Method for manufacturing a joint body, soldering metal body, and joint

Abstract

Provided is a method for manufacturing a bonded body, a metal body for welding, and a bonding member, which can reduce galvanic corrosion. A method for manufacturing a bonded body obtained by joining a partner member made of a ferrous metal to a non-ferrous metal material including a prescribed surface facing the partner member, the method including: a press-in step of pressing the bonding member made of a ferrous metal into the prescribed surface of the non-ferrous metal material; and a welding step of forming a molten portion between an exposed portion of the bonding member pressed into the non-ferrous metal material and the partner member. After the press-in step, a portion of the bonding member is exposed from the prescribed surface, and a remaining portion of the bonding member is buried in the non-ferrous metal material without being exposed, and the remaining portion of the bonding member includes a hooking portion including a surface facing the prescribed surface.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a joint capable of reducing galvanic corrosion, a metal body for welding, and a joint. Background Technology

[0002] Direct welding of non-ferrous metals such as aluminum, magnesium, and zinc to components made of ferrous metals (steel) is difficult. Therefore, existing construction methods involve joining ferrous metal components to non-ferrous metals using methods other than welding, and then welding these components to the other component. One such method involves inserting and pushing the ferrous metal component into the back side of the non-ferrous metal material opposite to the surface facing the other component, and then resistance spot welding the component, which extends to the surface of the non-ferrous metal material, to the other component (Patent Document 1).

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2017-87281 Summary of the Invention

[0006] The technical problem that the invention aims to solve

[0007] However, in the existing construction methods described above, the portion of the ferrous metal connector opposite to the part welded to the other component is exposed on the back side of the non-ferrous metal material. Therefore, measures to prevent galvanic corrosion between the non-ferrous metal material and the connector must be taken on the back side of the non-ferrous metal material. However, this approach increases the number of work steps and raises costs.

[0008] The present invention is proposed to solve the above-mentioned problems, and its purpose is to provide a method for manufacturing a joint that can reduce galvanic corrosion, a metal body for welding, and a joint.

[0009] Technical solutions for solving technical problems

[0010] To achieve this objective, the method for manufacturing a joint according to the present invention is a method for manufacturing a joint in which a ferrous metal component is joined to a non-ferrous metal material, the non-ferrous metal material including a predetermined surface facing the component. The method for manufacturing the joint includes: a pressing step, in which a ferrous metal component is pressed into the predetermined surface of the non-ferrous metal material; and a welding step, in which a molten portion is formed between the exposed portion of the pressed-in non-ferrous metal component and the component. After the pressing step, a portion of the joint is exposed from the predetermined surface, and the remaining portion of the joint is buried in the non-ferrous metal material and not exposed. The remaining portion of the joint has a hook portion, the hook portion including a surface facing the predetermined surface.

[0011] The welding metal body of the present invention comprises: a non-ferrous metal material including a specified surface; and a low-carbon steel connector having a carbon content of 0.4% by mass or less. The connector is pressed into the specified surface such that a portion of the connector protrudes from the specified surface, while the remaining portion of the connector is embedded in the non-ferrous metal material and not exposed. The remaining portion of the connector has a hook portion, which includes a surface facing the specified surface.

[0012] The connector of the present invention is made of a ferrous metal. The connector is pressed into a predetermined surface of a non-ferrous metal material and welded to a counterpart component made of a ferrous metal. The connector has a main body and a foot. The main body includes a mating surface and an outer peripheral surface. The mating surface is formed as a plane orthogonal to an imaginary axis. The outer peripheral surface is connected to the outer periphery of the mating surface and surrounds the imaginary axis. The foot includes an outer surface connected to the outer peripheral surface and protrudes from the side of the main body opposite to the mating surface, positioned around the imaginary axis. The outer peripheral surface is formed by at least one of a parallel portion and an inclined portion. The parallel portion is parallel to the imaginary axis in a cross-section including the imaginary axis, and the inclined portion moves away from the imaginary axis as it moves away from the mating surface.

