which they are welded, each of which penetrates the intermediate layers 11a, 11b in opposite directions, meet and weld each other.
[00115] Figure 11 shows that several combinations of layers can be joined according to one embodiment of the present description. As shown in combination G, a stack of materials can be aluminum 11A and 13S steel such as a stack shown and described above with reference to figure 7 in stage B7. As described above, the fastening element 210 can be pushed through the aluminum layer 11A and welded to the steel layer 13S. Combination H shows a stacking of two layers of aluminum 11A1 and 11A2 with a layer of 13S steel. In the same way as before, the fastening element 210 can be pushed through the aluminum layers 11A1 and 11A2 and then welded to the steel layer 13S. Combination I shows a stacking of the 11A aluminum layer and the 11M magnesium layer with a 13S steel layer. The fastener 210 can be pushed through the aluminum layer 11A and the magnesium layer 11M and then welded to the steel layer 13S. Combination J shows a stacking of an outer layer of magnesium 11M, an intermediate layer of aluminum 11A and a layer of steel 13S. The fastener 210 can be pushed through the magnesium layer 11M and the aluminum layer 11A and then welded to the steel layer 13S. In each of the stacks shown in G, H, I and J, the fastener 210 can be used to secure the shown laminated structure. Other combinations of material, thickness and number of layers are possible to be fixed by the fastening element 210, 110, 20, 10 of the present description.
[00116] Figure 12 shows a tip of the welding electrode 215 with a connection sleeve portion 215S and the welding portion 215W with rounded and inclined surfaces S4 and S5. A tip portion such as said is offered by CMW Contacts Metal Welding www.cmwinc.com and is called the G-cap portion.
[00117] Figures 13a and 13b show a cap portion nut reused to function as a fastener 310 in accordance with the present description. The fastener 310 has a cap portion 312, an axle portion 314 and an end portion 316. Protrusions 318 for interacting with a corresponding tool 318 can be used to retain the fastener 310 at an electrode tip such as the tip portion 115 and can also be used to twist the fastener as it is pushed through an intermediate layer 11 and / or when it is welded to layer 13.
[00118] Figures 14a and 14b are side and plan views, respectively, of a fixing element 410 according to another embodiment of the present description. The fixing element 410 can be produced as a stamping using a stamping tool and electrode body for several electrode tips as shown in figure 15. The cap portion 412 makes a transition passage within axis 414 on curve C1 and the axis 414 makes a transition passage to end 416 on curve C2. The curve C1, when rotated over the axis of symmetry S of the fixing element 410 and bounded by the edge 412e and its projection on the axis 414, circumscribes a volume V1 that can contain and seal the outcrop of the penetrated layer, for example, as shown at 11U in figure 5.
[00119] Figure 15 shows a fastener stamping tool 505 according to an embodiment of the present description. The stamping tool can be used to form the fasteners such as the fastener 410 from stock material 520, for example, the steel sheet. The fastener stamping tool 505 has a facing die 522 with a forming surface 522S (shown in dotted lines). A forming tool 524 (in dotted lines) driven by a punch 526 (axis shown in dotted lines), which acts in conjunction with the turned matrix 522 to form a fastener 410 (figure 14a, b) from the material of stock 520. In the embodiment shown, forming tool 524 not only cuts the fastening element 410 from stock material 520, but also forms it as it is oriented downwards through stock material 520 by punch 526. Alternatively, disk-shaped dies (not shown) having the dimensions necessary to form a fastener 410 may be cut from the stock material by a separate punch and filled into the die holder 530 prior to punching 526 be driven downward against the facing die 522 to form the die within the fastener 410. A spring 532 can be inserted between the retaining cap portion 534 and the die holder 530 to return the punch 526 to the neutral position after a fastener 410 has been stamped by the fastener stamping tool 505. The punch 526 can be coupled to a punch support member 528 that is driven mechanically, hydraulically or pneumatically in mode conventional method for triggering punches and presses.
[00120] Figure 16 shows welding stack 605 in which a fastener 610 is positioned against the first and second layers 611, 613 before penetration or welding. The first layer 611 can be an aluminum, magnesium or copper sheet and the second layer can be a steel, titanium or inconnel sheet. The layers 611, 613 and the fixing element 610 are fixed between the first and second tip portions 615, 617 which are in electrical continuity with the lower and upper electrodes 640, 642 of an electric spot welding machine offered in the market, such as the 250kVA welding station offered by Centerline Soldagem, Ltd.
[00121] In an example of the welding operation conducted in accordance with the present description, the 250kVA AC resistance point welding pedestal machine offered on the market was used to heat and dip a fastener / rivet through a sheet of aluminum and welded to a steel backing sheet. The upper tip of electrode 615 was the commercially available electrode called the G-cap portion (similar to tip portion 215 of Figure 12) and the lower tip of electrode 617 was a standard flat face (16 mm in diameter, Type C-Nose RWMA). The standard cap portion nut 610 as shown in figures 13a and 13b was used for the rivet. The joining parts were an aluminum alloy of 1.5 mm 7075-T6 and galvanized steel of 0.7 mm 270MPa. The cap portion nut 610 was disposed non-electrode of the cap portion-G 615 and then against the aluminum foil 611 in the stack as shown in Figure 16. Current pulses of about 1.5 second duration at 9,000 amps were generated to cause the cap portion nut 610 to penetrate the aluminum foil 611. After penetration, the cap portion nut 610 was welded to steel with a current impulse of around 15kA to 0.166. A welding button, approximately 5 mm in diameter, between the steel nut of the cap portion and the 0.7 mm steel sheet 270MPa was obtained.
[00122] Aspects of the present description include low distortion of the parts, since the layers to be fixed, for example, 11, 13, are kept in compression during the weld and the heat affecting the zone is mainly restricted in the footprint of the portion of cover, for example, 12 of the fastening element 10. The fastening elements, for example, 10, 20, 110, 210, 310, 410, 610 form a volume relative to the first layer 11 to capture intermetallic or materials displaced by the penetration of the fastening element via the first layer 11. The fastening elements, for example, 10 ... 610 can be used to fasten a range of layer thicknesses and number of layers of different types of materials, that is, by selecting one fastening element of adequate dimensions and material composition. In addition, a certain fixing element 10.610 can be operable over the thickness bands due to the elasticity of the materials from which it is formed, as well as the shape of the fixing element. For example, the lid portion 412 can flex flexibly with respect to the axis 414 when the fastener 410 is used to accommodate various thicknesses and to flexibly press on the layer (s), for example, 11 when welded to layer 13. Flexibly pressing cover portion 412 against the layer, for example, 11 can contribute to establishing and maintaining a seal around the perimeter of fastener 10.610 when it is in place.
[00123] The fixing element 10.610 of the present description can be applied through adhesives and / or other coatings applied between the layers, for example, 11, 13 and / or through coating applied to the top layer 11. The weld formed by the use of the fixing element, for example, Pe in figure 4, does not penetrate layer 13 nor disturb the surface of 13 opposite the weld, which preserves the appearance, the resistance to corrosion and is still airtight to water. During penetration of the fastener, for example, in stage C of figure 4 and the welding phase, stage D, the fastener 10c, 10d, 10e will continually collapse and expand along with the zone weld Pd, Pe, pushing out the intermetals from the weld zone. The methodology and apparatus of the present description are compatible with conventional RSW equipment developed for resistance welding of steel sheet and the fixing element, 10 ... 610 can be produced from a variety of materials, such as various categories steel (lower carbon, high strength, ultra high strength, stainless), titanium, aluminum, magnesium and copper. The fastening element of this description can optionally be coated (galvanized, galvaneal, heat-immersed, aluminized) to improve corrosion resistance.
[00124] As noted above, the fixing element 10.610 of the present description can be used by means of single-sided or two-sided access welding. The 10.610 fixing element does not require a pilot hole, but it can also be used with the pilot hole in the aluminum or top sheet. Pilot holes can also be used to allow electrical flow through dielectric layers such as the adhesive layer or anti-corrosive layers / coatings. The quality of the weld that results from the use of the 10.610 fixing element can be tested according to the quality assurance measurements applied in the cavity left by the weld, that is, by measuring the dimensions of the cavity. Ultrasonic NDE techniques can also be used on the back side, for example, layer 13 (the steel side) to monitor the quality of the weld.
[00125] Compared to FDS (EJOTS), SPR, and SFJ, the device used to apply the fixing element 10.610 of this description has a smaller footprint, which allows access to tighter spaces. The apparatus and method of the present description use lower insertion forces compared to SPR since the first layer 11 is heated / softened during the insertion phase of the fastener, for example, see stage C of figure 4. The methods and apparatus of the present description provide the ability to join high-strength aluminum (which is sensitive to breakage during SPR operations) and to join high and ultra-high strength steels, as there is no need to drill through steel metal with the fastener, but instead the fastener is welded to it.
