Indirect spot welding method

Abstract

This indirect spot welding is for welding members including at least two overlapping steel sheets that have a ferrite phase as a main phase by holding a welding electrode (23) against a steel sheet (21) from one side while applying pressure with the electrode (23), attaching a feeding point (24) to a steel sheet (22) at the other side at a location remote from the electrode (23), and allowing current to flow between the electrode (23) and the feeding point (24). This welding includes contacting magnetic rigid bodies (26-1, 26-2) to a peripheral area of the electrode (23) from the one side against which the electrode (23) is held and securing an overlapping region in the peripheral area of the electrode (23) by a magnetic force produced by the rigid bodies (26-1, 26-2), thereby obtaining a weld having fully satisfactory strength, regardless of the rigidity of the members.

Claims

1. An indirect spot welding method for welding members including at least two overlapping steel sheets that have a ferrite phase as a main phase by holding a welding electrode against a steel sheet from one side while applying pressure with the welding electrode, attaching a feeding point to a steel sheet at a location remote from the welding electrode, and allowing current to flow between the welding electrode and the feeding point, the method comprising: contacting a magnetic rigid body to the one side of the steel sheet in a peripheral area of the welding electrode; securing an overlapping region in the peripheral area of the welding electrode by a magnetic force produced by the rigid body; and welding the at least two overlapping steel sheets.

2. The indirect spot welding method of claim 1, wherein the welding is performed in a state such that an insulating viscous material is provided on an entire overlapping surface of the members except for in a welding area.

3. The indirect spot welding method of claim 1, wherein the magnetic rigid body has a circular or polygonal contact face disposed to surround the welding electrode.

4. The indirect spot welding method of claim 1, wherein during the contacting, a side of the steel sheet opposite the one side is unsupported in midair at least in the peripheral area of the welding electrode.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the accompanying drawings:

(2) FIG. 1(a) illustrates welding with a direct spot welding method, FIG. 1(b) illustrates welding with a series spot welding method, and FIG. 1(c) illustrates welding with an indirect spot welding method;

(3) FIGS. 2(a) to 2(c) illustrate how to perform our indirect spot welding method, where FIG. 2(a) is a schematic view of the arrangement of each part from the side, FIG. 2(b) is a schematic view, from above the electrode, of an example of the positional relationships between the electrode and a plurality of independent rigid bodies that have a circular or polygonal contact face, produce a magnetic force, and are disposed around the electrode, and FIG. 2(c) is a schematic view, from above the electrode, of an example of the positional relationship between the electrode and a rigid body that has a contact face shaped as a ring or a polygonal circuit, produces a magnetic force, and is disposed so as to surround the electrode;

(4) FIGS. 3(a) to 3(c) illustrate how to perform our indirect spot welding method, where FIG. 3(a) illustrates the stage at which an insulating viscous material is provided on the overlapping surface between the metal sheets, FIG. 3(b) illustrates the stage at which, after securing the peripheral area of the electrode with the rigid bodies that produce a magnetic force, the welding electrode is held against a metal sheet from one side while applying pressure with the welding electrode, and FIG. 3(c) illustrates the stage at which current is applied between the welding electrode and the feeding point; and

(5) FIG. 4 illustrates how to perform indirect spot welding on an Example.

DETAILED DESCRIPTION

(6) The following provides a detailed explanation in accordance with the drawings.

(7) FIG. 2(a) is a schematic view of the arrangement of each part from the side, illustrating how to perform our indirect spot welding in which welding is performed by contacting rigid bodies that produce a magnetic force to the peripheral area of the electrode from the side against which the welding electrode is pressed, thereby securing the overlapping members.

(8) In FIG. 2(a), since the basic structure is the same as that illustrated in FIG. 1(c), the same reference numerals are used, particularly with the addition of 26-1 and 26-2 indicating magnetic rigid bodies.