[0013] Invention Effects

[0014] According to the manufacturing method of the first embodiment, in the pressing process, the joint is pressed into a designated surface of the non-ferrous metal material. Because the hook portion includes a surface facing the designated surface, the portion of the joint filled with the non-ferrous metal material makes it difficult for the joint to detach from the non-ferrous metal material.

[0015] After the pressing process, a portion of the joint is exposed from a designated surface, and a welding process is performed to form a molten section between this portion and the other component to create the joint. Since the remaining portion of the joint is buried in a non-ferrous metal material and not exposed, galvanic corrosion is reduced.

[0016] According to the manufacturing method of the joint in the second embodiment, in the heating process, the portion of the non-ferrous metal material to which the joint will be pressed in the pressing process is heated. Therefore, since the portion of the joint pressed into the non-ferrous metal material and heated has increased ductility, in addition to the effects of the first embodiment, the non-ferrous metal material after the joint is pressed in is also made less prone to cracking.

[0017] According to the third embodiment of the welding metal body, the joint is pressed into a designated surface of a non-ferrous metal material. Because the hook portion of the joint, which is embedded in the non-ferrous metal material, includes a surface facing the designated surface, the joint is difficult to detach from the non-ferrous metal material. Since a portion of the joint is exposed from the designated surface of the non-ferrous metal material, the opposing component can be welded to that portion. Because the remaining portion of the joint is embedded in the non-ferrous metal material and not exposed, galvanic corrosion is reduced.

[0018] Furthermore, the joint is formed from raw materials suitable for welding, such as low-carbon steel with a carbon content of less than 0.4% by mass. This avoids the joint becoming too hard or brittle due to the heat effect generated during welding of the other component to the joint. As a result, because welding cracks and reduced toughness of the joint caused by hardening during welding can be suppressed, the bonding strength between the other component and non-ferrous metal materials through the joint can be ensured.

[0019] According to the fourth embodiment of the connector, a foot protruding from the side of the main body opposite to the joint surface is located around an imaginary axis orthogonal to the joint surface. Although it also depends on the dimensions of the connector and the non-ferrous metal material, by pressing the joint surface, the connector is pressed into the specified surface of the non-ferrous metal material from the foot, and the connector is pressed into the non-ferrous metal material without punching the non-ferrous metal material. As a result, the joint surface welded to the other component can be exposed from the non-ferrous metal material, while the back of the foot and the main body is not exposed from the non-ferrous metal material. Therefore, in the component obtained by pressing the connector into the non-ferrous metal material, galvanic corrosion can be reduced.

[0020] The outer peripheral surface is formed by at least one of a parallel portion parallel to the imaginary axis in a cross-section including the imaginary axis and an inclined portion moving away from the imaginary axis as it moves away from the mating surface. A foot, including an outer surface connected to the outer peripheral surface, protrudes from the main body. Compared to the case where a flange extending outward from the outer peripheral surface of the foot is located in the main body, the mating member can be easily pressed into the specified surface of the non-ferrous metal material up to the main body.

[0021] According to the fifth embodiment of the connector, the outer peripheral surface of the foot at the connection position includes an inclined portion connected to the outer peripheral edge of the joint surface. Therefore, when the connector is pressed into the non-ferrous metal material from the foot by pressing the joint surface, the deformation of the main body caused by the foot pressing can be absorbed by the deformation of the inclined portion being almost flush with the joint surface. As a result, since it is easier to make the joint surface of the connector pressed into the non-ferrous metal material contact the surface of the other component, in addition to the effects of the fourth embodiment, the welding strength between the connector and the other component can also be improved.

[0022] According to the sixth embodiment of the connector, the main body includes a back surface, which is the side opposite to the joint surface, and extends from the foot towards the imaginary axis. The boundary between the inclined portion and the joint surface is located further away from the imaginary axis than the boundary between the back surface of the main body and the foot. Therefore, when pressing the joint surface to insert the connector into the non-ferrous metal material from the foot, the joint surface can be pressed at a position after the foot has been extended axially along the imaginary axis. As a result, in addition to the effects of the fifth embodiment, it is also possible to prevent the main body of the connector, which has been pressed into the non-ferrous metal material, from sinking into the inside of the foot.

