JPH115180A - Welded structure - Google Patents

Abstract

(57) Abstract: An object of the present invention is to provide a welded structure having less welding distortion. In a welded structure made of an aluminum alloy,
Part or all of the welded structure is Si 0.4 by weight.
It is made of an aluminum alloy containing 〜0.9% and Mg 0.4〜1.2%, and is characterized by being joined by friction welding.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a novel welded structure made of an aluminum alloy, particularly to a vehicle structure,
The present invention relates to welded structures such as automobiles, ships, aviation, elevators, and pressure vessels.

[0002]

2. Description of the Related Art As a friction stir welding method, Japanese Patent Publication No. Hei 7-505 is used.
No. 090 allows continuous welding in the direction of the welding line by inserting a rotating tool made of a material substantially harder than the workpiece into the weld of the workpiece and moving the tool while rotating the tool. That is, this is a welding method of friction stir welding (hereinafter, referred to as a friction welding method) utilizing the plastic flow of metal due to frictional heat generated between the tool and the workpiece.
The welding method is characterized in that it is a solid-phase welding that can be performed without melting the conventional welding such as arc welding. Therefore, since the heating temperature is low, there are many advantages such as little deformation after bonding.

On the other hand, railway vehicles have conventionally been made of aluminum alloy. This aluminum alloy is melt-welded by an arc welding method and assembled as a vehicle. However, in the conventional arc welding, the deformation due to welding is large, and a large amount of working time is required for the modification. Here, by applying the friction welding method to the welding of a vehicle, effects such as little welding deformation and welding from both front and back surfaces due to solid phase welding can be expected.

[0004]

The above friction welding method comprises:
It utilizes plastic flow caused by frictional heat between a rotating tool and a welding material. For this reason, friction stir weldability greatly differs depending on the type of aluminum alloy. The aluminum alloy excellent in friction weldability is preferably an alloy excellent in plastic flow due to frictional heat with a rotary tool. However, not all aluminum alloys have excellent plastic fluidity. In the case of an aluminum alloy having poor plastic fluidity, a large load is applied to the rotating tool and the welding material. For this reason, tool wear is large and the life is shortened.
Particularly, in the case of a vehicle, since the welding length is as long as 25 m at maximum, if the wear of the rotary tool is large, the probability of occurrence of welding defects during welding increases. Therefore, if the welding material is long,
Continuous welding becomes impossible. Also, a large load is applied to the welding material. For this reason, it is necessary to increase the size, particularly the thickness, of the welding material. However, when the size of the welding material increases, the weight of the vehicle increases, which is not desirable for high-speed operation. Further, when the load of the rotating tool is large, the restraining force of the restraining jig for fixing the welding material also increases. For this reason,
The restraining jig becomes large, which causes problems in fixing the welding material and workability.

On the other hand, the friction welding method has a problem in reliability because the surface of the weld is cut by a rotary tool and the surface of the weld is concave. Further, in the conventional welded joint structure, there is a problem that the metal that has plastically flowed due to the frictional heat between the rotating tool and the welding material flows out of the groove and a defect is easily generated in the welded portion.

[0006] An object of the present invention is to provide a welded structure having less welding distortion.

[0007]

The present invention relates to a welded structure made of an aluminum alloy, wherein part or all of the welded structure is 0.4 to 0.9% of Si and 0.4 to 0.9% by weight of Mg.
It is made of an aluminum alloy containing 1.2% and is joined by friction welding.

[0008] The aluminum alloy is manufactured by extrusion, and after the processing, a solution heat treatment and an age hardening heat treatment are performed.

[0009] The surface of the friction welded portion of the aluminum alloy is raised by 0.5 to 3 mm before welding.

[0010] A part of the friction welded portion of the aluminum alloy is welded in a state of overlapping each other.

