CN101394963A - 用于摩擦搅动的热增强工具 - Google Patents
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Abstract
摩擦搅动工具和用于从具有超级磨料涂层的摩擦搅动工具通过化学刻蚀、电解浸蚀或相似手段(由此至少部分从超级磨料涂层除去次生相材料)除去次生相材料的方法，以由此增强工具的热稳定性并允许较长的寿命，以及减少或消除工具次生相材料和工件之间的化学反应。
Description
发明背景
相关申请的相互参照
本文件要求2006年1月31日提交的临时专利申请档案号码2293.SMII.PR2(序列号60/763950)的优先权，并将该临时申请包含的全部主题以引用的方式并入本文。
本发明的技术领域
本发明一般涉及摩擦搅动焊接和摩擦搅动处理，其中，通过压向或至少部分插入工件的工具的旋转搅拌针(pin)产生用于焊接或处理的热。更具体地，本发明涉及从PCBN和PCD摩擦搅动工具上除去次生相材料，以由此增强热性能。
相关技术的说明
在美国专利NO.6648246和NO.6779704中教导了一种新型工具，该工具能够实行金属基体复合物、铁基合金、有色金属合金和超级合金的摩擦搅动焊接。该发明一般涉及通过摩擦搅动(FS)对高软化温度材料(HSTM)固态处理的改进工具，其中摩擦搅动(FS)包括：摩擦搅动处理(FSP)、摩擦搅动混合(FSM)、摩擦搅动焊接(FSW)、及摩擦搅动点焊接(FSSW)。
对于该文献，HSTM应被认为是包括如金属基体复合物、铁基合金如钢和不锈钢、及有色金属材料和超级合金的材料。
超级合金可以是熔化温度比青铜或铝高的材料，还可以含有其它混入的元素。一些超级合金的实例是镍、铁镍合金，及通常在高于1000华氏度的温度下使用的钴基合金。通常在超级合金中发现的另外元素包括但不限于铬、钼、钨、铝、钛、铌、钽和铼。钛也应被认为是在考虑的材料种类内。钛是有色金属材料，但具有比其它有色金属材料更高的熔点。
典型地，将超级磨料材料布置在摩擦搅动工具表面，使得先前采用现有技术的工具不能进行摩擦搅动的材料能够进行摩擦搅动。典型地布置在工具上的超级磨料材料包括多晶立方氮化硼(PCBN)和多晶金刚石(PCD)。这些超级磨料材料会在元素周期表中发现，并被标识为包括III A、IV A、V A、VI A、III B、IV B和V B族元素的化合物。
超级磨料具有硬的初生或一次相和次生催化或金属相，该次生催化或金属相促进初生相晶体结构烧结和转变。
采用高温和高压处理(HTHP)将超级磨料材料布置在工具上，正如本领域技术人员现在所了解的。例如，立方氮化硼(CBN)晶体可与不同或次生相材料的粉末混合。次生相材料或是陶瓷基或是金属基的，并且可以在高温高压处理期间部分地作为催化材料发挥作用。CBN赋予了机械强度，而陶瓷会赋予对机械磨损的抵抗性。
目前已知次生相材料通常增加了PCBN的韧性和化学稳定性。韧性部分地归因于次生相材料抑制裂纹扩展的能力。CBN也在此起帮助作用，因为它具有天然地抵抗剥落的随机取向断面。较低的CBN含量通常用在需要更高化学耐磨性和更低机械耐磨性的硬化高温超级合金的机械加工操作中，其中次生相材料通常是金属性的以便获得增加的韧性。
CBN粉末在耐火金属容器中被布置在基材如烧结碳化钨、或甚至自立的PCBN坯体上。容器被密封并被返回到HTHP压机中，在这里粉末被烧结在一起，并与基材烧结在一起形成PCBN摩擦搅动工具坯体。然后，将PCBN摩擦搅动工具坯体研磨、精研、线EDM切割或激光切割以根据应用形成形状和尺寸。烧结后在HTHP压机中，次生催化相材料现在是次生相金属或次生相陶瓷。
摩擦搅动处理(包括FSW、FSP和FSSP)现在受限于可被加工的材料。例如，采用PCBN的摩擦搅动焊接工具难以加工钛基材料。由于PCBN材料中的铝，与钛基材料的化学发应是重要的限制。PCBN材料中的铝会与工件中的钛反应，通过工具中金属相的膨胀导致热损坏。摩擦搅动焊接工具中的一些次生相金属将因而降低工具的热稳定性，并减短工具的寿命。
同样，采用PCD和类PCD材料的摩擦搅动工具也因金属相而存在问题。PCD摩擦搅动焊接工具最通常是通过在HTHP压机中将金刚石粉末与合适的粘结剂-催化材料一起烧结形成。PCD通常与碳化钨基材配合。这样的基材通常包括钴。当在HTHP压机中经受高温时，钴从工具基材迁移进入金刚石层并充当粘结剂-催化材料。金刚石颗粒通过金刚石-金刚石结合而彼此结合，还使得金刚石层与工具基材结合在一起。
应注意，虽然钴最通常用作粘结剂-催化材料，然而任何VIII族元素，包括钴、镍、铁、及其合金可以作为金属相材料。