[0023] According to the seventh embodiment of the joint, the foot is formed as a cylinder that surrounds the imaginary axis. Therefore, when the joint is pressed into the non-ferrous metal material from the foot, air may sometimes remain between the main body and the non-ferrous metal material on the inner side of the foot. However, since the through-holes opening at the joint surface, outer peripheral surface, or outer surface of the foot of the main body communicate with the inner side of the foot, it becomes difficult for air to remain between the main body and the non-ferrous metal material after pressing. Thus, when welding the joint to the mating surface of the opposing component, the heat transfer from the joint to the non-ferrous metal material is less hindered by air between the main body and the non-ferrous metal material. Consequently, the cooling of the joint during welding is stable, and the shape and size of the molten portion between the joint and the opposing component are stable. As a result, in addition to the effects of the fourth embodiment, the welding strength between the joint and the opposing component can be improved.

[0024] According to the eighth embodiment of the joint, the foot is formed as a cylinder that surrounds the imaginary axis, and the back side of the main body, which is the side opposite to the joint surface, extends from the foot towards the imaginary axis. Therefore, when the joint is pressed into the non-ferrous metal material from the foot, air may sometimes remain between the back side of the main body and the non-ferrous metal material on the inner side of the foot. However, since at least a portion of the back side of the main body is convex, air accumulates between the periphery of the convexity and the non-ferrous metal material, and the central portion of the convexity easily adheres to the non-ferrous metal material. Thus, when welding the joint to the mating component abutting the joint surface, heat can easily move from the joint to the non-ferrous metal material. Therefore, the cooling of the joint during welding is stable, and the shape and size of the molten portion between the joint and the mating component are stable. As a result, in addition to the effects of the fourth embodiment, the welding strength between the joint and the mating component can be improved.

[0025] According to the ninth embodiment of the connector, since the foot is cylindrical and surrounds the imaginary axis, the rigidity of the foot can be made approximately uniform in the circumferential direction while ensuring the rigidity of the foot in the axial direction of the imaginary axis. Therefore, when the connector is pressed into the non-ferrous metal material by pressing the mating surface, the foot is less likely to bend or break, and the foot can reliably engage with the non-ferrous metal material. Thus, in addition to the effects of any of the fourth to eighth embodiments, the bonding strength between the non-ferrous metal material and the connector can also be ensured. Attached Figure Description

[0026] Figure 1 This is a cross-sectional view of the connector and non-ferrous metal material in the first embodiment.

[0027] Figure 2 It is a cross-sectional view of a weldable metal body obtained by pressing a joint into a non-ferrous metal material.

[0028] Figure 3It is a cross-sectional view of the joint obtained by welding the other component to the welding metal body.

[0029] Figure 4A This is a cross-sectional view of the connector in the second embodiment.

[0030] Figure 4B This is a cross-sectional view of the joint.

[0031] Figure 5 This is a cross-sectional view of the joint in the third embodiment.

[0032] Figure 6 This is a cross-sectional view of the joint in the fourth embodiment.

[0033] Figure 7A This is a cross-sectional view of the connector in the fifth embodiment.

[0034] Figure 7B This is a cross-sectional view of the joint.

[0035] Figure 8A This is a cross-sectional view of the connector in the sixth embodiment.

[0036] Figure 8B This is a cross-sectional view of the joint.

[0037] Figure 9A This is a cross-sectional view of the connector in the seventh embodiment.

[0038] Figure 9B This is a cross-sectional view of the joint.

[0039] Figure 10 This is a cross-sectional view showing a modified example of the joint.

