Friction stir welding method for structural steel and method of manufacturing joint for structural steel
09821407 · 2017-11-21
Assignee
Inventors
Cpc classification
B23K20/129
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
A process of pre-heating treatment is performed such that steel sheets or plates as working materials are heated by a heating unit provided ahead of a rotational tool moving in a welding direction to precisely control the surface temperature, area, position and the like of a heating region in the process of pre-heating treatment when performing friction stir welding on structural steel.
Claims
1. A friction stir welding method for structural steel comprising: inserting a rotational tool into an unwelded portion of steel sheets or plates, the rotational tool comprising a shoulder and a pin disposed on the shoulder and sharing an axis of rotation with the shoulder, at least the shoulder and pin being made of a material harder than the steel sheets or plates as working materials; moving the rotational tool in a welding direction while rotating the tool so that the steel sheets or plates are softened by frictional heat generated between the rotational tool and the steel sheets or plates, and a plastic flow is generated by the softened part being stirred by the rotational tool, and the steel sheets or plates are welded; and heating at least one of the steel sheets or plates with a heating unit provided ahead of the rotational tool moving in the welding direction, wherein when a part of the steel sheets or plates with a temperature Ts (° C.) of a surface of the steel sheets or plates satisfying T.sub.S≧0.8×T.sub.A1, where T.sub.A1 is represented by Formula (1), due to the heating is defined as a heating region, a minimum distance between a heating region and the rotational tool in the surface of the steel sheets or plates is equal to or smaller than the diameter of the shoulder of the rotational tool, an area of the heating region in the surface of the steel sheets or plates is equal to or smaller than a cross-sectional area of a maximum diameter part of the pin of the rotational tool, and 60% or more of the area of the heating region is positioned between a welding center line and a straight line parallel to the welding center line, the welding center line being a straight line passing through the axis of rotation of the rotational tool in the surface of the steel sheets or plates and is parallel to the welding direction and the straight line parallel to the welding center line being separated from the welding center line toward an advancing side by a distance corresponding to the maximum radius of the pin of the rotational tool,
T.sub.A1(° C.)=723−10.7[% Mn]−16.9[% Ni]+29.1[% Si]+16.9[% Cr]+290[% As]+6.38[% W] (1) wherein the content of the element is in the steel sheets or plates as working materials.
2. The method according to claim 1, wherein, when the maximum depth, from the surface of the steel sheets or plates, of a range in which a temperature T.sub.D (° C.) in the thickness direction of the heating region satisfies T.sub.D≧0.8×T.sub.A1, where T.sub.A1 is represented by Formula (1), is defined as depth D of the heating region, the depth D of the heating region is 30% or more of the thickness t of the steel sheets or plates,
T.sub.A1(° C.)=723−10.7[% Mn]−16.9[% Ni]+29.1[% Si]+16.9[% Cr]+290[% As]+6.38[% W] (1) wherein the content of the element is in the steel sheets or plates as working materials.
3. The method according to claim 1, wherein the heating unit is a laser heating device.
4. The method according to claim 1, wherein a rear heating unit is disposed behind the rotational tool moving in the welding direction, and the welded portion of the steel sheets or plates is heated by the rear heating unit.
5. The method according to claim 4, wherein a cooling unit is provided in a position behind the rotational tool and behind the rear heating unit, and the welded portion of the steel sheets or plates is cooled by the cooling unit.
6. The method according to claim 1, wherein a cooling unit is provided behind the rotational tool moving in the welding direction, and the welded portion of the steel sheets or plates is cooled by the cooling unit.
7. The method according to claim 6, wherein a rear heating unit is provided in a position behind the rotational tool moving in the welding direction and behind the cooling unit, and the welded portion of the steel sheets or plates is re-heated by the rear heating unit.
8. A method of manufacturing a joint for structural steel using the friction stir welding method according to claim 1.
9. The method according to claim 2, wherein the heating unit is a laser heating device.
10. The method according to claim 2, wherein a rear heating unit is disposed behind the rotational tool moving in the welding direction, and the welded portion of the steel sheets or plates is heated by the rear heating unit.
11. The method according to claim 3, wherein a rear heating unit is disposed behind the rotational tool moving in the welding direction, and the welded portion of the steel sheets or plates is heated by the rear heating unit.
12. The method according to claim 9, wherein a rear heating unit is disposed behind the rotational tool moving in the welding direction, and the welded portion of the steel sheets or plates is heated by the rear heating unit.
13. The method according to claim 10, wherein a cooling unit is provided in a position behind the rotational tool and behind the rear heating unit, and the welded portion of the steel sheets or plates is cooled by the cooling unit.
