JOINING METHOD

Abstract

A joining method including an overlapping step of overlapping a front surface of a first metal member and a back surface of second metal member such that the front surface is opposed to the back surface; and a welding step of performing a laser welding and a MIG welding by using a hybrid welding machine including a preceding laser welding unit and a following MIG welding unit, in which the laser welding is performed by emitting a laser beam onto a front surface of the second metal member, the MIG welding is performed on an inner corner portion formed by the front surface of the first metal member and an end surface of the second metal member, and a target position for the laser beam from the laser welding unit is located against the second metal member relative to a target position for a MIG arc by the MIG welding unit.

Claims

1. A joining method comprising: an overlapping step configured to overlap a first metal member and a second metal member with each other such that a front surface of the first metal member is opposed to a back surface of the second metal member; and a welding step configured to perform a laser welding and a MIG welding by using a hybrid welding machine including a laser welding unit for a preceding welding and a MIG welding unit for a following welding, wherein: the laser welding is performed by emitting a laser beam onto a front surface of the second metal member; the MIG welding is performed on an inner corner portion formed by the front surface of the first metal member and an end surface of the second metal member; and the welding step includes setting a target position for the laser beam from the laser welding unit such in a way that the target position is located against the second metal member relative to a target position for a MIG arc by the MIG welding unit.

2. A joining method according to claim 1, wherein the welding step comprises: setting a reference line parallel to a direction in which the hybrid welding machine moves; setting an imaginary line connecting a distal end of the laser welding unit and a distal end of the MIG welding unit; and setting a rotation angle between the reference line and the imaginary line to 20° to 70° in a view from above.

3. A joining method according to claim 1, wherein the welding step includes setting a distance between the target position for the laser beam for the preceding welding and the target position for the MIG arc for the following welding to 2 to 5 mm.

4. A joining method according to claim 1, wherein the welding step includes setting a target angle of the MIG arc to 40° to 80°.

5. A joining method according to claim 1, wherein the welding step includes setting an angle of advance of the MIG arc to 5° to 50°.

6. A joining method according to claim 1, wherein the overlapping step includes setting a clearance between the front surface of the first metal member and the back surface of the second metal member to 0 to 1.0 mm.

7. A joining method according to claim 1, wherein the welding step includes emitting the laser beam onto perpendicularly the front surface of the second metal member.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0012] FIG. 1 is a perspective view of a overlapping step of a joining method according to an embodiment of the present invention.

[0013] FIG. 2 is a side view of a welding step of the joining method according to the embodiment.

[0014] FIG. 3 is a front view of the welding step of the joining method according to the embodiment.

[0015] FIG. 4 is a plan view of the welding step of the joining method according to the embodiment.

[0016] FIG. 5 is a schematic side view of the welding step of the joining method according to the embodiment.

[0017] FIG. 6A is a cross-sectional view of a target position of a laser beam in the welding step of the joining method according to the embodiment.

[0018] FIG. 6B is a cross-sectional view of a target position of a MIG arc in the welding step of the joining method according to the embodiment.

[0019] FIG. 6C is a cross-sectional view of a state after the welding step of the joining method according to the embodiment.

[0020] FIG. 7 is a table of welding conditions for a strength test.

[0021] FIG. 8 is a table of target setting for the strength test.

[0022] FIG. 9 is a result table of the joint strengths and joint efficiencies of comparative examples according to the strength test.

[0023] FIG. 10 is a result table of the joint strengths and joint efficiencies of examples according to the strength test.

[0024] FIG. 11 is a schematic cross-sectional view diagram of conventional hybrid welding.

DETAILED DESCRIPTION OF THE INVENTION

[0025] A joining method according to an embodiment of the present invention is described in detail with reference to drawings. As illustrated in FIG. 1, in the joining method according to this embodiment, a second metal member 2 is overlapped on a first metal member 1, and then the first metal member 1 and the second metal member 2 are joined with each other by welding to form a lap joint. In the joining method according to this embodiment, an overlapping step and a welding step are performed. Note that, a “front surface” in the specification means a surface on the opposite side of a “back surface”.

[0026] As illustrated in FIG. 1, the overlapping step is a step of overlapping the second metal member 2 on the first metal member 1. The first metal member 1 and the second metal member 2 may have any shape; in this embodiment, both have a plate shape. The first metal member 1 and the second metal member 2 are properly selected from weldable metals such as aluminum, aluminum alloys, copper, copper alloys, titanium, titanium alloys, iron steels, and stainless steels.