[00126] The apparatus and method of the present description does not require rotating the parts and is favorable to solve fitting parts of the parts since the process in general is similar to conventional resistance spot welding (RSW) with respect to how the layers / component parts are fixed. In addition, the application of the 10 ... 610 fastener can be carried out providing fast processing speeds similar to those of the conventional RSW process. The apparatus and methods of the present description can be applied for use in cast and forged aluminum products and can be used to produce a compatible metal joint instead of a bi-metal weld as when welding aluminum to steel, which may be low joint strength. As noted above, the apparatus and methods of the present description can be used to join multiple layers of different materials, for example, two layers of aluminum, one layer of steel; one layer of aluminum, two layers of steel; or an aluminum layer, a magnesium layer, and a steel layer.
[00127] Figure 17a shows a cross-sectional view of a fastener 710 such as the fastener 410 of Figure 14a, in which the thickness of the cap portion 712, the shaft 714 and the end 716 are substantially constant thickness. The end 716 is flat.
[00128] Figure 17b shows a fastening element 810 in which the end 816 is flat and has a greater thickness than the cap portion axis 814 812.
[00129] Figure 17c shows a fastening element 910 with a rounded end 916 having a constant thickness. In one example, the radius R is in the range of (1 to 6 inches).
[00130] Figure 17d shows a fastener 1010 having a rounded end 1016 and grooves 1014s at the junction of end 1016 and axis 1014. Grooves 1014s can be aligned with the axis of symmetry / rotation S or arranged at an angle A with respect to it. The grooves can be used either to guide the fastener in a particular direction, for example, straight or spiral when the fastener is pressed through layer 11 and / or can be used as an anti-rotation feature that prevents rotation of layer 11 with respect to the installed fastening element 1010.
[00131] Figures 18-20 show a fastening element 1110 having a length L greater than its width W. In one example, the length L can be in the range 8 mm to 25 mm and the width in the range 4 mm to 8 mm.
[00132] Figure 21 shows a fastening element 1210 that in cross section has left and right portions 1210a, 1210b that converge in 1212c. The fastening element 1210 is a rotation solid over the line of symmetry / rotation S, so that the ends 1216a, 1216b form a continuous ring surface that can be welded to a substrate as further illustrated below.
[00133] Figure 22 shows the fastening element 1210 inserted through the first layer 11, for example, produced from aluminum and welded to layer 13, for example, produced from steel in the welding zones Pa, Pb, which would have a continuous ring shape. The ring-shaped weld can be distributed over a larger surface area then a disk-shaped weld, as will be produced, for example, by the use of a fastener such as 410 as shown in figure 14a. The tip portion 1215 has a surface 1215s that accommodates and supports the fastener 1210 as it is heated and pressed towards the tip portion 1217.
[00134] Figure 23 shows a fastening element 1310 in cross section inserted through a first layer 11 and welded to a second layer 13 in the welding zones Pa, Pb. In the same way as in figure 21, the fastening element 1310 is a rotation solid over the symmetry / rotation line S, so that the welding zones Pa and Pb are part of a continuous ring-shaped weld in layer 13. The fastening element 1310 features a threaded central socket 1342 having thread elements 1342t suitable for receiving a fastening element provided with corresponding threads, such as a screw (not shown). In this way, the fastening element 1310 can perform two functions, that is, retain the layer 11 to 13 and provide a threaded socket which allows the assembly to another member or structure (not shown) by means of a fastening element provided with corresponding threads (not shown). The tip portion 1315 has a recess 1315r for accommodating socket 1342 at the same time as welding.
[00135] Figures 24 and 25 show a fastener 1410 just like fastener 1310, but having a socket portion 1442 with threaded elements 1442t that are open end, which allows a fastener with corresponding threads (not shown) pass through socket portion 1442. As shown in figure 25, in preparation for installing the fastening element 1410, layers 11 and 13 are preferably drilled or otherwise provided with corresponding holes 11h , 13h through which socket portion 1442 can be inserted. Penetration of layer 11 and welding to layer 11 can then be carried out by resistance welding, as explained above. The tip portion 1415 has a surface 1415s for supporting the fastener 1410 as it is pressed through layer 11 and welded to layer 13. The tip portion 1417 has a recess 1417r that accommodates the socket portion 1442 that extends through layers 11, 13 during the welding process.
[00136] Figure 26 shows a fastener 1510 having an upper part 1510u and a lower part 1510l that can be welded together to fix the fastener to layer 11, for example, aluminum. The bottom portion 1510l features a threaded socket 1510t. The fixing element 1510 can be produced from steel or titanium. The welding process is conducted in the same way as before just instead of welding to a second layer 13, the upper part 1510u is welded to the lower part 1510l after the upper part is pushed through the aluminum layer 11. In the same way as before , the welding zones Pa, Pb are a part of a ring-shaped weld in that the fastening element 1510 is a rotating solid. The layer 11 is captured between the flange portion 1510f and the cap portion 1512. The fastening element 1510 allows a threaded socket 1510t, produced from a first material, for example, steel or titanium, to be attached to layer 11 dissimilar metal, for example aluminum or magnesium.
[00137] Figure 27 shows a fastener 1610 having an upper part 1610u and a lower part 1610l that can be welded together to fix the fastener to layer 11, for example, aluminum. The bottom 1610l features a 1610s threaded pin. The fixing element 1610 can be produced from steel or titanium. The welding process is carried out in the same way as before only instead of welding to a second layer 13, the upper part 1610u is welded to the lower part 1610l after the upper part is pushed through the aluminum layer 11. The welding zone Pa it is approximately disk-shaped and the fixing element 1610 is a rotating solid. The layer 11 is captured between the flange portion 1610f and the cap portion 1612. The fixing element 1610 allows the threaded pin 1610s, produced from a first material, for example, steel or titanium, to be attached to layer 11 of dissimilar metal, for example, aluminum or magnesium.
[00138] Figures 28 and 29 show a self-locking fastener 1710 with a sealant bead 1728 applied to the underside near the junction of the cap portion 1712 and shaft 1714. The sealant can be an adhesive or polymer and can be applied as a liquid, gel or paste and can cure to a solid or semi-solid or can remain in a soft or liquid state before using the 1710 fastener. When the 1710 fastener is used to couple 11 layers (aluminum ), 13 (steel) of material joined by welding the fixing element 1710 to the base sheet 13 or to another fixing element 1710, for example, as described above for the fixing elements 210 (figure 10), the sealant can undergo a change of state, for example, if solid, it can melt due to the heat generated by the insertion of the fixing element 1710 through an intermediate layer 11 by melting from electrical resistance or during the welding phase to form the 1710W solder. After the fixing element 1710 and the metal to which it is welded cool, the sealant 1728 can return to a solid after conforming to the surfaces of the top layer 11 and any inflow in the same 11U, thereby providing a sealed joint 1710J, with a seal between the top layer 11 and the fixing element 1710. Sealant 1728 prevents infiltration by elements present in the environment, for example oxygen or moisture, which can lead to corrosion of the fixing element 1710, of sheets 11, 13 and / or 1710W solder. in an alternative, the 1728 sealant may remain a semi-solid or gel after the 1710W weld is completed. Sealant 1728 can be applied in a number of different ways, including: (i) application to fixing element 1710 as a step in manufacturing the fixing element; (ii) application to the fixing element 1710 just before use in which the welded joint forms; for example, to be applied: a bead (ejected by a pressure nozzle), a preformed ring in solid or semi-solid form (and disposed in the fixing element 1710), or a sealant strip (provided in the form of a detachable strip) or painted by a contact applicator or sprayed under pressure) to the fixing element 1710 before coming into contact with the outer sheet 11. Alternatively, sealant 1728 can be applied to the surface of sheet 11, for example, in the form of an adhesive point disposed on the top surface 11S where the fixing element 1710 will be inserted or around the periphery of a pilot hole in the sheet 11 prior to the joining process. Sealant 1728 can be applied to the fixing element 1710 through the use of the ‘compound coating’ equipment currently used in beverages can finish the coating process. The technology described in US Patent No. 6,887,030, which is incorporated herein by reference in its entirety, can be used to stop the rotation of the fixing element 1710 during the application of sealant 1728, which reduces damage to the protective coating of the sealant 1728 applied to the fixing element 1710. Sealant 1728 can be used with any of the fixing elements 10, 110, 210, etc. and layers 11, 13, 11M, etc., described above. Figure 29 shows the sealant 1728 after the fastener 1710 has been welded to layer 13. The sealant 1728 can partially or widely fill the cavity between the underside 1710U of the fastener 1710 and the upper surface 11S of the sheet 11. Sealant 1728 can provide protection against corrosion, increase the strength of the joint between the fixing element 1710 and the top surface 11S, and / or eliminate water / moisture from the inlet of the J joint.