14. The method according to claim 11, wherein a cooling unit is provided in a position behind the rotational tool and behind the rear heating unit, and the welded portion of the steel sheets or plates is cooled by the cooling unit.
15. The method according to claim 12, wherein a cooling unit is provided in a position behind the rotational tool and behind the rear heating unit, and the welded portion of the steel sheets or plates is cooled by the cooling unit.
16. The method according to claim 2, wherein a cooling unit is provided behind the rotational tool moving in the welding direction, and the welded portion of the steel sheets or plates is cooled by the cooling unit.
17. The method according to claim 3, wherein a cooling unit is provided behind the rotational tool moving in the welding direction, and the welded portion of the steel sheets or plates is cooled by the cooling unit.
18. The method according to claim 9, wherein a cooling unit is provided behind the rotational tool moving in the welding direction, and the welded portion of the steel sheets or plates is cooled by the cooling unit.
19. The method according to claim 16, wherein a rear heating unit is provided in a position behind the rotational tool moving in the welding direction and behind the cooling unit, and the welded portion of the steel sheets or plates is re-heated by the rear heating unit.
20. The method according to claim 17, wherein a rear heating unit is provided in a position behind the rotational tool moving in the welding direction and behind the cooling unit, and the welded portion of the steel sheets or plates is re-heated by the rear heating unit.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
REFERENCE SIGNS LIST
(5) 1 Rotational tool 2 Axis of rotation 3 Steel sheets or plates 4 Welded portion 5 Heating unit 6 Cooling unit 7 Rear heating unit 8 Shoulder of rotational tool 9 Pin of rotational tool 10 Welding center line 11 AS line 12 Heating region 13 Cooling region 14 Re-heating region a Diameter of shoulder of rotational tool b Maximum diameter of pin of rotational tool c Probe length of rotational tool X Minimum distance between heating region and rotational tool D Depth of heating region T Thickness of steel sheets or plates α Inclination angle of rotational tool
DETAILED DESCRIPTION
(6) Our methods and components will be described in detail below.
(7) The disclosure relates to a friction stir welding method for structural steel, and as shown in
(8) In
(9) The advancing side is defined as the side where the rotating direction of the tool and the welding direction correspond, and the retreating side is defined as the side where the rotating direction of the tool and the welding direction are opposite to each other.
(10) Further, for the friction stir welding method described herein, the process of pre-heating treatment where steel sheets or plates are heated by a heating unit provided ahead of the rotational tool moving in the welding direction, is important. The process conditions of pre-heating treatment will be explained below with reference to
(11) Reference numeral 10 indicates a welding center line, and this welding center line indicates a straight line passing through the axis of rotation of the rotational tool in the surface of the steel sheets or plates and is parallel to the welding direction. Further, reference numeral 11 indicates a straight line parallel to the welding center line and is separated from the line toward the advancing side by a distance corresponding to the maximum radius of the pin of the rotational tool (hereinafter referred to as AS line), reference numeral 12 indicates a heating region, reference numeral 13 indicates a cooling region, reference numeral 14 indicates a re-heating region, “a” indicates the diameter of the shoulder of the rotational tool, “b” indicates the maximum diameter of the pin of the rotational tool, “X” indicates the minimum distance between the heating region and the rotational tool, “D” indicates the depth of the heating region, and “t” indicates the thickness of the steel sheets or plates.
(12) Surface temperature T.sub.S of steel sheets or plates in heating region: T.sub.S≧0.8×T.sub.A1
(13) As shown in
T.sub.A1(° C.)=723−10.7[% Mn]−16.9[% Ni]+29.1[% Si]+16.9[% Cr]+290[% As]+6.38[% W] (1).
[% M] is the content of M element (mass %) in the steel sheets or plates as working materials.
(14) However, to sufficiently heat the steel sheet in the thickness direction, there may be a temperature gradient in the surface of the heating region and, in such case, the surface temperature of the steel sheets or plates in the heating region is preferably 1.5×T.sub.M° C. or lower. Further, to avoid damages of the rotational tool and changes in microstructure caused by an excessive increase of the temperature of the welded portion, the surface temperature of the steel sheets or plates in the heating region is preferably lower than T.sub.M° C. by the time the steel sheets or plates come into contact with the rotational tool passing through the heating region.
(15) T.sub.M (° C.) is the melting point of the steel sheets or plates as working materials. Minimum distance between heating region and rotational tool in the surface of steel sheets or plates: equal to or smaller than diameter of shoulder of rotational tool
If the distance between the heating region in the surface of the steel sheets or plates and the rotational tool becomes too large, the temperature in the heating region before welding is lowered, and a sufficient effect of pre-heating cannot be obtained. Therefore, the minimum distance between the heating region in the surface of the steel sheets or plates and the rotational tool moving in the welding direction is equal to or smaller than the diameter of the shoulder of the rotational tool.