[0027] In the overlapping step, the first metal member 1 and the second metal member 2 are overlapped such that the front surface 1b of the first metal member 1 is opposed to the back surface 2c of the second metal member 2. The front surface 1b of the first metal member 1 and an end surface 2a of the second metal member 2 form an inner corner portion. A point at which the front surface 1b of the first metal member 1 and the end surface 2a of the second metal member 2 intersect with each other is called a corner portion P.

[0028] The welding step is a step of welding the inner corner portion by using a hybrid welding machine 10 as illustrated in FIGS. 2 to 5. In FIGS. 2, 4, and 5, the hybrid welding machine 10 is moved from the right side to the left side. In FIG. 3, the hybrid welding machine 10 is moved from the far side to the near side. The hybrid welding machine 10 includes a connecting portion 11, a laser welding unit 20, and a MIG welding unit 30. The connecting portion 11 is, for example, attached to a distal end of an arm robot. The laser welding unit 20 includes a laser head 21 and is formed on one end of the connecting portion 11. The laser head 21 emits a laser beam LB.

[0029] The MIG welding unit 30 includes an arc torch 31 and is placed on the other end of the connecting portion 11. The arc torch 31 supplies a filler material 32 and also generates a MIG arc 33 (see FIG. 5) at its distal end.

[0030] As illustrated in FIG. 2, the angle of advance θ1 of a shaft portion of the laser head 21 is set to 10°, for example. The angle of advance is the tilt angle of the shaft portion of the laser head 21 with respect to the vertical axis when the hybrid welding machine 10 is viewed from the side. The angle of advance θ1 may be set properly between −10° to 10° with respect to the vertical axis. As illustrated in FIG. 3, the target angle θ3 of the shaft portion of the laser head 21 is set to 90°, for example. That is, the laser beam LB is emitted perpendicularly to the front surface 2b of the second metal member 2. The target angle θ3 is the opening angle from the front surface 2b of the second metal member 2 to the shaft portion of the laser head 21. The target angle θ3 may be set properly between 70° to 110°.

[0031] As illustrated in FIG. 3, the target position Q1 of the laser beam LB emitted from the laser head 21 is set to the position 2.0 mm away from the end surface 2a in this embodiment. The target position Q1 may be properly set according to the plate thickness of the second metal member 2. For example, it may be set within a range of 0<L1≤5.0 (mm), where L1 is the distance from the end surface of the second metal member 1a to the target position Q1. The target position Q1 is set on the front surface 2b of the second metal member 2 and placed closer to the center of the surface of the second metal member 2 (placed away from the end surface 2a) relative to the target position Q2 of the MIG arc 33 described later.

[0032] As illustrated in FIG. 2, the angle of advance θ2 of a shaft portion of the arc torch 31 is set to 40°, for example. The angle of advance θ2 may be set properly between 30° to 50°. As illustrated in FIG. 3, the target angle θ4 of the shaft portion of the arc torch 31 is set to 70°, for example. The target angle θ4 is the opening angle from the front surface 1b of the first metal member 1 to the shaft portion of the arc torch 31. The target angle θ4 may be set properly within a range of 50 to 80°. The target position Q2 of the MIG arc 33 (see FIG. 5) generated from the arc torch 31 is set to be at the corner portion P.

[0033] As illustrated in FIG. 4, when the hybrid welding machine 10 is viewed from above, the opening angle (rotation angle θ5) between the imaginary line M1 connecting the distal end of the laser head 21 and the distal end of the arc torch 31 and a reference line M2 parallel to the direction of the movement of the hybrid welding machine 10 is set to 40°, for example. In this embodiment, the reference line M2 is the same as the in-plane direction of the end surface 2a of the second metal member 2. The rotation angle θ5 may be set properly between 30° to 50°. The distance L2 from the target position Q1 of the laser beam LB to the target position Q2 of the MIG arc 33 on the imaginary line M1 is set to about 3.0 mm. The distance L2 may be set properly within a range of 1.0<L2≤5.0 (mm).