[00139] Figures 30 and 31 show a cross section of the double layer of the fixing element 1810 with a first layer 1810S, for example, produced from steel, titanium, copper or a first aluminum alloy, for example, 1xxx, and a second layer 1810A, for example, produced from aluminum or a different type of aluminum alloy, for example, 6xxx. The fixing element 1810 can be formed, for example, stamped, from a double layer of multiliga sheet (1xxx clad in 6xxx, etc.) or multimaterial (aluminum clad steel, aluminum clad copper, etc.). Figure 31 shows the cross section of a joint 1810J formed with the double layer fixing element 1810, a first sheet 11, for example, of aluminum or aluminum alloy and a second sheet 13 of steel, titanium, copper, magnesium or other alloy other than layer 11 alloy. The double layer 1810 fastening element allows welding to aluminum member 11, that is, by welding layer 1810A to sheet 11. In said case, an opening 1810H is formed in the sheet 13, so that the fixing element 1810 can be inserted through opening 1810H instead of melting through it by resistance heating. One aspect of said approach is that it allows the steel sheet or member 13 to be joined to an aluminum sheet or member 11, for example, a tube, from a single side. The 1810 double-layer fastening element allows welding to occur using low current levels since the 1810S layer, which may be, for example, steel, in contact with the head portion of the 1815 electrode, provides greater heating layer 1810A and sheet 11 during welding. In a first approach, layer 1810A can be produced from or include a brazing alloy, which allows a brazing joint to the opposite sheet 11 instead of a resistance weld. This would be beneficial in reducing the amount of solder currently needed. The joint 1810J can be used to join an aluminum or plastic sheet 13 to an aluminum sheet 11 where low heat inlets are necessary to prevent the sheet 13 from melting. In another aspect of the present embodiment, a fixing element 1810 formed from aluminum clad steel can be used to join a plurality of aluminum sheets. A steel layer 1810S of the fixing element 1810 can come in contact with the electrode 1815, at the same time that the aluminum side 1810A can come in contact with the aluminum sheets 11 (in the present embodiment, the sheet 13 can also be aluminum). As the hot solder is applied, the steel layer 1810S can provide greater heating, allowing the aluminum portion 1810A of the fixture 1810 to weld with the aluminum sheets 11, 13 at low currents. In another aspect of the present embodiment, the 1810S layer can be formed from copper clad to a portion of 1810A aluminum. The copper portion 1810S may come in contact with electrode 1815 and the aluminum portion 1810A may come in contact with and weld the aluminum sheets 11, 13. In the present embodiment, the copper portion 1810S of the fixture 1810 would exhibit a good heat transfer and low electrode wear.
[00140] Figure 32 shows a fastening element of three metals 1910, with layers 1910S, 1910M and 1910A. The intermediate layer 1910M can be selected to avoid diffusion between the outer layers 1910S, 1910A when the fastener 1910 is exposed to high temperatures, providing joint strength. The 1910M intermediate layer can be composed of a variety of materials, including, but not limited to, high-purity aluminum, titanium or zinc. In one example, the outer layer 1910S is steel and the outer root layer 1910A is aluminum. The 1910M intermediate layer can be selected to be a thin titanium layer, which can prevent the 1910A aluminum layer and the 1910S steel layer from diffusing at high temperatures (> 200 degrees C).
[00141] Figure 33 shows a 2010 double layer fastening element having a 2010A aluminum disc attached to a portion of stamped / cold formed steel 2010S. The 2010A aluminum disc can be joined to the 2010S steel portion through a number of means not limited to cold, ultrasonic, friction, point and spot welding, high pressure, mechanical or brazing / welding. Optionally, the 2010A aluminum disc can be joined to the 2010S steel portion in wire form (cold welding, pressure welding) before forming the 2010S steel portion in the format shown. Fastener 2010 can be used in the same way as fastener 1810 shown in Figure 31 to secure sheet 13 to sheet 11.
[00142] Figure 34 shows a three-layer fastener 2110 like the 2010 fastener of figure 33, but having an additional layer 2110T, for example, produced from titanium disposed between layers 2110S, for example, made from steel and 2110A, for example, made from aluminum. Fastener 2110 can be used in the same way as fastener 1810 in figure 31 and fastener 2010 in figure 33, but additional layer 2110T can be used to prevent diffusion between layers 2110A and 2110S and, therefore, it can be useful for high temperature applications in the same way similar to the fastening element 1910 with the intermediate layer 1910M shown in figure 32.
[00143] Figure 35 shows a fastening element 2210 having mechanically interlocked portions 2210A, 2210S. Mechanical interlocking can be performed by stamping, forging, turning or bending. For example, portion 2210A can be formed with a peripheral recess 2210AR and portion 2210S can be formed having a peripheral edge portion extending inward 2210SL. The 2210A portion can then be forced into the 2210S portion so that the peripheral recess 2210AR and the peripheral edge portion 2210SL intersect. This can also be accomplished by a forging die that collapses and compresses the 2210S portion over the 2210A portion to create an interlocking relationship. In a first aspect, the materials of 2210S and 2210A can be different aluminum alloys (1xxx to 6xxx, 4xxx to 6xxx, 4xxx to Al-Li) or different materials (steel and aluminum, aluminum and magnesium, aluminum and titanium, etc.). ). The fastener 2210 is shown positioned with respect to a tip of the electrode 2215 and can be used in a similar way to the fastener 1810 shown in figure 31.
[00144] Figure 36 shows a fastener 2310 with a protective sleeve portion 2310T positioned on the 2310S portion close to the cap portion 2312 and the stem portion 2314 of the fastener 2310. The protective sleeve portion 2310T it can provide protection against corrosion between the fixing element 2310 and the sheet that is penetrated. For example, where the 2310S portion is steel and passes through an aluminum foil 11 by resistance heating to weld to the steel foil 13, as shown in figures 6 and 7, the 2310T coating can be titanium, stainless steel or powdered aluminum. cold. The sleeve portion 2310T can be mechanically interlocked to the portion 2310S as shown in figure 37 (showing the sleeve portion 2410A), applied by cold spray coating, plasma spray coating, etc. The protective sleeve portion 2310T can be produced from metal or from materials having low thermal or electrical conductivity, such as ceramics. In this regard, low conductivity (thermal / electrical) materials will focus heat and current through the 2316 end of the fixture 2310, which allows a lower current to weld on layer 13 than if the protective sleeve portion 2310T was not present. Once welded to layer 13, for example, to attach aluminum layer 11 to steel layer 13 (see figures 6 and 7), the protective sleeve portion 2310 can work to insulate the 2310S portion, which can be produced from steel, from the aluminum layer 11 through which it passes, preventing corrosion due to contact between dissimilar metals and the galvanic effect.
[00145] Figure 37 shows a fastening element 2410 having the protective sleeve portion 2410A arranged on the portion 2410S similarly to the fastening element 2310 described in figure 36. The protective sleeve portion 2410A is retained on the fastening element 2410 by an edge 2416R that captures the sleeve portion 2410A between the edge 2416R and the cap portion portion 2412. The edge 2416R can be preformed and the sleeve portion 2410A slid over the edge 2416R followed by compression by a die, or the sleeve portion 2410A can be slid over the axis 2414 followed by the formation of an edge 2416R, for example, by turning / forging. As with the fastening element 2310, the fastening element 2410 can exhibit greater resistance to corrosion and heat transfer and can be used in a similar way to couple a first sheet or member 11, for example, aluminum to a second sheet or member 13, for example, steel (See figures 6 and 7). Since the edge 2416R is the front element as the fastener is pushed through an intermediate layer 11 (see figures 6 and 7), and can be formed from steel, it will form an opening through of the intermediate layer 11 large enough to accommodate the sleeve portion 2410A, so that the sleeve portion itself does not need to play a role in forming the opening in the intermediate layer 11 and is therefore preserved from distortion or loosening in the axis 2414 when the fastener 2410 is pressed through the intermediate layer 11.
[00146] Figure 38 shows a "semi-solid" fixing element 2510 having a solid shaft 2514. The cap portion 2512 has an electrode depression 2512D which correspondingly accommodates an extension of electrode 2515E from electrode 2515. Said arrangement can be used to reduce wear on the 2515 electrode. In one example, the 2512D electrode depression and the 2515E electrode extension each approach 4-8 mm in diameter and have a depth of 1 to 4 mm. Since the axis 2514 is solid, it is not as collapsible as the thin wall of the axis such as axis 14 of fastener 10 shown in figures 1 and 2. When penetrating an intermediate layer 11 (for example, produced from aluminum) to reach layer 13 (for example, produced from steel) to weld to (See figures 6 and 7), the axis 2514 of the fixing element 2510 is shorter and does not have to bend. As a result, the fastening element 2515 reaches layer 13 more quickly. This reduces the amount of time that current flows through electrode 2515 and fixture 2510, reducing electrode erosion and improving process productivity. The contact area between the extension of the electrode 2515E and the depression of the electrode 2512D increases the area of electrical contact over that of the corresponding smooth surfaces, reducing the electrical resistance and providing a mechanical coupling that preserves the relative position of the fixing element 2510 and the electrode 2515 during the placement of the fixing element 2510.