能够提供具有包括次生金属或陶瓷相材料的超级磨料涂层的摩擦搅动工具是优于现有技术的一个优势，其中次生相的至少一部分被除去或反应，使得超级磨料涂层不会与工件反应。
作为摩擦搅动工具应用的例子，使用图1以透视图来说明正用于摩擦搅动焊接的工具，其特征在于通常为圆柱形的工具10具有肩部12和伸出肩部的搅拌针14。搅拌针14和肩部(shoulder)12其上布置有超级磨料涂层。
搅拌针14相对工件16旋转，直到产生足够的热，在该点处工具的搅拌针插入到塑化的工件材料中。工件16通常是在接头线18处相互邻接的两个片材或两个板材。搅拌针14在接头线18处被插入到工件16中。尽管该工具在现有技术中已经公开，但要说明的是该工具通过本发明得到改进。
由搅拌针14相对工件材料16的旋转运动产生的摩擦热引起工件材料软化但不达到熔点。工具10沿接头线18横向移动，从而随着塑化材料沿搅拌针周围从前缘流到后缘而产生焊接。其结果是在接头线18处的固相结合20，与其它焊接相比，通常难以区分固相结合20与工件材料16本身。
据观察，当肩部12与工件的表面接触时，它的旋转产生另外的摩擦热，该摩擦热会使插入的搅拌针14附近的较大圆柱状材料塑化。肩部12提供了含有由工具搅拌针14引起的向上金属流的锻造力。
在FSW中，待焊接区和工具彼此相对移动，使得工具穿过所需的焊接接头长度。旋转的FSW工具提供了连续热加工作用，当其沿基体金属横向移动时在窄区内塑化金属，同时将金属由搅拌针的前面传输到搅拌针的后缘。随焊接区变冷，由于当工具经过时无液体产生，因此典型地不存在凝固。通常(而并非总是)，在焊接区形成的最终焊缝是无缺陷、再结晶、细晶粒的显微组织。
发明概述
在一个优选实施方案中，本发明是一种摩擦搅动工具和用于从具有超级磨料涂层的摩擦搅动工具通过化学刻蚀、电解浸蚀或相似手段(以由此至少局部地从超级磨料涂层除去一部分次生相材料)除去次生相材料的方法，以由此增强工具的热稳定性并允许较长的寿命，以及减少或消除工具次生相材料和工件之间的化学反应。
结合附图考虑下面的详细描述，本领域技术人员将更清楚本发明的这些和其它目的、特性、优势和替代方面。
附图简要说明
图1是摩擦搅动焊接的现有技术教导的工具的透视图，其中工具得到本发明改进。
图2是摩擦搅动工具的搅拌针的剖面图，显示了超级磨料层和其中次生相材料被除去的区域。
发明详述
现在将参考附图，其中将给予本发明的不同部件数字标记，并讨论本发明使得本领域技术人员能够理解和使用本发明。应理解下面的说明仅是本发明原理的范例，而不应视为窄化后面的权利要求。
已知在PCD切割工具中次生相金属材料的去除在降低岩石(rock)切割工具中的热磨损中高度有效。摩擦搅动处理具有相似的稳定性问题。因此，本发明一个方面是通过从超级磨料涂层除去材料来改良摩擦搅动工具，该涂层限制了工具的总寿命和功能。
已知，由于PCBN中的铝金属相与工件反应并引起将劣化工具并缩短工具寿命的不希望的化学反应，因此异种材料尤其是包含钛的那些材料难以用于采用PCBN的摩擦搅动焊接。
虽然PCD化学惰性更好，然而具有PCD涂层的摩擦搅动焊接工具在一些应用中也可能具有热稳定性问题。PCD热稳定性问题归因于次生相金属材料，典型是钴，但也可是之前描述的任何金属。
本发明的实质是将与工件接触的超级磨料涂层中的次生相金属或陶瓷材料的薄层除去或转变。结果是热增强并由此延长工具寿命的摩擦搅动工具。通过热增强PCD，实现了该材料的惰性。
图2作为依据本发明原理进行调整的摩擦搅动工具30的剖面图和特写图提供。然而，应记住还有如本文献公开的其它方式，其中可以对摩擦搅动工具进行改变，但仍实现本发明的目的。
摩擦搅动工具30包括在其上布置超级磨料涂层34的搅拌针32。显示的超级磨料层材料的厚度不应认为是本发明的实际表现，而相反是夸大的尺寸，仅用于说明目的。超级磨料涂层34包括在摩擦搅动时与工件接触的工作表面36。
最重要地，超级磨料涂层34包括在工作表面36开始向下延伸进入超级磨料层的层38，其中次生相金属或陶瓷材料被除去或改性以避免与工件的反应，或干扰热传递特征性。
从事于PCBN和PCD的本领域技术人员清楚存在多种从超级磨料涂层将一部分次生相金属或陶瓷材料移动或转变的方法。
例如，可使用如下方式浸出次生相金属或陶瓷材料：酸刻蚀处理、放电处理、或者其它的电学或电流的处理、或者通过蒸发。
除去次生相金属或陶瓷材料的另一方法是通过将其与另外材料结合使得次生相金属或陶瓷材料不再能够执行催化功能。这样，该材料将保持在超级磨料材料中，只是不执行催化功能。