[0040] Explanation of reference numerals in the attached figures

[0041] 1, 40, 50, 60, 70, 90, 100 Joint; 2 Counterpart; 4 Melting part; 10, 30, 52, 62, 80, 92, 102, 110 Joint; 11, 31, 63, 81, 93 Main body; 12 Joint surface; 13, 103 Back side; 14 Parallel part; 15, 32 Inclined part; 16, 34, 83 Foot (hook part); 17, 35 Outer peripheral surface (outer surface); 20, 41, 51, 61, 71, 91, 101 Welding metal body; 21, 42 Non-ferrous metal material; 22 Surface (specified surface); 54 Foot; 55 First outer surface (part of outer surface); 56 Second outer surface (part of outer surface); 57, 65 Hook part; 82, 94, 111 Through hole; A Imaginary axis; B1, B2 Boundary. Detailed Implementation

[0042] Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings. First, referring to... Figure 1 The coupling 10 and the non-ferrous metal material 21 pressed into the coupling 10 will be described. Figure 1 This is a cross-sectional view of the connector 10 and the non-ferrous metal material 21. The connector 10 is used to join the non-ferrous metal material 21, which is made of different types of metals, and the other component 2 (see reference). Figure 3 The component 10 is formed by pressing non-ferrous metal material 21 into the other component 2 and then welding it to form a joint 1. See details below. Figure 3 To be described later.

[0043] The connector 10 is made of ferrous metal. In this embodiment, the connector 10 is formed of low-carbon steel. Low-carbon steel is steel with a carbon content of 0.4% by mass or less. Preferably, the carbon content of the low-carbon steel is 0.2% by mass or less. Examples of low-carbon steel include S15C steel and SS400 steel.

[0044] The connector 10 has a circular plate-shaped main body 11 and a cylindrical foot 16 protruding from the main body 11, which are integrally formed. The connector 10 is formed to be symmetrical about an imaginary axis A. Figure 1 The diagram shows a cross section including the imaginary axis A.

[0045] The main body 11 includes a mating surface 12, a back surface 13 opposite to the mating surface 12, and an outer peripheral surface connected to and surrounding the outer periphery of the mating surface 12. An imaginary axis A passes through the center of the circular mating surface 12, which is formed as a plane orthogonal to the imaginary axis A. The outer peripheral surface of the main body 11 surrounds the imaginary axis A. The back surface 13 is formed as a concave shape that is recessed toward the mating surface 12 as it moves toward the radial center (imaginary axis A).

[0046] The outer peripheral surface of the main body 11 is formed by a parallel portion 14 and an inclined portion 15. The parallel portion 14 is parallel to the imaginary axis A in a cross-section including the imaginary axis A, and the inclined portion 15 moves away from the imaginary axis A as it moves away from the mating surface 12. The inclined portion 15 is connected to the entire circumference of the outer peripheral edge of the mating surface 12. The parallel portion 14 is connected to the entire circumference of the end edge on the back side 13 side of the inclined portion 15.

[0047] The foot 16 is a portion that protrudes from the outer periphery of the back surface 13 of the main body 11 and is formed into a cylindrical shape centered on an imaginary axis A. The back surface 13 extends radially inward from the upper end of the foot 16 (towards the imaginary axis A). Because the foot 16 is cylindrical, the joint 10 can be easily formed by upsetting. Since the inner side of the foot 16 is hollow, even if the joint surface 12 is increased, the joint 10 can be made lighter compared to the case where the inner side of the foot 16 is filled. The outer peripheral surface 17 of the foot 16 is circumferentially connected to the parallel portion 14 (outer peripheral surface) of the main body 11. The outer peripheral surface 17 is parallel to the imaginary axis A in a cross section including the imaginary axis A and is formed as a straight line together with the parallel portion 14.

[0048] The inner circumferential surface of the foot 16 gradually widens towards the front end 19 of the foot 16, which is farther away from the main body 11. The inner circumferential surface of the foot 16 includes a front inner surface 18a and a base inner surface 18b. The front inner surface 18a is circumferentially connected to the annular front end 19, and the base inner surface 18b connects the entire circumference of the front inner surface 18a to the back surface 13 of the main body 11. In a cross-section including the imaginary axis A, the inclination angle of the front inner surface 18a relative to the imaginary axis A is greater than the inclination angle of the base inner surface 18b relative to the imaginary axis A.