[00147] Figure 39 shows a "solid" fastening element 2610 with a solid shaft 2614. The cap portion 2612 has an upper electrode receiving surface 2612S with a constant radius, for example (1 to 6 inches) ), which allows the use of a conventional, rounded spot welding electrode 2615 having a similar radius. This relationship reduces the need for special electrode designs and coating equipment and also reduces electrode wear. The lid portion 2612 can be provided to allow collapse towards the leaf 11 (see figures 6 and 7) through which the shaft 2614 is pushed during the insertion process, with the lid portion 2612 flattening against the leaf 11 when widely inserted. A small tip portion element 2616T can extend from end 2616 of fastener 2610, which can be used to concentrate the current and heating to help initiate the heating / softening of the sheet 11 to be pierced and initiate the sheet welding 13.
[00148] Figure 40 shows a solid fixing element 2710 similar to fixing element 2610, but having an electrode alignment projection 2712P that extends from the rounded surface 2712S. The projection 2712P can be received in a corresponding recess 2715R of the electrode 2715. The corresponding projection 2712P and the recess 2715R can help keep the fixing element 2710 aligned with the electrode 2715 during the insertion and welding processes (through the sheet 11 to weld to sheet 13, as shown in figures 6 and 7). The radius of the 2712P projection can be, for example, (3/16 "to 1/4"). While the 2715R recess requires a single electrode geometry, it is compatible with conventional electrode coating equipment.
[00149] Figure 41 shows a joint 2800J in which a pair of opposing fasteners 2810A, 2810B penetrates through layers 11A, 11B (such as aluminum foils), respectively, for example, by heating resistance and pressure, and welding to the central layer 13, for example, produced from steel. To achieve this configuration, the fasteners 2810A, 2810B can be inserted simultaneously (in a single operation) through the aluminum sheets 11A, 11B and welded to the steel layer 13. Alternatively, the fasteners 2810A, 2810B can be inserted and welded in a sequential operation.
[00150] Figure 42 shows the cross section of a 2910 fastener having an extended grip band. The cap portion 2912 extends downward to an extent comparable to the 2914 axis. A 2912I ring of insulating material is attached to the terminal end of the cap portion 2912, so that the bottom edge of the 2912I ring is approximately coextensive with the end 2916. In use, the fastening element 2910 can be arranged on the surface of the sheet 11, for example, produced from aluminum and then heated by electrical resistance by resistance welding as described above, for example, in relation to figures 6 and 7, to penetrate sheet 11 and weld to an underlying sheet 13, for example, made from steel. Because the 2912I ring is an insulating element, the electrical current passes only through the 2916 end. As the 2912 end presses through the leaf 11, the 2912I ring comes in contact with the leaf 11 as the 2016 end passes through the sheet 11. As a consequence, the cap portion 2912 flexes to a degree necessary to allow the end 2916 to reach and weld to sheet 13, at the same time that ring 2912I comes into contact with sheet 11. As as a result, the shaft 2914 can penetrate a variety of thicknesses of the sheet 11 and (the ring 2912I thereof) will still press against the sheet 11 by launching it in contact with sheet 13.
[00151] Figures 43 and 44 show a first panel 11, for example, made from an aluminum alloy, positioned against a second panel 13, for example, made from steel. The first panel 11 is flexed to form a J 11J shape, which encompasses the edge 13E of the panel 13. The panel 11 is stacked on the panel 13 close to the J 11J shape and the edge 13E by a fastener 3010 that passes through 11T thick of panel 11 and welds in 3010W to steel panel 13, which forms the 3000J joint. As shown, the 3010W weld does not disturb the remaining 11R of the panel 11, so the gasket 3000J is suitable for applications, such as in an automobile body, which needs a smooth surface appearance on the remaining 11R of the panel. As shown in figure 44A, electrodes 3015 and 3017 can approach the same direction, with 3015 pressing against the fixing element 3010 and electrode 3017 that comes in contact with the steel panel 13. As the resistance heating softens the sheet 11, the fastener 3010 is pressed through the sheet 11 and welds to the sheet 13. As shown in figure 44B, a plurality of fasteners 3010 can be used to form the "sheath" 3010H near the edge 13E of the sheet 13, with the shape of J 11J wrapped around the edge 13E. The 3010H sheathed joint can employ an adhesive to help keep sheets 11, 13 together.
[00152] Figure 45 shows a pair of sheets 11A, 11B, for example, of aluminum, coupled to layer 13, for example, of steel, by fixing element 3110. The fixing element 3110 has both penetrated aluminum sheets 11A, 11B, for example, by heating electrical resistance, before coming into contact with and subsequently welding to steel sheet 13 at 3110W and forming the 3100J joint. At the 3100J joint, heat from penetration and welding, for example, emitted from the fixing element 3110, which may be steel, locally melts the aluminum sheets 11A and 11B adjacent to the fixing element 3130, producing a weld 3110W2 between the sheets 11A and 11B which partially or completely circulates the fixing element 3110. The weld 3110W2 consolidates the aluminum sheets 11A, 11B, and strengthens the joint 3100J. The aluminum sheets 11A, 11B can be identical or dissimilar in thickness. An adhesive can be present between one or all of the sheet interfaces.
[00153] Figure 46 shows a gasket 3200J that couples two sheets 11A, 11B, for example, made from aluminum, by two fastening elements opposite each other 3210A, 3210B, for example, made from steel. The fixing elements 3210A, 3210B can be installed simultaneously from opposite sides by means of a pair of welding electrodes opposite each other in a similar way to the modality shown in figure 10. The fixing elements 3210A, 3210B are launched together and by resistance heating, the aluminum sheets 11A, 11B penetrate and then weld each other, which forms the 3210W solder. As noted above with respect to the modality shown in figure 45, when passing through the sheets 11A, 11B, the steel fasteners 3210A, 3210B locally heat the aluminum sheets 11A, 11B adjacent to them and create a weld 3210W2 that partially or completely encompasses the 3210W weld between the fixing elements 3210A, 3210B. Figure 46 shows the sheets 11A, 11B of equal thickness, which results in a symmetrical joint 3200J, but as shown below, the process will work for sheets 11A, 11B of different calibers. In another alternative, two different fasteners 3210A, 3210B, with different operating ranges (shaft lengths) can be used, the longest being applied to the sheet with the greatest thickness and vice versa.
[00154] Figure 47 shows a joint 3300J that couples two sheets 11A, 11B, for example, made from aluminum, by two fastening elements opposite each other 3310A, 3310B, for example, made from steel. The fasteners 3310A, 3310B can be installed simultaneously from opposite sides to each other by means of a pair of welding electrodes opposite each other in a similar way to the modality shown in figure 10. The fasteners 3310A, 3310B are launched together and by resistance heating, the aluminum sheets 11A, 11B penetrate and then weld each other, which forms the 3310W weld. As noted above with respect to the modality shown in figures 45 and 46, when passing through the sheets 11A, 11B, the steel fasteners 3310A, 3310B locally heat the aluminum sheets 11A, 11B adjacent to it and create a weld 3310W2 that partially or completely encompasses the 3310W weld between the fixing elements 3310A, 3310B. Figure 47 shows the sheets 11A, 11B of uneven thickness, which results in a 3300J asymmetric joint. As shown, the fasteners 3310A, 3310B, have equal operating ranges (shaft lengths) which results in a 3310W weld that is not at the 3311I interface between the sheets 11A, 11B. One aspect of the 3300J joint is that the load path through the 3300J joint follows different directions (not on the same axis) so that it will have a higher mechanical performance. As noted above, the 3300J joint can be employed with or without adhesives, for example, applied to the 3311I interface. The weld zone 3310W2 between the aluminum sheets 11A, 11B can be selectively produced to a greater or lesser extent by selecting a welding program employed during the welding process. Additional heating cycles can be added to extend the 3310W2 aluminum welding zone, and increase the overall performance of the 3300J joint.
[00155] Figure 48 shows a joint 3400J coupling three sheets 11A, 11B, 11C, for example, made from aluminum, by two opposite fastening elements 3410A, 3410B, for example, made from steel. The fasteners 3410A, 3410B can be installed simultaneously from opposite sides to each other by means of a pair of welding electrodes opposite each other in a manner similar to the modality shown in figure 10. The fasteners 3410A, 3410B are launched together and by resistance heating, the aluminum sheets 11A, 11B, 11C penetrate and then weld each other, which forms 3410W weld. As noted above with respect to the modalities shown in figures 45-47, when passing through the sheets 11A, 11B, 11C, the steel fasteners 3410A, 3410B locally heat the aluminum sheets 11A, 11B, 11C adjacent to them and create a 3410W2 weld that partially or completely encompasses the 3410W weld between the fixing elements 3410A, 3410B. Figure 48 shows the sheets 11A, 11B, 11C of approximately equal thickness, which results in a 3400J symmetrical joint. As shown, the fasteners 3410A, 3410B, have equal operating ranges (shaft lengths), so that when they come together to form the 3410W weld, they are basically in the middle of the 11B sheet, which results in the 3410W weld which is not on the interfaces 3411I1, 3411I2 between the sheets 11A, 11B, 11C and therefore has greater mechanical performance. As noted above, said joint 3400J can be employed with or without adhesives, for example, applied to interfaces 3411I1, 3411I2. The weld zone 3410W2 between the aluminum sheets 11A, 11B, 11C can be selectively produced to a greater or lesser extent by selecting a welding program employed during the welding process. Additional heating cycles can be added to extend the 3410W2 aluminum welding zone, and increase the overall performance of the 3400J joint. The sheets 11A, 11B, 11C can be of the same thickness or of varying thickness and types of alloy. The fasteners 3410A, 3410B can be designed to reach the center of the aluminum foil 11A, 11B, 11C stacks or elsewhere where it will maximize the performance of the joint and extend the loading path.