消除由次生相金属或陶瓷材料引起问题的又一种方法是将其转变成不再充当催化材料的材料。这样的转变可以是晶体结构改变、机加工、化学反应、热处理或其它处理方法。
本发明的另一方面是次生相金属或陶瓷材料的仅仅一部分需要被除去或不再有效作为催化剂。换言之，无需将整个超级磨料涂层34中的全部次生相金属或陶瓷材料彻底除去或变成惰性。
已确定，本发明在阻止PCBN或PCD摩擦搅动工具与工件反应中的有效性可通过如下方式实现：在从工作表面0.010mm至0.50mm深度或更深的范围使次生相金属或陶瓷材料浸出或转变。例如，由PCBN或PCD形成的摩擦搅动工具的工作表面可暴露于氢氟酸和硝酸的溶液或王水溶液中以从工作表面除去次生相金属或陶瓷材料。
应注意，使超级磨料层中次生相金属或陶瓷材料浸出或转变到较大深度是耗时的并且经常是昂贵的处理。此外，实验显示浸出或转变到较大深度对于阻止摩擦搅动工具和工件之间的反应不再有效。
应注意，可沿一定梯度除去次生相金属或陶瓷材料。因此，当进一步移动到超级磨料材料34中时，次生相金属或陶瓷材料的密度可能仅有逐渐的降低，或者其缺失可能较突然。重要的是不存在次生相金属或陶瓷材料，这足以增强热稳定性或显著减少与工件反应。
应理解，上述安排仅仅是说明本发明原理的应用。本领域技术人员可设计大量的调整和替代安排，而不背离本发明的精神和范围。所附权利要求旨在包括这样的调整和安排。
Claims (13)
1.制造能够功能地摩擦搅动高软化温度材料(HSTM)的摩擦搅动工具的方法，所述方法包含以下步骤：
a)采用高温和高压(HTHP)处理在摩擦搅动工具上提供超级磨料涂层，其中超级磨料涂层包括工作表面，且其中超级磨料包括硬的初生相和次生金属或陶瓷相；及
b)处理超级磨料涂层，使得超级磨料涂层从工作表面到期望的深度基本没有含次生相金属或陶瓷材料的材料。
2.如权利要求1所述的方法，其中处理超级磨料涂层包含从其工作表面将形成次生相金属或陶瓷材料的材料浸出。
3.如权利要求1所述的方法，其中处理超级磨料涂层包含将形成次生相金属或陶瓷材料的材料转变成一定形式使得该材料不有害地影响工件。
4.如权利要求1所述的方法，其中处理超级磨料涂层包含使形成次生相金属或陶瓷材料的材料进行反应，使得催化材料不再具有催化作用。
5.如权利要求1所述的方法，其中处理超级磨料涂层包含通过放电处理超级磨料涂层以由此除去次生相金属或陶瓷材料。
6.如权利要求1所述的方法，其中处理超级磨料涂层包含处理超级磨料涂层到至少0.010mm的深度以由此基本阻止工件与摩擦搅动工具之间的催化反应。
7.如权利要求1所述的方法，其中该方法还包含步骤：除去包含次生相金属或陶瓷材料的材料到基本阻止工件与摩擦搅动工具之间的催化反应的深度。
8.如权利要求1所述的方法，其中该方法还包含步骤：通过从超级磨料涂层至少局部地消除次生相金属或陶瓷材料来热增强摩擦搅动工具的性能。
9.摩擦搅动工具，包含：
摩擦搅动工具基材；
采用高温和高压(HTHP)处理布置在摩擦搅动工具基材上的超级磨料涂层，其中超级磨料涂层包括工作表面，并且其中超级磨料包括硬的初生相和次生金属或陶瓷相；及
其中超级磨料涂层的至少一部分从工件表面到期望的深度基本没有含次生相金属或陶瓷材料的材料。
10.如权利要求9所述的摩擦搅动工具，其中超级磨料涂层选自包含以下材料的组：该材料包含包括元素周期表III A、IV A、V A、VI A、III B、IV B和V B族元素的化合物。
11.如权利要求10所述的摩擦搅动工具，其中超级磨料涂层选自多晶立方氮化硼(PCBN)或多晶金刚石(PCD)。
12.如权利要求9所述的摩擦搅动工具，其中包含次生相金属或陶瓷材料的材料被去除到基本阻止工件和摩擦搅动工具之间催化反应的深度。
13.制造摩擦搅动焊接工具的方法，该摩擦搅动工具能够功能地摩擦搅动焊接高软化温度材料(HSTM)，所述方法包含以下步骤：
a)采用高温和高压(HTHP)处理在摩擦搅动焊接工具上提供超级磨料涂层，其中超级磨料涂层包括工作表面，且其中超级磨料包括硬的初生相和次生金属或陶瓷相；及
b)在超级磨料涂层内从工作表面的至少一部分到期望深度除去包含次生相金属或陶瓷材料的材料。
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| JP4916879B2 (ja) * | 2003-08-04 | 2012-04-18 | エスアイアイ・メガダイアモンド・インコーポレーテッド | 金属母材複合材料、鉄合金、非鉄合金、及び超合金を含む材料での、摩擦攪拌接合を使用したクラック修復システム及び方法 |