A railway vehicle is manufactured by extruding a long aluminum alloy having a length of at most 25 m. For this reason, an aluminum alloy having excellent extrudability is required. Further, railway vehicles are required to have excellent mechanical strength. Furthermore, in order to produce a weld with low distortion and high reliability, a friction welding method capable of solid-phase welding instead of conventional fusion welding is desirable. As an aluminum alloy having excellent friction weldability, the Si content is 0.4 to 0.9 wt%.
And an aluminum alloy having a Mg content of 0.4 to 1.2 wt% as a main component is preferably subjected to a solution heat treatment and then an age hardening heat treatment. That is, as described above, when a vehicle structure made of an aluminum alloy is assembled by the friction welding method, it is desirable that the aluminum alloy be an aluminum alloy having excellent friction weldability, extrudability, and mechanical strength. Therefore, in the present invention, the vehicle of the present invention can be manufactured by assembling an aluminum alloy having excellent extrudability, mechanical strength, and friction weldability by the friction welding method.

On the other hand, the depression on the surface of the welded portion due to the cutting of the rotary tool can be prevented by machining the welded portion in advance. If the height (H) is less than 0.5 mm, the effect is small, and if it is more than 3 mm, the height after welding is undesirably increased. Therefore, it is desirable that the height is 0.5 mm or more and 3 mm or less. Further, the occurrence of defects due to the outflow of the plastic flow of the weld metal can be prevented by adopting a structure in which a part of the weld joint portion is overlapped with each other.

[0013]

(Embodiment 1) Table 1 summarizes the chemical composition of typical aluminum alloys, extrudability, mechanical strength as a vehicle, and friction weldability. No. 1 in Table 1 as an aluminum alloy
Means that the Si content is 0.4 to 0.9 wt% and the Mg content is 0.4 to 1.0.
Aluminum alloy containing 2wt% as main composition (JIS standard A60
(Equivalent to 00 series) and excels in all of extrudability, mechanical strength and friction weldability. The aluminum alloy is a heat-treated aluminum alloy that has been subjected to a solution heat treatment and an age hardening heat treatment after extrusion.

[0014]

[Table 1]

When the Si content of No. 2 is 0.2-0.8 wt%, N
Aluminum alloy (equivalent to JIS A2000 series) with Mg content of 1.2 wt% or more, even though it is almost the same as o.1, has excellent mechanical strength when applied to vehicles, but has excellent extrudability and friction weldability. There's a problem.

The Mg content of No. 3 is 0.4 to 1.2 wt% and N
O.1, but with an Si content of 0.6 wt% or less and Mn
Aluminum alloys having a high content of 1.0 to 1.5 wt% (equivalent to JIS A3000 series) have excellent extrudability and friction weldability, but have problems in mechanical strength when applied as vehicles. . When the Si content of No. 4 is 0.4 wt% or less, Mg
Aluminum alloy with an amount of 4.0 to 4.9 wt% (JIS standard A5
000 series) is excellent in mechanical strength, but has a problem in extrudability. No.5 Si content is 0.4w
An aluminum alloy having a Mg content of 2 to 2.9 wt% at t% or less (J
IS standard A7000 series) is excellent in mechanical strength, but has problems in extrudability and friction weldability.

As described above, aluminum alloys that are excellent in friction weldability, extrusion workability, and mechanical strength are:
No. 1 has a Si content of 0.4 to 0.9 wt% and a Mg content of 0.4.
An aluminum alloy (corresponding to JIS A6000 series) having a main composition of up to 1.2 wt% is subjected to a solution heat treatment and an age hardening heat treatment. A vehicle made of the aluminum alloy by friction welding has less distortion, is lightweight, and has high reliability.

(Embodiment 2) FIG. 1 is a perspective view of a vehicle structure in which a part of a side outer panel for a railway vehicle is welded by a friction welding method. Weld gap 3 between side skin 1 and side skin 2 of vehicle
The welding tool 5 is formed by inserting the rotating tool 4 at the center of the workpiece and moving it in the welding direction while rotating.

FIG. 2 shows a cross-sectional structure in which a part near the welded portion in FIG. 1 is enlarged. As shown in FIG. 2, the side skin 1 and the side skin 2 are fixed to the backing plate 6. A groove 7 is provided directly below the welded portion of the backing plate 6. A part of the back side of the welded portion 5 is formed in the groove 7. Thereby, sound welding can be performed without forming an unwelded portion on the back surface of the welded portion.