[00156] Figure 49 is a photograph of a 3500J joint cut to show its cross section. The 3500J gasket couples two aluminum sheets 11A, 11B of 1.0 mm C710-T4 aluminum alloy between a 3510 fixing element and the steel sheet 13 of 0.9 mm galvanized steel. The 3510 fastener is a G1A rivet. The welding zone 3510W2 shows the melting of the sheets 11A, 11B close to the fixing element 3510. The welding was carried out on the sheets 11A, 11B without a pilot hole. The 3500J joint was created with a solder input of 8kA @ 400 ms of preheating plus 16kA @ 100 ms of welding pulse, (800 lb). The sample was relatively distorted at the same time that it was being cut for cross section.
[00157] Figure 50 is a photograph of a 3600J joint cut to show its cross section. The 3600J gasket couples two sheets of aluminum 11A, 11B of 1.6 mm 7075-T6 aluminum alloy between two fasteners 3610A, 3610B. The fasteners 3610A, 3610B are rivets G1A. The weld zone 3610W2 shows the melting of the sheets 11A, 11B close to the fasteners 3610A, 3610B. Welding was conducted on sheets 11A, 11B without a pilot hole. The 3500J joint was created with a solder input of 8kA @ 400 ms of preheating plus 12kA @ 300 ms of welding pulse, (800 lb).
[00158] Figure 51 shows a 3715 electrode with a 3715T tip portion having a standard geometry. The tip of the 3715T electrode inserts into and is retained on the 3715S electrode shaft by means of corresponding tapered surfaces 3715TS1, 3715TS2. The tip portion 3715T has a riveting surface 3715RS having a radius R of about 8 mm. The electrode 3715 is shown in contact with a fastening element 3710 with a short solid shaft 3714 and a large portion of cap 3712 having a concave surface 3712CS, which may have a radius R1 of curvature that approximates that of the riveting surface 371RS of the 3715T tip. The fixing element 3710 is in place on the stacked sheets 11, for example, made from aluminum and 13, for example, made from steel. The 3710 "semi-solid" fastening element accommodates a standard electrode radius. The 3715 electrode is in common use in the industry and provides excellent wear and electrode coating capabilities. Deviations in electrode orientation from perpendicular occur frequently, particularly in high volume production. The 3712CS rounded contact surface allows the electrode to have a small amount of angularity with respect to the perpendicular and still work for the orientation and welding of the 3710 fixture. For very thick penetration needs (4 mm or greater) the 3714 axis of the fixture 3710 can be very thick compared to other configurations of the fixture, for example, shown in figures 1-11, where the electrode, for example, 15, 115, 215 penetrates relatively and deeply into the fixture, for example, 10, 110, 210. The fixing element 3710 can be fed to the welding electrode 3715 by means of a vehicle blanket or tape or some other means to keep it in place before contact with the electrode, which presses it against the workpiece (s) to be joined.
[00159] Figure 52 shows a tip of the 3815T electrode having a "bottle neck" geometry. As in figure 51, the tip of the 3815T electrode would be inserted into and would be retained on an electrode axis such as 3715S. The tip portion 3815T has a riveting surface 3815RS having a radius R of about 4 mm. The tip of the 3815T electrode is shown in contact with a fixing element 3810 with a short solid shaft 3814, for example, having a length greater than 1.5 mm. The fixing element 3810 has a large portion of cover 3812 having a concave surface 3812CS, which may have a radius of curvature that approximates that of the riveting surface 3815RS of the 3815T tip. The height of the fastener is about 4 to 5 mm in general. The fixing element 3810 is positioned on the sheet 11, for example, made from aluminum and 13, for example, made from steel. The 3810 "semi-solid" fastening element accommodates the 3815T "bottle neck" tip portion. As noted above, deviations in electrode orientation from perpendicular often occur and the rounded 3812CS contact surface allows the electrode to have a small amount of angularity with respect to the perpendicular and still work for orientation and welding of the 3810 fastener. The smaller surface radius 3815RS provides greater flexibility to operate in an angular deviation from the welding electrode and greater penetration of the electrode into the 3810 fixture, which more closely resembles sheet-to-sheet spot welding. Furthermore, this type of tip portion geometry will work with a wide range of lengths of the fastener axis since a very thick base is not required when welding sheets 11, 13 having a thickness of 4 mm or greater. The smallest "neck" radius of the 3815T electrode tip will have a 3815RS surface that closely matches the radius on the 3812CS contact surface. The transition from the 3815RS surface to the 3815OW outer wall of the 3815T electrode tip can be accomplished using a variety of shapes, including: a larger radius, an angled rectilinear wall or a double curvature, as shown in figures 52-55 (Figure 52 showing a double curvature). The 3815T electrode tip maintains the advantages of the standard electrode shown in Figure 51, such as excellent electrode wear and electrode coating.
[00160] Figure 53 illustrates that the bottle neck shape of the 3815T tip can accommodate a variety of fasteners, for example, 3910 and stacking thicknesses, making the 3815T electrode tip capable of processing a wide variety of stacking thicknesses with the same electrode tool.
[00161] Figure 54 shows another type of 4015T bottle neck electrode tip that can reduce electrode wear. The radius R of the riveting surface 4015RS has a smaller radius than that shown in figures 52 and 53, that is, 3 mm versus 4 mm. In general, the radius of the riveting surface 4015RS should be greater than 2 mm but less than 8 mm, preferably 3 to 6 mm. In figure 54, the contact surface of the 4010CS fastener has a radius of 4 mm, relatively larger than the riveting surface 4015RS. The riveting surface 4015RS makes a transition passage to the outer wall 4015OW through a straight wall 4015TW arranged at an angle, for example, of 45 degrees with respect to the outer wall 4015OW. The 4015T electrode tip exhibits operational capability despite the angular deviations ex, y in orientation and position of the 4015T electrode tip relative to that of the 4010 fastener. In some applications, it is preferred that the 4010CS contact surface radius is relatively larger than that of the 4015RS riveting surface and in one embodiment, the 4010CS contact surface can be from 3 to 12 mm or from 4 to 8 mm.
[00162] Figure 55 shows a tip of the 4115T electrode that can reduce the wear of the electrode. The radius R of the riveting surface 4115RS can be from 3 to 8 mm. The riveting surface 4115RS makes a transition passage to the outer wall 4115OW through a curved wall 4115TW with a large radius, for example, between 50 to 150 mm. Said geometry provides greater heat transfer and cooling.
[00163] Figure 56 shows the tip of the 4015T bottle neck electrode described above in relation to figure 54 in a misaligned orientation with the fixing element 4010, for example, in an angular displacement α of up to 30 degrees from in a perpendicular orientation with the leaves 11, 13. The tip portion of the 4015T bottle neck will accommodate angular misalignment of up to 30 degrees or more and still provide a workable electrical and mechanical contact. If the fixture 4010 has a relatively larger radius R it will increase the ability of the 4015T electrode tip spot welding apparatus to push the fixture 4010 through sheet 11 and otherwise accommodate variations from an ideal production adaptation. The ability to adjust to angular misalignments is new for projection-type welding processes that typically employ large, flat-faced electrodes and represents another significant departure from the technique currently described from traditional electrical resistance welding.
[00164] Figure 57 shows composite fasteners 4250, 4260 and 4270, each of which has a plurality of components 4250A, 4250B, 4260A, 4260B and 4270A, 4270B, respectively. As shown, components 4250A, 4260A and 4270A can be a fastener such as any of the fasteners 10, 110, 210, 310, etc. described above. The components 4250B, 4260B and 4270B can be in the form of a sheet of material that is snapped on or adhered to the component of the fastener 4250A, 4260A and 4270A. A sheet member 4250B, 4260B and 4270B can be composed of materials including: polymer, resin, adhesive (a and b above) or a metal (a, b, and c). A sheet member 4250B, 4260B and 4270B can be integral with and capable of being cut from a larger web strip that serves as a transport or holding mechanism for positioning the 4250 fasteners, etc. with respect to the materials to be fastened, for example, sheets 11, 13 of figures 4-7, during the process of applying fasteners 4250, 4260, etc. by means of electric resistance heating and welding as described above. Components 4250B, 4260B, 4270B can be selected to remain captured in a joint formed by the fasteners 4250A, 4260A, 4270A. For example, the sheet members 4250B, 4260B and 4270B can be a plastic / polymer sealant to seal and protect a joint formed by the fastener from corrosion.