| US7494040B2 (en) * | 2003-09-25 | 2009-02-24 | Sii Megadiamond, Inc. | Friction stir welding improvements for metal matrix composites, ferrous alloys, non-ferrous alloys, and superalloys using a superabrasive tool |
| CA2489187C (en) * | 2003-12-05 | 2012-08-28 | Smith International, Inc. | Thermally-stable polycrystalline diamond materials and compacts |
| US7128547B2 (en) * | 2004-01-13 | 2006-10-31 | Chien-Min Sung | High pressure split die and associated methods |
| US20050249978A1 (en) * | 2004-04-02 | 2005-11-10 | Xian Yao | Gradient polycrystalline cubic boron nitride materials and tools incorporating such materials |
-
2007
- 2007-01-31 WO PCT/US2007/002735 patent/WO2007089890A2/en active Search and Examination
- 2007-01-31 US US11/700,724 patent/US20070187465A1/en not_active Abandoned
- 2007-01-31 EP EP07762816A patent/EP1979121A4/en not_active Withdrawn
- 2007-01-31 CA CA002640730A patent/CA2640730A1/en not_active Abandoned
- 2007-01-31 JP JP2008552511A patent/JP2009525181A/ja not_active Withdrawn
- 2007-01-31 CN CNA2007800074709A patent/CN101394963A/zh active Pending
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102655977A (zh) * | 2009-12-17 | 2012-09-05 | 住友电气工业株式会社 | 被覆旋转工具 |
| US8978957B2 (en) | 2009-12-17 | 2015-03-17 | Sumitomo Electric Industries, Ltd. | Coated rotary tool |
| CN105436697A (zh) * | 2015-12-02 | 2016-03-30 | 浙江理工大学 | 高效、隔热的搅拌摩擦焊搅拌头及方法 |
| CN114423560A (zh) * | 2019-12-19 | 2022-04-29 | 六号元素(英国)有限公司 | 具有纹理表面层的pcbn基材料的摩擦搅拌焊接工具插入件 |
| CN114423560B (zh) * | 2019-12-19 | 2023-12-22 | 六号元素(英国)有限公司 | 具有纹理表面层的pcbn基材料的摩擦搅拌焊接工具插入件 |
Also Published As
| Publication number | Publication date |
|---|---|
| CA2640730A1 (en) | 2007-08-09 |
| US20070187465A1 (en) | 2007-08-16 |
| WO2007089890A2 (en) | 2007-08-09 |
| JP2009525181A (ja) | 2009-07-09 |
| EP1979121A2 (en) | 2008-10-15 |
| EP1979121A4 (en) | 2009-10-28 |
| WO2007089890A3 (en) | 2007-12-27 |
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