(16) However, if the distance between the heating region and the rotational tool is too small, the rotational tool may be damaged by the heat from the heating unit, and therefore the minimum distance between the heating region in the surface of the steel sheets or plates and the rotational tool moving in the welding direction is preferably 0.1 times or more of the diameter of the shoulder of the rotational tool.
(17) The diameter of the shoulder of the rotational tool is around 8 mm to 60 mm. Area of heating region in surface of steel sheets or plates: equal to or smaller than cross-sectional area of maximum diameter part of pin of rotational tool
If the heating region becomes too large, the microstructures in the region and the surrounding regions change. Particularly with high tension steel sheets or plates strengthened by the martensite structure, martensite is tempered to cause softening of the steel sheets or plates and leads to a significant decrease in joint strength even if heating is performed at or below the ferrite-austenite transformation temperature. Therefore, the area of the heating region in the surface of the steel sheets or plates is equal to or smaller than the cross-sectional area of a maximum diameter part of the pin of the rotational tool.
(18) On the other hand, if the area of the heating region is too small, a sufficient effect of pre-heating cannot be obtained. Therefore, the area of the heating region in the surface of the steel sheets or plates is preferably 0.1 times or more of the cross-sectional area of the maximum diameter part of the pin of the rotational tool.
(19) The maximum diameter of the pin of the rotational tool is around 2 mm to 50 mm. Area of heating region in surface of steel sheets or plates, positioned between welding center line and AS line: 50% or more of the area of heating region in surface of steel sheets or plates
In friction stir welding of steel sheets or plates, a plastic flow starts on the advancing side, moves along the rotational direction of the rotational tool toward the front side in the welding direction, then toward the retreating side, then passes the rear side in the welding direction, and ends on the advancing side. As described above, the starting point of the plastic flow is on the advancing side. Therefore, when insufficient heating of the steel sheets or plates as working materials easily occurs and an insufficient plastic flow causes defects mostly on the advancing side.
(20) Therefore, by positioning 50% or more of the area of the heating region in the surface of the steel sheets or plates between the welding center line and the AS line which is parallel to the welding center line to preferentially heat the advancing side, it is possible to facilitate the plastic flow, reduce defects, and increase the welding rate. The area is preferably 60% or more of the area of the heating region, and more preferably 80% or more of the area of the heating region. It may also be 100% of the area of the heating region.
(21) Further, from the viewpoint of preferentially heating the advancing side, the center of the heating region is positioned between the straight line passing through the middle point of the welding center line and the AS line, and the AS line. In other words, it is preferable for the center of the heating region to be positioned to the advancing side of the welding center line, and the distance from the center of the heating region to the welding center line to be at least one-half of and at most equal to the maximum radius of the pin of the rotational tool.
(22) Temperature T.sub.D in thickness direction of heating region: T.sub.D≧0.8×T.sub.A1
(23) As previously mentioned, steel sheets or plates to be welded by the friction stir welding method described herein normally have strength of around 30% of the strength at room temperature, at a temperature of around 80% of T.sub.A1 which is the transformation temperature of steel. Further, when exceeding this temperature, the strength further decreases. Therefore, the temperature is 0.8×T.sub.A1° C. or higher in the thickness direction of the heating region to previously soften the steel sheets or plates. Further, it is preferable to stir the steel sheets or plates and facilitate the plastic flow to thereby further reduce the load on the rotational tool and further increase the welding rate. Therefore, the temperature T.sub.D in the thickness direction of the heating region specifying the depth D of the heating region, which is described later is defined as 0.8×T.sub.A1° C. or higher. T.sub.A1 (° C.) can be obtained from Formula (1):
T.sub.A1(° C.)=723−10.7[% Mn]−16.9[% Ni]+29.1[% Si]+16.9[% Cr]+290[% As]+6.38[% W] (1)
[% M] represents the content of M element (mass %) in the steel sheets or plates as working materials.
(24) However, to sufficiently heat the steel sheet in the thickness direction, there may be a temperature gradient in the thickness direction of the heating region and, in such case, the temperature of the thickness direction of the steel sheets or plates in the heating region is preferably 1.5×T.sub.M° C. or lower. Further, to avoid damages of the rotational tool and changes in microstructure caused by an excessive increase in the temperature of the welded portion, the temperature of the steel sheets or plates in the thickness direction in the heating region is preferably lower than T.sub.M° C. by the time the steel sheets or plates come into contact with the rotational tool passing through the heating region.