[00165] If the sheet members 4250B, 4260B and 4270B are metallic and are integral with the largest structure, for example, a tape or strip used as a transport / positioning mechanism, the fixation to the tape or strip can be by a perforated connection or an otherwise frangible connection, which allows the 4250B, 4260B and 4270B leaf member to be disconnected from the largest structure when the associated fastening element 4250A, 4260A, 4270A is used. The 4250B, 4260B and 4270B sheet members can be produced from a variety of materials, for example, stainless steel, aluminum brazing alloys, high purity aluminum, etc., in order to reduce the potential for galvanic corrosion and / or extend the joint connection between the fixing element 4250A, 4260A, 4270A and all surfaces, for example, the sheets, 11, 13, with which it can come into contact with. If the brazing alloy is used, it can be pre-fluidized to offer improved humidification close to the contact surfaces and improved bonding performance. The sheet members 4250B, 4260B and 4270B can be associated with the corresponding fastening elements 4250A, 4260A, 4270A mechanically, for example, an interference fit, or other means, such as by adhesion by means of surface attraction or use of a sticker. The composition and function of the leaf members 4250B, 4260B and 4270B can be similar or the same as those of the sleeve portions 2310T and or 2410A of figures 36 and 37. The fastening elements 4250A, 4260A, 4270A and the leaf members 4250B, 4260B and 4270B can be assembled before carrying out the clamping operation and different combinations of clamping elements 4250A, 4260A, 4270A and 4250B, 4260B and 4270B sheet members can be selected based on the needs and objectives of the clamping task.
[00166] Figure 58 shows a feeding mechanism 4380 and means 4382 for supplying the fastening elements 4310 between the tip portion 4315T of a welding electrode and the workpiece, for example, the sheets 11, 13 to be fixed resistance welding joints with 4310 fasteners, according to an embodiment of the present description. The fasteners 4310 are mounted and carried by means 4382, which can be in the form of a belt or ribbon that runs between the left L and right R springs of the 4380 feed mechanism. The means can be guided by guide rollers or other guide shape, such as a channel or guiding surfaces 4380S1, 4380S2 through frame 4380F, so that the fastening elements 4310 carried through the middle are periodically presented between the tip of the electrode 4315T and the leaf 11. The tip of the electrode is periodically moved up and down to perform the penetration / welding operation as described above in the present description by heating electric resistance and welding. The feed mechanism 4380 can also move up and down with respect to the sheet 11. Medium 4382 can be partially or widely consumed when fastening element 4310 is applied to sheets 11, 13. Alternatively, the remaining portion 4382R from medium 4382 can pass beyond the applied fastener 4310 and be captured by a winding roller or other pickup mechanism, for disposal or reuse. As described above in relation to figure 57, medium 4382 can be selected to provide a beneficial attribute to a joint formed by fastening element 4310, for example, medium 4382 can be a corrosion-reducing sealant or film, an adhesive or brazing medium. Two forms of medium 4382A and 4382B with openings 4382O for receiving the fastening element 4310.
[00167] The aspects of the fastening elements 10, 110, 210, etc. and the methods of fixing the present description include those below. The process for applying the fasteners is associated with low distortion of the parts since the layers of material, for example, 11, 13 and the fastener 10, 110, etc. are held in compression during welding and the heat-affected zone is captured below the cap portion, for example, 12. Cap portion 12 may have a preformed recess or bend to form a recess to accommodate and capture metals castings, intermetals, etc. displaced by the welding operation. Because a certain fastening element, for example, 10, 110, etc., can deform, for example, melt and bend during the penetration and welding phases, it can handle the sheet thickness bands, for example example, 11, 13 to be fixed. During penetration and welding of the fastener, as the fastener 10, 110, etc., bends and expands near the weld zone, the intermetals are displaced from the weld zone. When the fastening element 10, 110, etc. (ie, the cap portion 12 thereof), if it compresses against the top sheet, for example, 11, under the influence of electrode 15, 115, 215, etc., it will come to a stop with the cap portion 12 sealing against the top sheet 11. The fixing element 10, 110, etc., can be applied through adhesives applied between the sheets, 11, 13. Once the fixing element 10, 110, 210, etc. , is welded or brazed to one side of the second sheet 13, the other side of the sheet 13 is not perforated and remains airtight. The welding process of the present description is compatible with conventional RSW equipment developed for resistance welding of steel sheet, for example, as used in the manufacture of automobiles.
[00168] The fastening element 10, 110, 210, etc., can be produced from a variety of materials such as different categories of steel (lower carbon, high strength, ultra-high strength, stainless), titanium, aluminum , magnesium, and copper and can be coated (galvanized, galvaneal, heat-immersed, aluminized) to improve corrosion resistance. The fastening element 10, 110, 210, etc., can be applied by means of single-sided or double-sided access welding techniques. In one approach, no pilot holes are used and the fastener drills through a first layer 11 softened by resistance heating. In another approach, the pilot hole can be provided in a top sheet 11, which can be aluminum, plastic, or in the case of a fastener having an aluminum shaft end 16, the first sheet can be steel, titanium, or copper and the second aluminum foil. In the case where the fastener is inserted through a pilot hole in the first sheet, the first sheet does not need to be electrically conductive and does not need to have a lower melting temperature than the second sheet (since the fastener does not penetrates the first sheet by electrical resistance heating. Quality assurance measurements can be conducted in the cavity left from the destructive disassembly of the weld that attaches a fastener to a second sheet, for example, to inspect the dimensions, for example , depth, volume, etc. of the weld NDE ultrasonic techniques can be used on the opposite side of the sheet to which the fastener is welded to monitor the quality of the weld.
[00169] The equipment used to apply the fastening element of this description 10, 110, 210, etc., has a much smaller footprint than FDS (EJOTS), SPR, and SFJ, which allows access to tighter spaces . The insertion forces used to orient the fastener of the present description are lower compared to those used in SPR, since the aluminum foil 11 is either heated or perforated, which facilitates the insertion of the fastener, increasing the ability to bond high strength aluminum which is sensitive to cracking during SPR operations. The approaches of the present description also facilitate the joining of high- and ultra-high-strength steels since there is no need to pierce metal-to-metal with a fastening element, instead of the fastening element being welded to the metal sheet. The methods of the present description do not require rotation of the fastener or workpiece which facilitates the fitting of the parts, since the process is similar to the conventional RSW in terms of how the parts to be joined are fixed. The fasteners 10, 110 can be applied at processing speeds that approach those of conventional RSW and the process can be used not only in forged aluminum, but also in cast aluminum. Since aluminum-to-steel welding is avoided, the low joint strength associated with bimetallic weld is also avoided. The process of the present description allows multiple sheets of aluminum and steel and other metals, for example, 2 layers of aluminum and 1 layer of steel; 1 layer of aluminum and 2 layers of steel; or 1 layer of aluminum, 1 layer of magnesium and 1 layer of steel are attached.
[00170] During the application of the fastener 10, 110, 210, etc., the first sheet 11 or sheets 11A, 11B that are penetrated by the fastener can also be melted and welded together, which increases the weld zone and the strength of the joint in general. The fixture can be manufactured from a variety of materials for welding on compatible sheets 13 and can be multilayered, so the fixture can have mechanical and galvanic properties that are a suitable combination for welding and to prevent corrosion. For example, a fastener can be manufactured having an end portion which is aluminum and compatible for welding to a second aluminum sheet 13, but having a layer of steel, titanium or copper to improve its mechanical properties. Multilayer fasteners can be useful in high temperature applications and can include a layer or layers of material to prevent diffusion through the interfaces of multiple materials.
[00171] A film, adhesive, or coating can be applied to the fastener or inserted between the fastener and the first sheet 11 to improve the sealing of the cap portion 12 to the sheet 11. The process of the present description can be used to join a wide range of sheet thicknesses by incorporating a portion of the retrograde cover that faces back towards the end of the shaft, which can be coated with an insulating element to prevent the conduction of electricity through the interface of the portion portion. p / sheet 11, the lid portion flexing during heating that penetrates the phase to accommodate different thicknesses in stacks. This description includes fasteners made from a variety of materials including aluminum, steel, stainless steel, copper and titanium. The fixing element can be produced from two or more different types of aluminum to allow not only resistance welding, but also low heating processes such as brazing resistance or welding. The joints produced with the fixing elements and methods of the present description can exhibit improved performance against fatigue due to the parts being kept in compression during the welding process.
[00172] It will be understood that the modalities described here are merely exemplary and that those skilled in the art can perform many variations and modifications without deviating from the spirit and scope of the subject claimed. All such variations and modifications are intended to fall within the scope of the claims

