Abstract
A method for joining components includes providing a first component where the first component is an aluminum die-cast component and has a joining region for disposing and fastening a second component, generating at least in regions an adhesive layer on the joining region by a thermal spraying method, and fastening the second component to the adhesive layer by joining by pressure welding.
Claims
1.-15. (canceled)
16. A method for joining components, comprising the steps of: providing a first component, wherein the first component is an aluminum die-cast component and wherein the first component has a joining region for disposing and fastening a second component; generating at least in regions an adhesive layer on the joining region by a thermal spraying method; and fastening the second component to the adhesive layer by joining by pressure welding.
17. The method according to claim 16, wherein the pressure welding is resistance spot welding.
18. The method according to claim 16, wherein the thermal spraying method is cold gas spraying.
19. The method according to claim 16, wherein the adhesive layer extends along the joining region such that the adhesive layer along the joining region has a profiled surface, a structured surface, or a wave profile and wherein a region of a wave crest of the adhesive layer is resistance spot welded.
20. The method according to claim 19, wherein a ratio of a height of a wave crest to a height of a wave trough is in a range from 1.05 to 2.7.
21. The method according to claim 19, wherein the profiled surface, the structured surface, or the wave profile is generated by an adapted advancement speed while generating the adhesive layer.
22. The method according to claim 16, wherein the generating of the adhesive layer is by way of a material application in a plurality of tracks disposed next to one another.
23. The method according to claim 16, further comprising the step of fastening the second component to the joining region by additional joining by adhesive bonding.
24. The method according to claim 23, further comprising the step of applying cement to and/or beside the adhesive layer.
25. The method according to claim 24, wherein the cement is distributed while positioning the second component on the joining region and by a force introduction during the pressure welding.
26. The method according to claim 16, further comprising the steps of: providing the first component with a surface treatment; and removing in regions the surface treatment by and while generating the adhesive layer.
27. A component connection, comprising: a first component, wherein the first component is comprised of an aluminum material; and a second component, wherein the second component is comprised of a steel material, wherein the first component and the second component are fastened to one another along a joining region, and wherein the first component in the joining region at least in regions has an adhesive layer which is generated by a thermal spraying method; wherein the second component is fastened to the adhesive layer by pressure welding.
28. The component connection according to claim 27, wherein the adhesive layer along the joining region has alternating wave crests and wave troughs and wherein at least one welding spot is respectively disposed on the wave crests.
29. The component connection according to claim 27, wherein a surface of the adhesive layer has an Sa value in a range from approximately 5 to 30 ?m.
30. The component connection according to claim 27, wherein the first component and the second component are adhesively bonded at least in regions along the joining region.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0080] FIG. 1 shows a schematic view of an embodiment of a method sequence;
[0081] FIG. 2 shows a schematic view of two components prior to joining;
[0082] FIG. 3 shows the components known from FIG. 2 after joining;
[0083] FIG. 4 shows a schematic sectional view of an adhesive layer; and
[0084] FIG. 5 shows a schematic sectional illustration of an adhesive layer when viewed along an advancement direction.
DETAILED DESCRIPTION OF THE DRAWINGS
[0085] FIG. 1 in a schematic illustration shows an embodiment of a method sequence for joining two components 10 and 20. A first component 10 is schematically illustrated. An adhesive layer 30 is applied to a joining region 26 of the first component 10 by way of a thermal coating or spraying method, cf. the coating tool 70. Cement 40, which is pre-distributed while positioning a second component 20 on the joining region 26, is applied directly to the adhesive layer 30. The joining of the two components 10 and 20 subsequently takes place by means of pressure welding, presently in particular resistance spot welding, cf. the two welding caps 60. In the context of the welding process, the two components 10 and 20 are pressed against one another by way of the introduction of force, cf. the arrows directed toward one another, wherein the cement 40 is further distributed and now advantageously completely encapsulates the adhesive layer 30. It can be seen that the welding caps 60 are of dissimilar configurations. The lower welding cap 60, which bears on the first component 10, thus preferably the aluminum material, is spherically embodied, while the upper welding cap 60, which bears on the second component 20, thus the steel material, is configured to be flat or planar. This design embodiment has proven advantageous because an impression on the aluminum side can be avoided in this way. Moreover, it can effectively be prevented that the welding caps 60 stick. The last image shows the removal of the welding caps 60 as is indicated by the two arrows. The two components 10 and 20 are now connected by way of the welding spot 50 and by way of the cement 40. It can be seen that the cement 40 bears on the adhesive layer 30, in particular circumferentially thereon, but also on the two components 10 and 20.