(25) T.sub.M (° C.) is the melting point of the steel sheets or plates as working materials. Depth D of heating region: 30% or more of overall thickness of steel sheets or plates
(26) The depth D of the heating region is specified by the maximum depth, from the surface of the steel sheets or plates as working materials, of a range in which the temperature T.sub.D in the thickness direction of the above heating region is 0.8×T.sub.A1° C. or higher. The depth D of the heating region is preferably 30% or more of the thickness of steel sheets or plates. This is because by setting the depth D of the heating region to 30% or more of the thickness of the steel sheets or plates, the plastic flow is further facilitated. By doing so, it is more advantageous in reducing the load on the rotational tool and increasing the welding rate. More preferably, the depth D is 50% or more of the thickness of the steel sheets or plates.
(27) However, if the depth D of the heating region exceeds 90% of the thickness of the steel sheets or plates, the heating becomes excessive and concerns of changes in the microstructure will arise. Therefore, the depth D of the heating region is preferably 90% or less of the thickness of the steel sheets or plates.
(28) Further, although the heating unit to be used in the process of pre-heating treatment is not particularly limited, a laser heating device is preferably used.
(29) This is because by using a laser having a high energy density as a heat source, the process conditions of pre-heating treatment can be controlled more accurately, and welding workability can be improved without compromising joint characteristics.
(30) Conditions other than the above are not particularly limited, and it would suffice, for example, if the movement rate of the heating unit used in the process of pre-heating treatment is nearly the same as the welding rate. Further, when using a laser heating device as this heating unit, it would suffice to appropriately set the laser output and the beam diameter depending on the welding conditions.
(31) The process of pre-heating treatment in the friction stir welding method described herein is as explained above. In the friction stir welding method described herein, a cooling unit is provided behind the rotational tool moving in the welding direction, and joint strength can be improved by the cooling unit.
(32) This is because, normally, the welded portion is allowed to cool naturally after completing welding and, therefore, sufficient joint strength could not be obtained when the quench hardenability of the steel materials as working materials is low. Regarding this point, strength enhancement by quenching can be achieved by cooling the welded portion of the steel sheets or plates using the cooling unit provided behind the rotational tool moving in the welding direction while appropriately controlling the cooling rate. As a specific cooling unit, cooling by ejecting inert gas is preferable. For example, the cooling rate is preferably 30° C./s to 300° C./s in the range of 800° C. to 500° C.
(33) On the other hand, when quench hardenability of the steel sheets or plates as working materials is high, excessive hardening could occur and cause a decrease in toughness of the joint. Regarding this point, excessive hardening can be suppressed by providing a rear heating unit to heat the rear part near the rotational tool and appropriately controlling the cooling rate to gradually cool the steel sheets or plates. As a specific heating unit, high frequency induction heating or heating performed by using laser as the heat source is preferable. For example, the gradual cooling rate is preferably 10° C./s to 30° C./s at 800° C. to 500° C.
(34) Further, a rear heating unit may be provided in a position behind the rotational tool moving in the welding direction and behind the above described cooling unit, and the welded portion of the steel sheets or plates may be re-heated by the rear heating unit.
(35) By doing so, an increase in hardness can be suppressed when the welded portion is quenched and excessively hardening by the cooling performed by the cooling unit, by performing tempering using the rear heating unit, and the resulting joint may have characteristics providing a desirable balance between strength and toughness. For example, the cooling rate is preferably 30° C./s to 300° C./s at 800° C. to 500° C., and the re-heating temperature is preferably 550° C. to 650° C.
(36) Further, a cooling unit may be provided in a position behind the rotational tool moving in the welding direction and behind the above described rear heating unit, and the welded portion of the steel sheets or plates may be cooled by the cooling unit.
(37) By decreasing the cooling rate with the rear heating unit and then increasing the cooling rate with the cooling unit right after welding, a composite microstructure can be obtained and the resulting joint may have characteristics providing a desirable balance between strength and ductility. For example, the cooling rate is preferably around 10° C./s to 30° C./s at 800° C. to 600° C., and then around 30° C./s to 300° C./s at 600° C. to 400° C.
(38) Regarding the welding conditions other than the above, conventional methods may be followed. However, as the torque of the rotational tool is larger, the plastic flowability of the steel sheets or plates is lower, and defects occur more easily.
(39) Therefore, it is contemplated herein that the rotational speed of the rotational tool is 100 rpm to 1000 rpm to suppress the torque of the rotational tool and increase the welding rate to 1000 mm/min or more.
(40) Further, as the type of steel targeted in the disclosure, general structural steel or carbon steel such as rolled steel material for welded structure of JIS G 3106 and carbon steel for mechanical structure of JIS G 4051 are preferably used. Further, the disclosure can also be advantageously applied to high strength structural steel with tensile strength of 800 MPa or more, and strength of 85% or more, or even 90% or more of the tensile strength of the steel sheet (base material) can be obtained in the welded portion in such case.