权利要求:
Claims (7)
[0001]
1. Fixing element (10, 20, 110, 210) for fixing a first electrically conductive material to a second electrically conductive material using electrical resistance welding, characterized by the fact that it comprises: a cover (12), an axis (14) extending from the lid (12) and having an end (16) distal to the lid (12), the fixing element (10, 20, 110, 210), when arranged in a stack including first and according to electrically conductive materials positioned in electrical contact and subjected to an electrical potential applied through the stack, capable of conducting an electric current, the current causing resistive heating and welding to the second electrically conductive material at the end (16) distal to the cover ( 12), the first electrically conductive material being captured between the cover (12) and the second electrically conductive material after the end (16) is welded to the second electrically conductive material, the fastener (10, 20, 11 0, 210) having a plurality of layers, a first layer having a first composition and a second layer having a second composition different from the first composition, the first layer and the second layer being held together by mechanical interlocking.
[0002]
2. Fixing element (10, 20, 110, 210), according to claim 1, characterized by the fact that the first layer defines the cover (12) and a portion of the shaft (14) close to the cover (12) and the second layer is an insert received in a cavity in the shaft (14) distal to the lid (12) and defines the tip of the shaft (14).
[0003]
3. Fixing element (10, 20, 110, 210), according to claim 1, characterized by the fact that the first layer defines the cover (12), the shaft (14) and the shaft end and the second layer is arranged around the axis (14) and under the cover (12), being retained by a peripheral edge that extends from the tip.
[0004]
4. Fixing element (10, 20, 110, 210), according to claim 3, characterized by the fact that the first layer is compatible for welding to the second electrically conductive material and the second layer is an electrical insulating element through from which the first layer extends to make electrical contact with the second electrically conductive material.
[0005]
5. Fixing element (10, 20, 110, 210) for fixing a first electrically conductive material to a second electrically conductive material using electrical resistance welding, characterized by the fact that it comprises: a cover (12), an axis (14) extending from the cover and having an end (16) distal to the cover (12), the fixing element (10, 20, 110, 210), when arranged in a stack including first and second electrically conductive materials positioned in electrical contact and subjected to an electrical potential applied through the stack, capable of conducting an electric current that passes through the stack, the current causing resistive heating and welding to the second electrically conductive material at the end (16) distal to the cover (12) , the first electrically conductive material being captured between the cap (12) and the second electrically conductive material after the end (16) is welded to the second electrically conductive material, the cap (12) if curving backwards towards the end (16) of the shaft (14), so that its outer periphery thereof is approximately coextensive with the end (16) and still comprising an electrical insulating element fixed to the outer periphery of the cover (12) , the insulating element capable of preventing the electric current from flowing through the outer periphery in parallel to the electric current flowing through the end (16), the cap (12) capable of being flexed to accommodate the passage of the end (16) through through the first electrically conductive material and welding to the second electrically conductive material while the insulating element comes into contact against a surface of the first electrically conductive material.
[0006]
6. Method for fixing a plurality of adjacent layers of a first electrically conductive material to a second electrically conductive material using electrical resistance welding, characterized by the fact that it comprises: arranging the first and second materials together in physical and electrical contact, the first electrically conductive material having a lower melting point than the second electrically conductive material; have an electrically conductive fastening element (10, 20, 110, 210) which is capable of being welded to the second electrically conductive material and which has a higher melting point than the first electrically conductive material in physical and electrical contact with the first electrically conductive material to form an electrically conductive stack including the fastener (10, 20, 110, 210), the first electrically conductive material and the second electrically conductive material; apply an electrical potential through the cell, induce a current to flow through the cell and cause resistive heating, resistive heating causing a softening of the first electrically conductive material; launching the fastening element (10, 20, 110, 210) through the plurality of softened layers of the first electrically conductive material towards the second electrically conductive material; after the fastener (10, 20, 110, 210) comes into contact with the second electrically conductive material, weld the fastener (10, 20, 110, 210) to the second electrically conductive material, the plurality of layers of the first electrically conductive material welding to each other close to where the fixing element (10, 20, 110, 210) passes.
[0007]
Method according to claim 6, characterized by the fact that the second electrically conductive material is a second fixing element (10, 20, 110, 210) and in which the plurality of layers of the first electrically conductive material are welded joints close to at least one of the first fastener (10, 20, 110, 210) and the second fastener (10, 20, 110, 210).