[0034] In the welding step, laser welding is performed by the laser beam LB emitted from the preceding laser head 21 as illustrated in FIG. 6A. The target position Q1 of the laser beam LB is set to a position away from the end surface 2a of the second metal member 2, and an end portion of the second metal member 2 is melted substantially parallel to the end surface 2a. For this process, it is preferable to set the output of the laser beam LB to a degree that allows a keyhole KH formed by the laser welding to be formed in the first metal member 1 as illustrated in FIG. 5. With this, the end portion of the second metal member 2 is cut and melted by the laser beam LB.

[0035] In the welding step, MIG welding is performed by the arc torch 31 following the laser head 21 as illustrated in FIG. 6B. The target position Q2 of the arc torch 31 is set to overlap the corner portion P. As also illustrated in FIG. 5, the following MIG arc 33 is guided to a cathode spot (laser-induced plasma LP generated around the distal end of the laser beam LB) generated by the laser welding. A weld pool WP formed by the MIG arc 33 is fused with the end portion of the second metal member 2 melted (cut) by the laser beam LB, and a weld metal W is formed at the inner corner portion as illustrated in FIG. 6C.

[0036] Note that, although the output of the laser beam LB is set as described above in the welding step, the output of the laser beam LB may be set to a depth at which the end portion of the second metal member 2 is not completely cut.

[0037] According to conventional hybrid welding, the target position of the laser beam LB and the target position of the MIG arc 33 are both at the corner portion P as illustrated in FIG. 11. This method has a disadvantage that the deposited metal becomes small when the welding speed is increased. Additionally, since the deposited metal becomes small, there is a problem of low robustness for allowing a clearance between the metal members and misalignment of the welding target position.

[0038] In contrast, in the joining method according to this embodiment, the laser beam LB is emitted to the front surface 2b from above the second metal member 2, and thereby a part of the second metal member 2 melted by the preceding laser beam LB serves as a deposited metal of the following MIG welding. Thus, it is possible to increase the amount of the deposited metal in the inner corner portion (throat thickness Wd: see FIG. 6C) in combination with the filler material 32. Therefore, the welding speed increases as well as the joint strength improves. Additionally, with the increase in the amount of the deposited metal, it is possible to improve the robustness for allowing a clearance between the metal members and misalignment of the welding target position.

[0039] Moreover, like the welding step in this embodiment, it is preferable to set the rotation angle of the reference line M2 that is parallel to the direction of movement of the hybrid welding machine 10 and the imaginary line M1 connecting the distal ends of the laser welding unit 20 and the MIG welding unit 30 to 20° to 70°, when viewed from above. Furthermore, like the welding step in this embodiment, it is preferable to set the distance L2 between the target position Q1 of the preceding laser beam LB and the target position Q2 of the following MIG arc 33 to 2 to 5 mm. If the distance L2 is shorter than 2 mm, the distance between the laser head 21 and the arc torch 31 is too close, and it is difficult to make proper joining. If the distance L2 exceeds 5 mm, the cathode spot of the laser welding does not induce the MIG arc 33, which results in that the deposited beads (deposited metal W) may meander.

[0040] Additionally, in the overlapping step, it is preferable to set a clearance between the front surface 1b of the first metal member 1 and the back surface 2c of the second metal member 2 to 0 to 1.0 mm. If the clearance exceeds 1.0 mm, there is a possibility of a decrease in the joining strength. Moreover, in the welding step, it is preferable to set the target angle θ4 of the MIG arc 33 to 40° to 80°. Furthermore, in the above-described welding step, it is preferable to set the angle of advance θ2 of the MIG arc 33 to 5° to 50°.

EXAMPLES

[0041] Next, examples according to this embodiment are described. Here, the first metal member 1 was joined with the second metal member 2 by using the hybrid welding machine 10 to form a lap joint, and a tensile test was conducted for the lap joint. The first metal member 1 of an aluminum alloy A5052-H34 with a thickness of t=2.0 mm was used for both a group of comparative examples and a group of examples. The second metal member 2 of an aluminum alloy A6061-T6 with a thickness of t=3.0 mm was used for both the group of comparative examples and the group of examples.

[0042] As indicated in FIG. 7, the welding speeds were set to 5.0 (m/min) in the comparative examples and the examples. The laser outputs were set to 2.5 (kW) in the comparative examples and set to 5.0 (kW) in the examples. A welding currents of the MIG arc were set to 228 (A) in the comparative examples and set to 250 (A) in the examples. Other conditions were as indicated in FIG. 7.