(41) Further, according to the method of manufacturing a joint for structural steel using the above friction stir welding method, it is possible to improve welding workability and manufacture a joint for structural steel having high joint strength.
EXAMPLES
Example 1
(42) Using steel sheets with sheet thickness of 1.6 mm having the chemical composition and tensile strength shown in Table 1, friction stir welding was performed. The joint butting face of the steel sheets was a non-angled or so-called I type groove, and welding was performed with a one-sided single pass in a surface state as for milling. The welding conditions of friction stir welding are shown in Table 2. Further, a rotational tool (with shoulder diameter a: 12 mm, maximum diameter b of pin: 4 mm, probe length c: 1.4 mm) made of tungsten carbide (WC) with a cross-sectional dimension shown in
(43) TABLE-US-00001 TABLE 1 Tensile Chemical Composition (mass %) Strength 0.8 × T.sub.A1 No. C Si Mn P S (MPa) (° C.) 1 0.3 0.21 0.69 0.012 0.003 1015 577 2 0.16 0.07 0.69 0.016 0.009 420 574
(44) TABLE-US-00002 TABLE 2 Inclination Angle of Tool Rotational Welding Rate Tool (°) Speed (rpm) (mm/min) 3 400 400
(45) Before welding, to confirm the heating region pre-heated using a laser as the heat source, laser beam irradiation was performed under each irradiation condition shown in Table 3 (movement rate of laser, laser output, and beam diameter) on steel sheet 1 of Table 1, and the surface temperature was measured by thermography. Further, the cross-section of the laser irradiated portion was observed, and the microstructure was observed using a nital etching solution.
(46) A range at a temperature of the transformation point (T.sub.A1° C.) or higher was etched most heavily, and a range existing outside the range where the temperature is lower than the transformation point (T.sub.A1° C.), but high hardness microstructures such as martensite within the base material are tempered was etched relatively lightly. Therefore, the range at a temperature of the transformation point (T.sub.A1° C.) or higher, the tempering range at a temperature lower than the transformation point (T.sub.A1° C.), and the range of the base material are each distinguishable from the others. Further, from the knowledge regarding heat treatment of steel materials, it is known that the tempering range at a temperature lower than the transformation point (T.sub.A1° C.) corresponds with the range at a temperature of 0.8×T.sub.A1° C. or higher and lower than T.sub.A1° C. By performing such microstructure observation using a nital etching solution, the depth D.sub.0 of the range at a temperature of the transformation point (T.sub.A1° C.) or higher, and the depth (depth D of heating region) of the range at a temperature of 0.8×T.sub.A1° C. or higher were measured. The measurement results are shown in Table 4.
(47) TABLE-US-00003 TABLE 3 Irradiation Movement Rate Laser Output Beam Diameter Condition (mm/min) (kW) (mm) A 400 1.4 3.0 B 400 1.4 1.8 C 400 0.7 4.0
(48) TABLE-US-00004 TABLE 4 Diameter of Heating Region Depth D of Irradiation Shape of in Steel Sheet D.sub.0 Heating Condition Heating Region Surface (mm) (mm) Region (mm) A Circular Shape 3.5 0.28 0.30 B Circular Shape 2.0 0.47 0.50 C Circular Shape 4.5 0.09 0.10
(49) As shown in Table 4, it can be seen from the measurement results of surface temperature obtained by thermography that, under irradiation condition A, the range at a temperature of 0.8×T.sub.A1° C. or higher was a circular shape with a diameter of 3.5 mm. Since the maximum diameter of the pin of the rotational tool used herein is 4.0 mm, the area of the heating region in the steel sheet surface is equal to or smaller than the maximum diameter part of the pin of the rotational tool.
(50) Further, under irradiation condition B, the range at a temperature of 0.8×T.sub.A1° C. or higher was a circular shape with a diameter of 2.0 mm. Therefore, similarly to the above, the area of the heating region in the steel sheet surface is equal to or smaller than the cross-sectional area of the maximum diameter part of the pin of the rotational tool.
(51) On the other hand, under irradiation condition C, the range at a temperature of 0.8×T.sub.A1° C. or higher was a circular shape with a diameter of 4.5 mm. Since the maximum diameter of the pin of the rotational tool used herein is 4.0 mm, the area of the heating region in the steel sheet surface exceeds the cross-sectional area of the maximum diameter part of the pin of the rotational tool.