类似技术:

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公开号 | 公开日 | 专利标题

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BR112016017920B1|2021-01-26|fastening element for fixing a first electrically conductive material to a second electrically conductive material and method for attaching a plurality of adjacent layers of a first electrically conductive material to a second electrically conductive material

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JP6646679B2|2020-02-14|Resistance welding fastener, apparatus and method for joining similar and dissimilar materials

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JP6509205B2|2019-05-08|Resistance welding fastener, apparatus and method

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US20150000956A1|2015-01-01|Apparatus and methods for joining dissimilar materials

同族专利:

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公开号 | 公开日

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WO2015117059A1|2015-08-06|

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US10903587B2|2021-01-26|

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US20190109388A1|2019-04-11|

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JP2017510464A|2017-04-13|

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EP3102357A4|2017-12-27|

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JP6533855B2|2019-06-19|

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CA3067710A1|2015-08-06|

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CA2938420A1|2015-08-06|

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CN106163721A|2016-11-23|

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KR20160117556A|2016-10-10|

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US20220059952A1|2022-02-24|

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JP2018171658A|2018-11-08|

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CN106163721B|2021-10-15|

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JP6448667B2|2019-01-09|

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US11196185B2|2021-12-07|

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EP3102357A1|2016-12-14|

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MX2016010014A|2017-04-27|

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KR101936486B1|2019-01-08|

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US20150217395A1|2015-08-06|

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CA2938420C|2020-03-10|

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法律状态:
2017-08-29| B25D| Requested change of name of applicant approved|Owner name: ARCONIC INC. (US) |

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2019-08-06| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-12-08| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-01-26| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 02/02/2015, OBSERVADAS AS CONDICOES LEGAIS. |

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2021-10-26| B25D| Requested change of name of applicant approved|Owner name: HOWMET AEROSPACE INC. (US) |

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2021-11-16| B25G| Requested change of headquarter approved|Owner name: HOWMET AEROSPACE INC. (US) |

优先权:

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申请号 | 申请日 | 专利标题

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US201461934951P| true| 2014-02-03|2014-02-03|

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US61/934,951|2014-02-03|

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PCT/US2015/014062|WO2015117059A1|2014-02-03|2015-02-02|Resistance welding fastener, apparatus and methods|

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