Laser metal deposition welding of automotive parts

Abstract

A part, such as an automotive part, is provided. The part includes at least two work pieces of steel which are joined together at a weld seam which includes at least one of nickel and iron and is substantially entirely free of silicate islands. The part also includes a painted, phosphated or electrocoated coating which is bonded with at least a portion of the substantially entirely silicate island free weld seam.

Claims

1. A part comprising: at least two work pieces attached together by a weld seam; said weld seam being free of silicate islands; a coating applied to said weld seam; said part being formed according to a process which includes the steps of: placing the at least two work pieces of steel into a joint; directing a stream of powder at the joint, the powder only consisting of nickel and iron or only consisting of nickel or only consisting of iron; melting with a laser beam a portion of each of the work pieces and the powder to produce the weld seam that is free of silicate islands; and without removing any material from the weld seam through material abrasion or chemical processes, applying the coating onto at least a portion of the weld seam through a painting, phosphating, or electrocoating process.

2. The part as set forth in claim 1 wherein the powder only consists of nickel.

3. The part as set forth in claim 1 wherein the powder only consists of iron.

4. The part as set forth in claim 1 wherein the step of applying the coating is defined as painting at least a portion of the weld seam.

5. The part as set forth in claim 1 wherein the step of applying the coating is further defined as phosphating at least a portion of the weld seam.

6. The part as set forth in claim 1 wherein the step of applying the coating is further defined as electrocoating at least a portion of the weld seam.

7. The part as set forth in claim 1 wherein the process further includes the step of directing a shielding gas at the joint.

8. The part as set forth in claim 7 wherein the laser beam and the powder and the shielding gas are all emitted from a single laser head.

9. The part as set forth in claim 8 wherein the laser beam and the powder and the shielding gas are all emitted from the single laser head coaxially with one another.

10. The part as set forth in claim 8 wherein the stream of powder is emitted radially outwardly of the laser beam and wherein the shielding gas is emitted outwardly of the stream of powder.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) These and other features and advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

(2) FIG. 1 is a cross-sectional view of an exemplary automotive part including a weld seam formed through a LIVID welding process;

(3) FIG. 2 is a cross-sectional view of a pair of exemplary work pieces placed into a butt joint; and

(4) FIG. 3 is a schematic view showing an LMD head melting a portion of the work pieces of FIG. 2 and a nickel and/or iron powder.

DETAILED DESCRIPTION OF THE ENABLING EMBODIMENTS

(5) Referring to FIG. 1, an aspect of the present invention is related to a part 20, such as an automotive part 20, which includes at least two work pieces 22, 24 of steel that joined together at a weld seam 26 which includes at least one of nickel and iron. The part 20 also includes a coating 28 which was applied on top of at least a portion of the weld seam 26 through painting, phosphating or electrocoating (e-coating). As discussed in further detail below, the work pieces 22, 24 are joined together through a laser metal deposition (LMD) welding process which includes melting a nickel and/or iron powder 30 into the metal of the first and second work pieces 22, 24 such that the weld seam 26 includes nickel and/or iron and is substantially entirely free of silicate islands. This allows for a very strong bond between the metal of the weld seam 26 and the coating 28, thereby reducing the risk of the coating 28 falling off of or otherwise separating from the part 20 at the weld seam 26. The outer surface of the weld seam 26 may also be smoother than the weld seams formed from other known processes.

(6) In the exemplary embodiment of FIG. 1, the work pieces 22, 24 are welded together in a butt joint. However, the work pieces 22, 24 may be joined together in any suitable type of welding joint including, for example, an edge joint, a corner joint, a T-joint, a lap joint, etc. The work pieces 22, 24 could be any suitable automotive or non-automotive work pieces 22, 24 made of steel. For example, the work pieces 22, 24 could be pieces 22, 24 of a vehicle frame or chassis and may have any suitable thicknesses. It should be appreciated that the use of the term steel herein is meant to include alloy steels.

(7) Another aspect of the present invention provides for a method of making a part 20, such as the automotive part 20 shown in FIG. 1. The method includes the step of placing at least two work pieces 22, 24 of steel into a joint. Preferably, the work pieces 22, 24 are spaced from one another by a predetermined gap 32 (see FIG. 2), e.g. 0.4 mm. Referring now to FIG. 3, the method proceeds with the step of melting with a laser beam 34 material from the first and second work pieces 22, 24 and a powder 30 of nickel and/or iron. Preferably, a shielding gas 36, such as of carbon dioxide and/or argon, is used during the melting step to protect the melted area from atmospheric gasses. Upon cooling, the steel of the work pieces 22, 24 and the nickel and/or iron forms a very hard weld seam 26 which is substantially entirely free of silicate islands.

(8) Preferably, the laser beam 34, the nickel and/or iron powder 30, and the shielding gas 36 are all simultaneously emitted from a single LMD head 38, such as the LMD head 38 shown in FIGS. 2 and 3. This LIVID head 38 may be moved relative to the work pieces 22, 24 or vice versa along the joint between the first and second work pieces 22, 24 to melt the material of the first and second work pieces 22, 24 and the nickel and/or iron powder 30 until the desired weld seam 26 is formed. The resulting weld seam 26 may be harder than the weld seams formed through other known processes.

(9) Referring back to FIG. 1, the method proceeds with the step of applying a coating 28 onto the work pieces 22, 24 including onto at least a portion of the weld seam 26 with nickel and/or iron through at least one of painting, phosphating and electrocoating. Because the weld seam 26 is substantially entirely free of silicate islands, the bond between the coating 28 and the weld seam 26 is very strong. This process is particularly efficient and cost effective because no material abrasion or chemical processes are required after the work pieces 22, 24 are joined together and before the coating 28 is painted, phosphated or electrocoated onto the weld seam 26.

(10) Obviously, many modifications and variations of the present invention are possible in light of the above teachings and may be practiced otherwise than as specifically described while within the scope of the appended claims.