(52) As shown in Table 4, it can be seen from the cross-section observation of the laser irradiated portion that, under irradiation condition A, the depth D.sub.0 of the range at a temperature of T.sub.A1° C. or higher and the depth (depth D of heating region) of the range at a temperature of 0.8×T.sub.A1° C. or higher were 0.28 mm and 0.30 mm, respectively. Thickness t of the steel sheets as working materials is 1.6 mm, and depth D of the heating region which is the depth of the range at a temperature of 0.8×T.sub.A1° C. or higher is approximately 18.8% of thickness t of the steel sheets.
(53) Under irradiation condition B, depth D.sub.0 of the range at a temperature of T.sub.A1° C. or higher and the depth (depth D of the heating region) of the range at a temperature of 0.8×T.sub.A1° C. or higher were 0.47 mm and 0.50 mm, respectively. Thickness t of the steel sheets as working materials is 1.6 mm, and depth D of the heating region is approximately 31.3% of thickness t of the steel sheets.
(54) On the other hand, under irradiation condition C, depth D.sub.0 of the range at a temperature of T.sub.A1° C. or higher and the depth (depth D of the heating region) of the range at a temperature of 0.8×T.sub.A1° C. or higher were 0.09 mm and 0.10 mm. respectively. Thickness t of the steel sheets as working materials is 1.6 mm, and depth D of the heating region is approximately 6.3% of thickness t of the steel sheets.
(55) Next, the process conditions of the pre-heating by laser irradiation performed before welding the working materials and the process conditions performed after the welding are shown in Table 5. In the process after the welding, cooling was performed by gas injection, and heating (and re-heating) was performed by induction heating.
(56) The indication of “-” in process conditions of pre-heating and process conditions performed after the welding in Table 5 each indicate that the pre-heating process and the process after the welding such as cooling and heating were not performed. Further, the indications of “(AS)” and “(RS)” in the distance from the welding center line to the center of the heating region indicate whether the center of the heating region is positioned to the advancing side of the welding center line or to the retreating side of the welding center line.
(57) TABLE-US-00005 TABLE 5 Process Conditions of Pre-heating Distance Process Conditions Minimum from Performed after Welding Distance Welding Ratio of Area of Cooling Re- X between Center Line Heating Region (Gradual heating Steel Laser Heating Region to Center Positioned between Cooling) Temper- Sheet Irradiation and Rotary of Heating Welding Center Line Additional Rate ature Sample Condition Tool (mm) Region (mm) and AS Line (%) Process (° C./s) (° C.) Example 1 1 A 1 1.0 (AS) 50 or more 70 — — — Example 2 1 B 1 0.5 (AS) 50 or more 80 — — — Example 3 1 B 1 1.0 (AS) 50 or more 100 — — — Example 4 1 B 1 1.8 (AS) 50 or more 63 — — — Example 5 1 B 3 1.8 (AS) 50 or more 63 — — — Example 6 1 B 1 1.8 (AS) 50 or more 63 Cooling and then 250*.sup.1 600 Re-heating Example 7 1 B 3 1.8 (AS) 50 or more 63 Cooling and then 250*.sup.1 600 Re-heating Example 8 2 B 3 1.8 (AS) 50 or more 63 Only Cooling 100*.sup.1 — Example 9 1 B 3 1.8 (AS) 50 or more 63 Only Heating 10*.sup.1 — Example 10 1 B 3 1.8 (AS) 50 or more 63 Heating and then 10*.sup.2 and then — Cooling 100*.sup.3 Comparative 1 — — — — — — — — Example 1 Comparative 1 B 13 1.8 (AS) 50 or more 63 — — — Example 2 Comparative 1 B 1 2.3 (AS) 50 or less 31 — — — Example 3 Comparative 1 B 1 1.8 (RS) 50 or less 0 — — — Example 4 Comparative 1 C 1 2.3 (AS) 50 or less 42 — — — Example 5 *.sup.1Cooling Rate from 800° C. to 500° C. *.sup.2Cooling Rate from 800° C. to 600° C. *.sup.3Cooling Rate from 600° C. to 400° C.
(58) Further, Table 6 shows the measurements of the torque of the rotational tool of when performing the welding, and the tensile strength obtained by conducting tensile tests on tensile test specimens of the size of #1 specimen specified by JIS Z 3121 which were collected from the obtained joint.
(59) As the torque of the rotational tool is larger, the plastic flowability is lower, and defects occur more easily.
(60) TABLE-US-00006 TABLE 6 Torque of Rotational Tensile Strength Tool (N .Math. m) (MPa) Example 1 75 918 Example 2 68 920 Example 3 60 916 Example 4 53 931 Example 5 72 911 Example 6 52 1010 Example 7 71 1012 Example 8 70 418 Example 9 72 950 Example 10 71 975 Comparative 90 919 Example 1 Comparative 88 914 Example 2 Comparative 82 905 Example 3 Comparative 87 918 Example 4 Comparative 85 921 Example 5
(61) Table 6 shows that, in Examples 1 to 10, even when the welding rate is increased, strength of 85% or more of the tensile strength of the steel sheets which are the base materials was obtained, and the torque of the rotational tool was 75 N.Math.m or less, and good plastic flowability was obtained. Particularly, in Examples 6 and 7 where cooling and re-heating were performed after the welding, strength of 99% or more of the tensile strength of the base material was obtained.