(9) The rigid bodies 26 that produce a magnetic force are disposed in a peripheral area of the electrode 23 at the side against which the welding electrode is pressed and are secured to a support via a shank. This support (not illustrated) is either a bracket for securing the force controller to which the welding electrode 23 is connected via the shank or is a structure that is independent of the system to which the welding electrode 23 is connected and can follow the movement of the welding electrode 23 when the welding position is changed.

(10) As for the shape of the rigid body 26 that produces a magnetic force and the arrangement with respect to the electrode 23, a plurality of independent rigid bodies 26-1 to 26-4 that have a circular or polygonal contact face and produce a magnetic force may be disposed around the electrode 23, as in FIG. 2(b), or a rigid body 26, which has a contact face shaped as a ring or a polygonal circuit and produces a magnetic force, may be disposed to surround the electrode 23, as in FIG. 2(c).

(11) As the magnet that is the source of the magnetic force, either an electromagnet or a permanent magnet may be used. Using an electromagnet is advantageous, however, since such a magnet can easily be secured to the member before welding and detached from the member after welding. The surface that contacts the member needs to be flat and to be made from a material with high rigidity.

(12) When using a permanent magnet, advantageous examples of such material include an alnico magnet, an iron-chrome-cobalt magnet, a ferrite magnet, a neodymium magnet, and a samarium-cobalt magnet. When using an electromagnet, iron-based material is advantageous, and it suffices to provide a flat surface on an iron core that uses such iron-based material and contact the flat surface to the member. It is advantageous for the total area of the flat surface necessary for securing the member to be 1000 mm.sup.2 or more.

(13) The magnetic flux density of the rigid body that produces a magnetic force is 0.2 tesla to 0.6 tesla at the surface of the face that contacts the member. At under 0.2 tesla, a magnetic force sufficient for securing the members cannot be obtained, whereas upon exceeding 0.6 tesla, iron scraps and the like are attracted and attach to the weld, which may cause welding defects.

(14) The overlapping members need to be metal materials having, as a base material, a ferromagnetic body that has the property of being attracted by a magnetic force. In the case of iron and steel, a steel sheet having a ferrite phase as the main phase is preferable. Some of the latest high-strength steel sheets for automobiles are designed to allow for high elongation by including retained austenite. In such steel sheets, the proportion of ferrite decreases as the proportion of retained austenite increases, and hence the magnetic property weakens. In our welding method, using steel sheets in which the proportion of the ferrite phase is 90% or more is preferable in terms of achieving satisfactory effects.

(15) In our method, the peripheral area of the electrode is defined so that when a portion of an object is within a 50 mm radius from the central axis of the electrode, the object is considered to be disposed in the peripheral area of the electrode.

(16) In our method, material with rigidity is defined as material corresponding to metal, intermetallic compounds, or inorganic material. For example, material that can flexibly deform, such as a magnetic sheet yielded by mixing a magnet into an organic material such as rubber, is excluded.

(17) In addition to the above welding method to contact a rigid body that produces a magnetic force to the peripheral area of the electrode from the side against which the welding electrode is pressed so as to secure the overlapping members, an even better weld can be obtained by providing an insulating viscous material on the entire overlapping surface of the members and welding in a state such that the overlapping surface between the steel sheets is electrically insulated by the viscous material, except for in the welding area.

(18) FIGS. 3(a) to 3(c) illustrate how to perform our indirect spot welding method, in which welding is performed in a state such that an insulating viscous material is provided between the steel sheets on the overlapping surface, i.e. in a state such that the overlapping surface between the steel sheets is electrically insulated by the viscous material, except for in the welding area.

(19) First, as illustrated in FIG. 3(a), insulating viscous material 27 is provided on the overlapping surface between the overlapping steel sheets. The metal sheets are thus electrically insulated from each other.

(20) Next, as illustrated in FIG. 3(b), after contacting rigid bodies 26 that produce a magnetic force to the peripheral area of the electrode from the side against which the welding electrode 23 is pressed, thereby securing the overlapping members, the welding electrode 23 is pressed against the one side of the steel sheets while applying pressure. With this electrode pressure, the viscous material 27 is pushed out of the welding area, guaranteeing a contact surface between the steel sheets.