The material of the aluminum alloy in this embodiment is obtained by extruding an aluminum alloy having the following composition (weight).
It has been subjected to solution heat treatment and age hardening heat treatment.

Si: 0.40-0.8%, Fe: 0.7%
The following (preferably 0.1 to 0.6%), Cu: 0.15 to
0.40%, Mn: 0.15% or less (0.05 to 0.13%
Is preferable), Mg: 0.8 to 1.2%, Cr: 0.04.
To 35%, Zn: 0.25% or less (0.05 to 0.20%
), Ti: 0.10% or less (0.03-0.10)
%), Other metals: 0.15% or less (0.03% or less)
~ 0.10% is preferred). The aluminum alloy having the above composition is referred to as an alloy number of Japanese Industrial Standard (JIS) A60.
Equivalent to 61. The mechanical properties of the aluminum alloy after heat treatment were as follows: tensile strength: 30 kg / mm ² , proof stress: 25 kg / mm,
Elongation: 13%.

The aluminum alloy has a rim structure formed by extrusion to a thickness of 4 mm, a width of 500 mm, and a length of 20 mm.

The rotary tool 4 for friction welding is practically made of a material harder than the welding material. In this embodiment, Ni
The base heat-resistant steel is used. In the rotating tool 4, the diameter (D) of a thick portion (hereinafter referred to as a shoulder portion) of the tool is at least 2-3 times larger than the diameter (d) of a thin portion (hereinafter referred to as a tool tip). A normal M screw is provided at the tip of the tool. In this embodiment, the shoulder diameter (D) of the tool is 15 mm, the tip diameter (d) is 5 mm, the rotation speed of the tool is 1500 rpm, and the welding speed is 400 mm / min.

FIG. 3 shows a cross section of a welded portion welded by the above method. FIG. 4 is a perspective view of a railway vehicle manufactured by further welding a plurality of friction welded structures as shown in FIG. Weld lines 11 and 8 are friction welds. Note that FIG.
Are partially welded by the arc welding method. 9
And 10 are arc welds.

(Embodiment 3) FIG. 5 shows the structure of an extruded member having a hollow inside manufactured by extrusion (hereinafter, referred to as an extruded member) and the arrangement of rotary tools. FIG. 6 shows a cross-sectional structure in which a part near the welded portion in FIG. 5 is enlarged. As shown in FIGS. 5 and 6, welding of the extruded sections is performed by connecting the end section 14 of one extruded section 12 to the end section 15 of the other section 13.
And are welded together. That is, the end portion 14 of one extrusion 12 is supported by the end 15 of the other extrusion 13. As a result, even when the gap of the welding line is widened, the downward flow of the metal softened by the plastic flow can be prevented at the overlapping portion 16 at the end of the extrusion. Accordingly, even when the gap is large, no defect occurs in the welded portion, and the reliability of the welded portion is improved.

On the other hand, as shown in FIG. 6, a part of the welded portion is higher by H. This is because a part of the weld is cut by the rotating tool and a dent is created on the surface of the weld,
The height is previously increased by an amount corresponding to the thickness reduced by cutting. The height (H) in this embodiment is 1 mm. It is desirable that the width (W) of the high part is almost the same as the diameter (D) of the thick part of the rotary tool.

The material of the aluminum alloy in this embodiment is obtained by extruding an aluminum alloy having the following composition (weight).
It has been subjected to solution heat treatment and age hardening heat treatment. The following elements can have the same preferable contents as described above.

Si: 0.4 to 0.9% Fe: 0.35% or less C
u: 0.35% or less Mn: 0.50% or less Mg: 0.40 to 0.8% C
r: 0.30% or less Zn: 0.25% or less Ti: 0.10% or less In addition, metals other than Al: 0.15% or less The aluminum alloy having the above-mentioned composition is based on Japanese Industrial Standard (JIS). The alloy number corresponds to A6N01. The mechanical properties of the aluminum alloy after heat treatment were as follows: tensile strength: 29
kg / mm ² , yield strength: 25 kg / mm, elongation: 12%.

After extruding this aluminum alloy to a length of 25 m, it was subjected to a solution heat treatment and an age hardening heat treatment. Also,
The welding conditions in this embodiment are the same as those in the first embodiment.