(62) On the other hand, in Comparative Examples 1 to 5, the torque of the rotational tool was 80 N.Math.m or more and the plastic flowability was poor.
Example 2
(63) Similar to Example 1, using steel sheets with a sheet thickness of 1.6 mm having the chemical composition and tensile strength shown in Table 1, friction stir welding was performed with a one-sided single pass in a surface state as for milling, on a non-angled or so-called I type groove in the joint butting face. The welding conditions of friction stir welding are shown in Table 7. Similar to Example 1, a rotational tool (with shoulder diameter a: 12 mm, maximum diameter b of pin: 4 mm, probe length c: 1.4 mm) made of tungsten carbide (WC) with a cross-sectional dimension shown in
(64) TABLE-US-00007 TABLE 7 Inclination Angle of Tool Rotational Welding Rate Tool (°) Speed (rpm) (mm/min) 3 600 1000
(65) Further, before welding, to confirm the heating region pre-heated using laser as the heat source, laser beam irradiation was performed under each irradiation condition shown in Table 8 (movement rate of laser, laser output, and beam diameter) on steel sheet 1 of Table 1, and the surface temperature was measured by thermography. Further, the cross-section of the laser irradiated portion was observed and, similar to Example 1, the microstructure was observed using a nital etching solution, and the depth D.sub.0 of the range at a temperature of the transformation point (T.sub.A1° C.) or higher and the depth (depth D of heating region) of the range at a temperature of 0.8×T.sub.A1 or higher were measured.
(66) The measurement results are shown in Table 9.
(67) TABLE-US-00008 TABLE 8 Irradiation Movement Rate Laser Output Beam Diameter Condition (mm/min) (kW) (mm) D 1000 3.5 3.0 E 1000 3.5 1.8 F 1000 1.8 4.0
(68) TABLE-US-00009 TABLE 9 Major Minor Diameter Diameter Depth of Heating of Heating D of Shape of Region in Region in Heating Irradiation Heating Steel Sheet Steel Sheet D.sub.0 Region Condition Region Surface (mm) Surface (mm) (mm) (mm) D Elliptical 3.8 3.2 0.30 0.32 E Elliptical 2.2 1.8 0.51 0.54 F Elliptical 4.9 4.1 0.10 0.11
(69) As shown in Table 9, it can be seen from the measurement results of surface temperature obtained by thermography that, under irradiation condition D, the range at a temperature of 0.8×T.sub.A1° C. or higher had an elliptical shape with a major diameter in the direction of laser movement and a minor diameter in a direction orthogonal to the direction of laser movement, and the major diameter was 3.8 mm and the minor diameter was 3.2 mm. Since the maximum diameter of the pin of the rotational tool used herein is 4.0 mm, the area of the heating region in the steel sheet surface is equal to or smaller than the maximum diameter part of the pin of the rotational tool.
(70) Further, under irradiation condition E, the range at a temperature of 0.8×T.sub.A1° C. or higher had an elliptical shape with a major diameter in the direction of laser movement and a minor diameter in a direction orthogonal to the direction of laser movement, and the major diameter was 2.2 mm and the minor diameter was 1.8 mm. Therefore, similar to the above, the area of the heating region in the steel sheet surface is equal to or smaller than the cross-sectional area of the maximum diameter part of the pin of the rotational tool.
(71) On the other hand, under irraditation condition F, the range at a temperature of 0.8×T.sub.A1° C. or higher had an elliptical shape with a major diameter in the direction of laser movement and a minor diameter in a direction orthogonal to the direction of laser movement, and the major diameter was 4.9 mm and the minor diameter was 4.1 mm. Since the maximum diameter of the pin of the rotational tool used herein is 4.0 mm, the area of the heating region in the steel sheet surface is larger than the cross-sectional area of the maximum diameter part of the pin of the rotational tool.
(72) As shown in
(73) Under irradiation condition E, depth D.sub.0 of the range at a temperature of T.sub.A1° C. or higher and the depth (depth D of the heating region) of the range at a temperature of 0.8×T.sub.A1° C. or higher were 0.51 mm and 0.54 mm, respectively. Thickness t of the steel sheets as working materials is 1.6 mm, and depth D of the heating region is approximately 33.8% of the thickness t of the steel sheets.