[0049] It should be noted that, in the cross-section including the imaginary axis A, when the inner circumferential surface (base end inner surface 18b) of the foot 16 is connected to the back surface 13 by a curve, the position where the angle between the tangent of the curve and the imaginary axis A is 45 degrees is set as the boundary B1 between the foot 16 and the back surface 13 of the main body 11. The boundary B2 (outer periphery of the joint surface 12) between the inclined portion 15 and the joint surface 12 is located further away from the imaginary axis A than this boundary B1. That is, a portion of the joint surface 12 is located at the position after extending the foot 16 along the direction of the imaginary axis A.

[0050] The non-ferrous metal material 21 is a component made of non-ferrous metals such as aluminum, magnesium, zinc, or alloys thereof, which are particularly difficult to weld with ferrous metals. In this embodiment, the non-ferrous metal material 21 is a casting made of aluminum alloy, and the portion into which the connector 10 is pressed is formed in a plate shape. The non-ferrous metal material 21 includes a surface (prescribed surface) 22 into which the connector 10 is pressed and a back surface 23 on the side opposite to the surface 22 in the plate thickness direction. The thickness of the non-ferrous metal material 21 before the connector 10 is pressed in is formed to be approximately constant.

[0051] Reference Figure 1 and Figure 2 The process of pressing the joint 10 into the non-ferrous metal material 21 to form a welding metal body 20 will be described. Figure 2 This is a cross-sectional view of the welding metal body 20. Figure 2 In, with Figure 1Similarly, a cross-section including the imaginary axis A is shown. By... Figure 1 The shown joint 10 is pressed into the surface 22 of the non-ferrous metal material 21 to form Figure 2 The welding metal body 20 shown.

[0052] To press in the coupling 10, specifically, firstly, a non-ferrous metal material 21 is clamped using a forging die (not shown) that contacts the back surface 23 and a cylindrical clamp (material clamping member, not shown) that contacts the surface 22. Next, the coupling 10 is placed inside the clamp so that the parallel portion 14 and the outer peripheral surface 17 of the coupling 10 slide on the inner peripheral surface of the clamp, and the front end 19 of the foot 16 of the coupling 10 abuts against the surface 22.

[0053] In this state, surface 22 is a plane perpendicular to the imaginary axis A, and the fixture is cylindrical with the imaginary axis A as its center. By pressing the mating surface 12 with a punch (not shown) that slides within the fixture along the imaginary axis A, the joint 10 is pressed from the foot 16 into the non-ferrous metal material 21 without punching the non-ferrous metal material 21. The joint 10, including the mating surface 12, is partially exposed from the non-ferrous metal material 21, while the remaining portion of the joint 10 (the portion of the joint 10 other than the portion exposed from the non-ferrous metal material 21) is not exposed, thus forming a welding metal body 20.

[0054] It should be noted that, depending on the raw material of the non-ferrous metal material 21, the non-ferrous metal material 21 may sometimes crack when the fitting 10 is pressed into it. To reduce this cracking, the non-ferrous metal material 21 is generally subjected to heat treatment as a whole to change its metal structure and improve its ductility. In addition, even without heat treatment, cracking during pressing can be reduced by using raw materials that are less prone to cracking during pressing into the non-ferrous metal material 21.

[0055] Compared to these methods, in this embodiment, the portion of the non-ferrous metal material 21 into which the joint 10 is pressed is preheated before the joint 10 is pressed in, forming a high-ductility portion 21a. Therefore, even without heat treatment of the entire non-ferrous metal material 21, it is difficult for the non-ferrous metal material 21 to crack during the pressing of the joint 10. Figure 1 The part of the double-dotted line closer to the imaginary axis A is the high-ductility part 21a.