FIG. 7 shows a cross section of the welded portion 5 which has been friction-welded by the above method. A plurality of frictionally welded structures as shown in FIG. 7 were further welded to produce a railway vehicle as shown in FIG.

(Embodiment 4) FIG. 9 shows a welded joint structure when floor plates of a vehicle manufactured by extrusion molding are welded to each other by the friction welding method. The feature of FIG. 9 is that the inside of the welding groove has a fitting structure. This structure facilitates welding setting. In addition, the metal softened by plastic flow is pushed down by the tool,
It is possible to prevent the occurrence of defects inside the welded portion.

The material of the aluminum alloy in this embodiment is obtained by extruding an aluminum alloy having the following composition (weight).
It has been subjected to solution heat treatment and age hardening heat treatment.

Si: 0.4 to 0.9% Fe: 0.35% or less C
u: 0.35% or less Mn: 0.50% or less Mg: 0.40 to 0.8% C
r: 0.30% or less Zn: 0.25% or less Ti: 0.10% or less In addition, metals other than Al: 0.15% or less The aluminum alloy having the above-mentioned composition is based on Japanese Industrial Standard (JIS). The alloy number corresponds to A6N01. The mechanical properties of the aluminum alloy after heat treatment were as follows: tensile strength: 29
kg / mm ² , yield strength: 28 kg / mm, elongation: 12%.

After extruding this aluminum alloy to a length of 15 m, it was subjected to a solution heat treatment and an age hardening heat treatment. Also,
The welding conditions in this embodiment are the same as those in the first embodiment.

According to the present invention, an aluminum alloy containing 0.4 to 0.9% of Si and 0.4 to 1.2% of Mg by weight can be manufactured by friction stir welding to obtain a railway vehicle.

[0036]

According to the present invention, it is possible to manufacture a highly reliable welded structure having a small welding distortion and a lightweight structure, particularly a high-speed vehicle for railways.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a method of manufacturing a vehicle structure according to the present invention.

FIG. 2 is an enlarged sectional view of a welded portion in FIG.

FIG. 3 is a cross-sectional view of the welded portion of FIG.

FIG. 4 is a perspective view of a vehicle manufactured by the method of the present invention.

FIG. 5 is a sectional view showing a structure of a hollow structure manufactured by an extrusion method for a vehicle and a welding method.

FIG. 6 is a sectional view showing the welded joint structure of FIG. 5;

FIG. 7 is a sectional view after welding of FIGS. 5 and 6;

FIG. 8 is a sectional view of a welded joint structure.

[Description of Signs] 1, 2 ... side outer plate, 3 ... welding groove, 4 ... rotating tool, 5
... weld, 6 ... backing plate, 7 ... groove, 8, 9, 10, 11
... welding line, 12, 13 ... extrusion material, 14,15 ... end, 16 ... overlapping part.

 ──────────────────────────────────────────────────の Continued on front page (72) Inventor Kinya Aota 794, Higashitoyoi, Katsumatsu-shi, Yamaguchi Prefecture Inside the Kasado Plant of Hitachi, Ltd. (72) Inventor Masakuni Esumi 794, Higashitoyoi, Kudamatsu-shi, Yamaguchi Prefecture Stock Company (72) Inventor Yasuo Ishimaru Kasamatsu, Yamaguchi Prefecture 794, Higashi-Toyoi, Yamagata Prefecture, Japan Inside Kasado Factory, Hitachi, Ltd.

Claims (4)

[Claims] 1. A welded structure made of an aluminum alloy,
Part or all of the welded structure is Si 0.4 by weight.
A welded structure made of an aluminum alloy containing 0.9 to 0.9% and Mg 0.4 to 1.2% and joined by friction welding. 2. The welded structure according to claim 1, wherein said aluminum alloy is manufactured by extrusion processing, and after said processing, is subjected to a solution heat treatment and an age hardening heat treatment. 3. A welded structure according to claim 1, wherein the surface of said friction welded portion of said aluminum alloy is raised by 0.5 to 3 mm before welding. 4. The welded structure according to claim 1, wherein a part of the frictionally welded portions of the aluminum alloy are welded in a state where they are overlapped with each other.