(74) On the other hand, under irradiation condition F, depth D.sub.0 of the range at a temperature of T.sub.A1° C. or higher and the depth (depth D of the heating region) of the range at a temperature of 0.8×T.sub.A1° C. or higher were 0.10 mm and 0.11 mm respectively. Thickness t of the steel sheets as working materials is 1.6 mm, and depth D of the heating region is approximately 6.9% of the thickness t of the steel sheets.
(75) Next, the process conditions of the pre-heating by laser irradiation performed before welding the working materials and the process conditions performed after the welding are shown in Table 10. In the process after welding, cooling was performed by gas injection, and heating (and re-heating) was performed by induction heating.
(76) The indication of “-” in process conditions of pre-heating and process conditions performed after welding in Table 10 each indicate that the pre-heating process and the process after the welding such as cooling and heating were not performed. Further, the indications of “(AS)” and “(RS)” in the distance from the welding center line to the center of the heating region indicate whether the center of the heating region is positioned to the advancing side of the welding center line or to the retreating side from the welding center line.
(77) TABLE-US-00010 TABLE 10 Process Conditions of Pre-heating Distance Ratio of Minimum from Area of Heating Process Conditions Distance Welding Region Performed X between Center Positioned after Welding Heating Line to between Cooling Re- Region Center of Welding (Gradual heating Steel Laser and Rotary Heating Center Cooling) Temper- Sheet Irradiation Tool Region Line and Additional Rate ature Sample Condition (mm) (mm) AS Line (%) Process (° C./s) (° C.) Example 11 1 D 1 1.0 (AS) 50 or more 75 — — — Example 12 1 E 1 0.5 (AS) 50 or more 85 — — — Example 13 1 E 1 1.0 (AS) 50 or more 100 — — — Example 14 1 E 1 1.8 (AS) 50 or more 65 — — — Example 15 1 E 3 1.8 (AS) 50 or more 65 — — — Example 16 1 E 1 1.8 (AS) 50 or more 65 Cooling and then 300*.sup.1 600 Re-heating Example 17 1 E 3 1.8 (AS) 50 or more 65 Cooling and then 300*.sup.1 600 Re-heating Example 18 2 E 3 1.8 (AS) 50 or more 65 Only Cooling 150*.sup.1 — Example 19 1 E 3 1.8 (AS) 50 or more 65 Only Heating 30*.sup.1 — Example 20 1 E 3 1.8 (AS) 50 or more 65 Heating and then 30*.sup.2 and — Cooling then 150*.sup.3 Comparative 1 — — — — — — — — Example 6 Comparative 1 E 13 1.8 (AS) 50 or more 65 — — — Example 7 Comparative 1 E 1 2.3 (AS) 50 or less 28 — — — Example 8 Comparative 1 E 1 1.8 (RS) 50 or less 0 — — — Example 9 Comparative 1 F 1 2.3 (AS) 50 or less 41 — — — Example 10 *.sup.1Cooling Rate from 800° C. to 500° C. *.sup.2Cooling Rate from 800° C. to 600° C. *.sup.3Cooling Rate from 600° C. to 400° C.
(78) Further, Table 11 shows the measurements of the torque of the rotational tool of when performing the welding, and the tensile strength obtained by conducting tensile tests on tensile test specimens of the size of #1 specimen specified by JIS Z 3121 which were collected from the obtained joint.
(79) As the torque of the rotational tool is larger, the plastic flowability is lower, and defects occur more easily.
(80) TABLE-US-00011 TABLE 11 Torque of Rotational Tensile Strength Tool (N .Math. m) (MPa) Example 11 95 940 Example 12 94 952 Example 13 87 934 Example 14 85 946 Example 15 95 933 Example 16 87 1015 Example 17 96 1014 Example 18 91 418 Example 19 95 971 Example 20 95 990 Comparative — — Example 6 Comparative — — Example 7 Comparative — — Example 8 Comparative — — Example 9 Comparative — — Example 10
(81) Table 11 shows that, in Examples 11 to 20, even when the welding rate is increased to 1000 mm/min, welding can be performed with the torque of the rotational tool of 100 N.Math.m or less, and strength of 85% or more of the tensile strength of the steel sheets which are the base materials, and joints were successfully obtained without defects. Particularly, in Examples 16 and 17 where cooling and re-heating were performed after the welding, strength of 99% or more of the tensile strength of the base material was obtained.
(82) On the other hand, in Comparative Example 6, the rotational tool was damaged during welding and the steel sheets could not be welded. Further, in Comparative Examples 7 to 10, unwelded portions remained and the steel sheets could not be welded, and therefore it was not possible to obtain joints without defects. Therefore, for Comparative Examples 6 to 10, the torque of the rotational tool, and the like were not measured.