(21) In the above state with electrode pressure applied, welding is performed by applying current between the welding electrode 23 and the feeding point 24, as illustrated in FIG. 3(c).

(22) By welding in the above-described way, warping of the members is suppressed. Furthermore, current passage between the steel sheets is limited to the welding area, yielding a high current density. Therefore, a weld having satisfactory strength can be stably formed regardless of the rigidity of the members.

(23) In our method, the insulating viscous material is preferably formed from a material that has a sufficiently large specific resistance and that, when disposed between the steel sheets, has enough resistance to cut off current passage between the steel sheets at the time of welding. Furthermore, the insulating viscous material preferably has appropriate viscosity and coating thickness, i.e. viscosity and coating thickness such that, when the steel sheet is pressed by the electrode, the viscous material is pushed out from the welding area to guarantee current passage between the steel sheets.

(24) The viscosity is preferably in a range of 0.1 Pa.Math.s to 1000 Pa.Math.s. If the viscosity is smaller than this range, the viscous material is excessively pushed out when the steel sheet is pressed by the electrode, and the effect of limiting current passage to the welding area is not sufficiently achieved. Conversely, if the viscosity exceeds this range, the viscous material cannot be sufficiently pushed out from the welding area when the steel sheet is pressed by the electrode, and current might not pass through the welding area. A more preferable viscosity range is 0.7 Pa.Math.s to 20 Pa.Math.s.

(25) The coating thickness is preferably set to approximately 0.1 mm to 3.0 mm. If the coating thickness is smaller than this range, then the viscous material is excessively pushed out when the steel sheet is pressed by the electrode, and the effect of limiting current passage to the welding area is not sufficiently achieved. Conversely, if the coating thickness exceeds this range, the viscous material cannot be sufficiently pushed out from the welding area when the steel sheet is pressed by the electrode, and current might not pass through the welding area. A more preferable coating thickness is 0.5 mm to 2.0 mm.

(26) Examples of the viscous material used in our method include liquid heat curing epoxy-based organic resin, an adhesive based on this organic resin, and the like. In particular, when using a heat curing adhesive such as epoxy-based organic resin, the adhesive can be hardened by heating at the time of coating by baking the steel sheets, which is normally done after welding. Therefore, a special step for hardening such unhardened adhesive need not be provided.

(27) The steel sheets that are welded with our method may be of any thickness, yet our method is particularly effective when the effects of warping at the time of welding are a concern due to the total thickness of the steel sheets being 2.0 mm or less.

EXAMPLES

Example 1

(28) Our indirect spot welding method was performed on members including two overlapping rectangular steel sheets, one side of which was 500 mm or more. The steel sheets had a thickness of 0.65 mm and were cold rolled steel sheets (SPC270) having the chemical composition listed in Table 1 and a tensile strength of 270 N/mm.sup.2 or more.

(29) TABLE-US-00001 TABLE 1 Chemical composition (mass %) C Si Mn P S 0.003 tr 0.09 0.016 0.004

(30) As illustrated in FIG. 4, the overlapping members were supported on a jig at 300 mm intervals, and welding was performed by securing the members formed by two overlapping steel sheets with electromagnets at two locations on either side of the weld. The electromagnets were attached via shanks to supports provided in the same system as for securing the force controller. Each electromagnet had a structure such that a flat surface on an iron core that used an iron-based material was contacted with the member. The flat surface was a square measuring 50 mm on each side. The surface magnetic flux density of the flat surface was 0.5 tesla. The interval between the electromagnets was 30 mm, and the welding electrode was applied from the upper sheet to the intermediate point between the electromagnets. A chromium-copper alloy electrode having a curved surface of R 40 mm at the tip was used as the welding electrode, a welding electrode feeding point was attached to the bottom sheet at a location remote from the weld, and welding was performed using a direct-current inverter current controller. Table 2 lists the welding time, welding current, and electrode pressing force.