[0043] As indicated in FIG. 8, the angles of advance θ1 of the laser head 21 were set to 10° for both the group of comparative examples and the group of examples, and the angles of advance θ2 of the arc torch 31 were set to 40° for both sets. The target angles of the laser head 21 in the comparative examples were set to 45°, and the target angles θ3 of the laser head 21 in the examples were set to 90°. The target angles of the MIG arc 33 in the comparative examples were set to 45°.

[0044] In the comparative examples, the target positions Q1 of the laser beam LB and the target positions Q2 of the MIG arc 33 were both set to be at the corner portion P of the inner corner portion. The distances L2 in the comparative examples were set to 3.0 mm.

[0045] Unlike the above setting, the target positions Q1 of the laser beams LB in the examples were set to three kinds of positions: a position 2.0 mm away from the end surface 2a of the second metal member 2 which is used as a reference position (offset distance 0 mm), a position −0.5 mm which is placed toward the end surface 2a from the reference (offset distance −0.5 mm), and a position+0.5 mm which is placed away from the end surface 2a (offset distance 0.5 mm). The target positions Q2 of the MIG arc 33 in the examples were set to be at the corner portion P of the inner corner portion. The rotation angles θ5 in the examples were set to 40°, and the distances L2 therein were set to 3.0 mm.

[0046] Additionally, the clearances between the first metal member 1 and the second metal member 2 in both the group of comparative examples and the group of examples were set to three kinds, 0 mm, 0.5 mm, and 1.0 mm, for each of the above-described offset distances. Consequently, Nos. 1 to 9 test specimens were obtained as the comparative examples, and Nos. 10 to 18 test specimens were obtained as the examples.

[0047] For both the group of comparative examples and the group of examples, a tensile test was performed on each specimen, and the joint efficiency (%) was calculated according to the following formula (1). Joint efficiencies having over 70% were regarded as “favorable” results.

[00001]$\begin{array}{cc}\left[\mathrm{Formula}.1\right]& \\ \mathrm{Joint}\mathrm{efficiency}\left(\%\right)=\frac{F_J}{F_{BM}.Math.t.Math.w\text{/}w}\times 100& \mathrm{Formula}\left(1\right)\end{array}$

F.sub.J: the tensile shear strength (N/mm) of the joint
F.sub.BM: the lower-limit strength (N/mm.sup.2) in the JIS standard of the second metal member 2 (thin-plate side base material)
t: the plate thickness (mm) of the second metal member 2 (thin-plate side base material)
w: the width (mm) of the tensile test specimen

[0048] As indicated in FIG. 9, the largest joint strength in the comparative examples was 299 (N/mm) exhibited by NO. 2, and the joint efficiencies were all below 70%. Also, the deposited metal W was thin and dented toward the inner corner portion.

[0049] In contrast, as indicated in FIG. 10, the joint strengths in the examples were 336 to 429 (N/mm), and the joint efficiencies were all over 70%. Also, the deposited metal W was formed to have a great throat thickness and to be convex in the direction away from the inner corner portion. The average cross-section area of the deposited metals W of the examples was about three times greater than the average cross-section area of the deposited metals W of the comparative examples.

[0050] It was found that the joint strengths and the joint efficiencies in the examples are high even if the clearances between the front surface 2b of the first metal member 1 and the back surface 2c of the second metal member 2 are 0 to 1.0 mm. Additionally, it was found that the joint strengths and the joint efficiencies in the examples are high even if the positions of the laser beam LB are shifted from the target position by ±0.5 mm. That is to say, according to the examples, a thickness of the deposited metal W became large even under a situation of a fast welding speed, resulting in improvement of the robustness for allowing a clearance between metal members and misalignment of the welding target position.

[0051] It was also found that, according to the examples, the smaller the clearances between the front surface 1b of the first metal member 1 and the back surface 2c of the second metal member 2 are, the higher both the joint strengths and the joint efficiencies are.

REFERENCE SIGNS LIST

[0052] 1 first metal member [0053] 2 second metal member [0054] 10 hybrid welding machine [0055] 20 laser welding unit [0056] 21 laser head [0057] 30 MIG welding unit [0058] 31 arc torch [0059] 32 filler material [0060] 33 MIG arc [0061] LB laser beam [0062] W weld metal [0063] θ1 angle of advance of laser head [0064] θ2 angle of advance of arc torch [0065] θ3 target angle of laser head [0066] θ4 target angle of arc torch [0067] θ5 rotation angle