[0086] FIG. 2 in a schematic view shows a second component 20 and a first component 10. An adhesive layer 30 extends along a joining region 26 along the first component 10. The adhesive layer 30 is generated by way of a thermal spraying method. For this purpose, the joining region 26 is traveled along a displacement direction V by a corresponding tool and the adhesive layer 30 is applied. This can be performed in a plurality of layers which are applied on top of one another. The required thickness of the adhesive layer 30 is preferably generated in one pass. The width of the adhesive layer 30, which is measured transversely to the displacement direction V, can be covered by being passed over in a plurality of tracks or traces lying next to one another, wherein a plurality of layers can be applied on top of one another here too. In the case of a corresponding choice of nozzle, the width can alternatively be adjusted in one pass. The adhesive layer 30 along the displacement direction V is expediently designed in such a manner that the adhesive layer 30 forms a profiled surface, structured surface or a wave profile. This wave profile comprises wave crests 34 and wave troughs 36. A thickness of the adhesive layer 30 in the region of the wave crests 34, cf. the hatched fields, is greater than in the wave troughs 36. According to preferred embodiments, the thickness of the adhesive layer 30 in the region of the wave crests 34 is approximately 1000 ?m. The thickness of the adhesive layer 30 in the intervening wave troughs 36 is below this value or may even tend to be 0, depending on the process management. The function of the structured surface will become evident in particular with a view to FIG. 3. The wave crests 34, also referred to as plateaus or fields, in the plan view from above have a lateral length of preferably 20 mm?20 mm. the spacing of successive wave crests 34 in terms of the centers of the latter is approximately 60 mm, for example.
[0087] FIG. 3 shows the diagram known substantially from FIG. 2, whereby the component 20 now is fastened to the joining region 26 of the first component 10. The fastening expediently takes place by joining by means of pressure welding, presently preferably in particular resistance spot welding. The welding spots 50 here are positioned on the wave crests 34, cf. also FIG. 2 to this end. As already mentioned, a spacing of the wave crests 34 is approximately 60 mm, at a lateral length of the fields of preferably approximately 20 mm?20 mm. The size of the fields, or of the wave crests 34, respectively, enables the welding spots 50 to be positioned or aligned in a reliable manner in terms of the process. The spacing of the fields or the wave crests 34 is designed such that the mechanical target values of the connection are achieved. It is particularly advantageous for a cement connection also to be used apart from the welded connection for joining the components 10 and 20. The cement can ideally extend into the wave troughs 36, or be disposed in the latter, respectively. Optimal adhesion or interlocking of the cement can be achieved by virtue of the roughness or porosity of the adhesive layer 30, caused by the application by means of spraying, this benefiting the strength of the component connection.
[0088] FIG. 4 in in a schematic view shows a section along an adhesive layer 30, disposed on a first component 10, when viewed along a displacement direction V of a coating tool. Schematically indicated is a wave profile comprising wave crests 34 and wave troughs 36. The adhesive layer 30 in the region of the wave crests 34 has a significantly greater wall thickness than therebetween. This is achieved in that a displacement speed of the coating tool is increased in the region of the wave troughs 36, for example. It can be clearly seen that the size of the adhesive layer 30 in the region of the wave troughs 36 can be reduced to a minimum by this method, this significantly lowering the weight and the material costs and thus the method costs. By way of a further adaptation of the method this could also be managed so that no coating material at all remains present in the region of the wave troughs 36, if desired. In this instance, an adhesive layer 30 is configured exactly only in the region of the wave crests 34. In terms of the afore-mentioned adhesive method however, an at least thin adhesive layer 30 in the region of the wave troughs 36 may offer great advantages because the surface in this region is increased on account of the roughness or porosity of the adhesive layer 30, which is associated with great advantages for a cement connection.
[0089] FIG. 5 schematically shows a cross section of an adhesive layer 30. The adhesive layer 30 in the present case is generated by a multiplicity of tracks 31 disposed next to one another. It can be seen that gaps 32 are formed between these tracks 31. The further apart the tracks 31, the larger the gaps 32. If welding now takes place over a structure of this type, welding spatters may be created among other things, cf. FIG. 1 to this end. The problem arises in particular when an electrode is positioned in the region of or above a gap 31. The method, by adapting the offset of the trace or track and/or a suitable choice of the nozzle diameter, is advantageously managed such that a uniform surface is achieved across the entire region of the adhesive layer 30, presently in particular in terms of the width direction, so that the welding spot can be set arbitrarily, so to speak.
LIST OF REFERENCE CHARACTERS
[0090] 10 First component [0091] 20 Second component [0092] 26 Joining region [0093] 30 Adhesive layer [0094] 31 Track, trace [0095] 32 Gap [0096] 34 Wave crest, plateau [0097] 36 Wave trough [0098] 40 Cement (layer) [0099] 50 Welding spot [0100] 60 Welding caps [0101] 70 Coating tool [0102] V Displacement direction, advancement direction