(31) TABLE-US-00002 TABLE 2 Electrode Welding Welding time Welding current pressing force conditions (s) (kA) (N) a 0.16 7 200 b 0.16 7 400

(32) As illustrated in FIGS. 3(a) to 3(c), welding was also performed with insulating viscous material provided on the overlapping surface between the overlapping steel sheets. As the viscous material, liquid heat curing epoxy-based organic resin (coating thickness: 0.3 mm) was used.

(33) Table 3 lists combinations of the above test conditions.

(34) TABLE-US-00003 TABLE 3 Peripheral area of welding electrode Organic resin secured by Welding provided between No. electromagnet conditions steel sheets Notes 1 yes a no Example 1 2 yes b no Example 2 3 yes b yes Example 3 4 no a no Comparative Example 1 5 no b no Comparative Example 2 6 no b yes Comparative Example 3

(35) In Table 3, welding was performed according to our method on Examples 1 to 3. In Examples 1 and 2, the weld was secured with electromagnets. In Example 3, the weld was secured with electromagnets, and welding was performed after organic resin was provided between the steel sheets. The weld was not secured with electromagnets in Comparative Examples 1 to 3.

(36) Table 4 lists the results of examining the nugget diameter, nugget thickness, and nugget thickness/diameter of the weld when welding under the conditions listed in Table 3.

(37) In Table 4, the nugget diameter was taken to be the length, in a cross-section cut along the center of the weld, along the overlapping surface between the upper and lower steel sheets. The nugget thickness was taken to be the maximum thickness, in a cross-section cut along the center of the weld, of the fused portion formed across the upper and lower steel sheets.

(38) It can be determined that a weld with satisfactory strength has been obtained by forming a nugget with a good oval shape that is formed in a fused state if the nugget diameter ND satisfies Expression (1) below and if the nugget thickness/diameter is 0.22 or greater:
ND2.5TExpression (1)

(39) where ND is the nugget diameter (mm), and

(40) T is the total thickness (mm) of the overlapping steel sheets.

(41) TABLE-US-00004 TABLE 4 Nugget Nugget Nugget diameter thickness thickness/ No. (mm) (mm) diameter Notes 1 3.6 1.0 0.28 Example 1 2 3.3 0.8 0.24 Example 2 3 4.0 1.3 0.33 Example 3 4 0 0 Comparative Example 1 5 0 0 Comparative Example 2 6 0 0 Comparative Example 3 Note: Unable to pass current in No. 6

(42) Table 4 shows that for all of the Examples 1 to 3, in which indirect spot welding was performed according to our method, a fused nugget having a sufficient nugget diameter satisfying Expression (1) and a sufficient thickness for this diameter was obtained.

(43) By contrast, a fused nugget was not obtained in Comparative Examples 1 to 3. In particular, in Comparative Example 3, warping of the members at the time of pressing with the electrode was too great, the organic resin provided between the steel sheets could not be pushed out, and current could not be passed between the steel sheets.

INDUSTRIAL APPLICABILITY

(44) In an indirect spot welding method for welding members including at least two overlapping steel sheets by holding a welding electrode against a steel sheet from one side while applying pressure with the welding electrode, attaching a feeding point to a steel sheet at the other side at a location remote from the welding electrode, and allowing current to flow between the welding electrode and the feeding point, when welding a portion where overlapping steel sheets are pressed by an electrode from only one side with the other side of the steel sheets being unsupported in midair, a weld with satisfactory strength can be obtained, regardless of the rigidity of the members.

REFERENCE SIGNS LIST

(45) 1, 2 Metal sheet 3, 4 Electrode 5 Weld 6, 7 Force controller 8 Current controller 11, 12 Metal sheet 13, 14 Electrode 15-1, 15-2 Weld 21, 22 Metal sheet 23 Electrode 24 Feeding point 25 Weld 26 Rigid member