Process for Manufacturing a Composite Cast Part, and Composite Cast Part

Abstract

Process for manufacturing a part, in particular a composite cast part, includes the steps of: providing at least one insertion element; casting a casting material around at least a portion of the at least one insertion element such that at least one contact area is formed between the at least one insertion element and the casting material; and welding the at least one insertion element to the casting material in the contact area.

Claims

1. A method for producing a component or a component connection, comprising: providing at least one insert element; encapsulating at least certain regions of the at least one insert element with a cast material, wherein at least one contact region is formed between the at least one insert element and the cast material; and welding at least certain regions of the at least one insert element to the cast material in the contact region.

2. The method according to claim 1, wherein the act of welding comprises: pressure welding in the contact region.

3. The method according to claim 1, wherein the act of welding comprises: friction stir welding in the contact region.

4. The method according to claim 1, wherein the contact region has at least two contact surfaces, the method further comprising: welding the at least two contact surfaces to the cast material.

5. The method according to claim 4, wherein the at least two contact surfaces are opposite contact surfaces.

6. The method according to claim 1, further comprising: forming a punctiform and/or linear weld seam.

7. The method according to claim 1, wherein the act of encapsulating comprises: encapsulating in a die-casting operation.

8. The method according to claim 1, further comprising: performing a heat treatment before the welding.

9. A composite cast part, comprising: at least one insert element; a cast material, wherein at least certain regions of the at least one insert element are encapsulated by the cast material, wherein the encapsulating forms at least one contact region between the at least one insert element and the cast material; and a weld by which the at least one insert element is connected to the cast material in the contact region.

10. The composite cast part according to claim 9, wherein the weld is a pressure weld in the contact region.

11. The composite cast part according to claim 9, wherein the weld is a friction stir weld in the contact region.

12. The composite cast part according to claim 9, wherein the weld is over an entire surface area of the at least one insert element.

13. The composite cast part according to claim 9, wherein the at least one insert element forms or constitutes at least one fastening flange which protrudes out from the cast material.

14. The composite cast part according to claim 9, wherein the composite cast part is a chassis component or structural component of a motor vehicle.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] FIG. 1 is a schematic view of a composite cast part before the welding.

[0037] FIG. 2 is a further schematic view of a composite cast part during the welding.

[0038] FIG. 3 is a force-displacement diagram for different connection techniques.

DETAILED DESCRIPTION OF THE DRAWINGS

[0039] FIG. 1 shows a schematic view of a component 10, wherein the component 10 is formed from a cast material 40 in which an insert element 20 is embedded. This arrangement forms a contact region 30 which is outlined by the vertical dashed lines. The contact region 30 comprises a plurality of contact surfaces 32 on the circumference. The insert element 20 is formed or positioned in such a way that at least certain regions thereof protrude out of the cast material 40, as a result of which a fastening flange 22 is formed. A tool, in particular a friction stir welding tool, with the reference sign 60 is outlined and comprises a shoulder 62 as well as a pin 64. The positioning thereof during the welding operation is outlined in FIG. 2.

[0040] FIG. 2 substantially shows the component 10 known from FIG. 1, wherein the dimensions of the insert element 20 are formed differently, however. In particular, here a contact region 30 is substantially as wide as a diameter of a shoulder 62 of the friction stir welding tool 60. It can be seen that a pin 64 at least grazes the insert element 20. The pin 64 penetrates the cast material 40 and scrapes against the surface of the insert element 20. Diffusion processes are initiated by the resulting input of heat, wherein, depending on the material pairing, one or both parts to be joined are plasticized such that they enter into a bond with one another. The low input of energy as well as the absence of a chemical pretreatment during the friction stir welding is particularly advantageous. Further, this welding process does not give rise to any smoke or gas. The weld seam is high-quality and moreover able to bear high loads, since the welding process remains below the melting point of the parts to be joined.

[0041] Finally, FIG. 3 shows a force-displacement diagram for different connection techniques with the three curves k1, k2 and k3. The displacement is plotted on the x axis and the force is plotted on the y axis. The curve k1 shows punch-riveting in combination with adhesive bonding, the curve k2 shows pure encapsulating and the curve k3 shows encapsulating in combination with friction stir welding. It can be seen that the combination of encapsulating and friction stir welding in the tensile test illustrated here makes it possible to produce connections/components with outstanding strengths. Moreover, the achievable values for the elongation at break are very high, in particular in comparison with pure welded connections (not shown here) as well.

LIST OF REFERENCE SIGNS

[0042] 10 Component [0043] 20 Insert element [0044] 22 Fastening flange [0045] 30 Contact region [0046] 32 Contact surface [0047] 40 Cast material [0048] 60 Tool [0049] 62 Shoulder [0050] 64 Pin [0051] k1 Punch-riveting and adhesive bonding [0052] k2 Encapsulating [0053] k3 Encapsulating and friction stir welding [0054] x Displacement [0055] y Force

[0056] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.