[0056] For example, to form the high-ductility portion 21a, firstly, with the front end 19 of the connector 10 abutting against the surface 22 of the non-ferrous metal material 21, electrodes 26 and 27 connected to the power supply 25 are connected to the connector 10 and the non-ferrous metal material 21, respectively. A current is applied between electrodes 26 and 27, generating a concentrated resistance near the front end 19. This concentrated resistance is used to resistively heat a portion of the non-ferrous metal material 21. By resistively heating to a temperature that softens a portion of the non-ferrous metal material 21, the high-ductility portion 21a is formed. By softening a portion of the non-ferrous metal material 21 held by a forging die and fixture to form the high-ductility portion 21a, and pressing the connector 10 into this high-ductility portion 21a, the high-ductility portion 21a is less prone to breakage.

[0057] It should be noted that, in addition to resistance heating, other methods for heating a portion of the non-ferrous metal material 21 include laser heating, electromagnetic induction heating, light heating using halogen light, and contact heating through contact with a high-temperature medium. Furthermore, the high-ductility portion 21a is not limited to areas that soften at high temperatures; it can also be a portion whose ductility is increased by changes in the metal structure resulting from heating and cooling. By heating the portion to be pressed into the joint 10 at an appropriate temperature according to the raw material of the non-ferrous metal material 21, or by cooling after heating, the degree of freedom in selecting the raw material of the non-ferrous metal material 21 can be increased.

[0058] like Figure 2 As shown, in the welding metal body 20, the joint 10 is pressed into the non-ferrous metal material 21 such that the joint surface 12 becomes flush with the surface 22. It should be noted that, in this specification, "the joint surface 12 is flush with the surface 22" means that the protrusion of the joint surface 12 from the surface 22 is within 1 mm.

[0059] In the welding metal body 20, the back surface 23 of the non-ferrous metal material 21 at the location where the joint 10 is pressed in is raised relative to the surrounding area, and a cover portion 24 is formed on the non-ferrous metal material 21 through this raised portion. A recess with a diameter larger than the outer diameter of the joint 10 is formed on the forging die, and the non-ferrous metal material 21 that is ejected due to the pressing of the joint 10 fills the recess, thereby forming the cover portion 24. The cover portion 24 covers the back surface 13 and foot portion 16 of the joint 10 in such a way that a portion of the joint 10, including the joint surface 12, is exposed from the surface 22 of the non-ferrous metal material 21, while the remaining portion of the joint 10 is not exposed from the back surface 23 of the non-ferrous metal material 21. The back surface 23 at the cover portion 24 is a plane perpendicular to the imaginary axis A, that is, a plane parallel to the joint surface 12 and the surface 22.

[0060] because Figure 1The inner surface 18a at the front end and the inner surface 18b at the base end of the foot 16, before being pressed in, gradually widen in diameter towards the front end 19. Therefore, when the fitting 10 is pressed in, a radially outward force is applied from the non-ferrous metal material 21 towards the foot 16. For this purpose, in Figure 2 In the welding metal body 20 shown, the foot 16, which is filled with non-ferrous metal material 21, undergoes plastic deformation such that its outer peripheral surface 17 bends (inclins) radially outward as it moves toward the front end 19. Since a hook portion is formed through this foot 16, and this hook portion includes an outer peripheral surface 17 facing the surface 22 of the non-ferrous metal material 21, it is possible to prevent the joint 10 from detaching from the non-ferrous metal material 21. It should be noted that the outer peripheral surface 17 facing the surface 22 at the hook portion only needs to be slightly oriented toward the surface 22, so that it hooks onto the non-ferrous metal material 21 when the joint 10 is to be pulled out from the surface 22 side of the non-ferrous metal material 21. For example, in a cross-section including the imaginary axis A, even if the inclination angle of the outer peripheral surface 17 relative to the imaginary axis A is about 1°, it can be said that the outer peripheral surface 17 is oriented toward the surface 22.

[0061] Furthermore, in the cross-section including the imaginary axis A, the inclination angle of the front inner surface 18a relative to the imaginary axis A is larger than the inclination angle of the base inner surface 18b relative to the imaginary axis A. Therefore, while ensuring the wall thickness of the foot 16 at the base inner surface 18b to ensure the rigidity of the foot 16, the front end 19 of the foot 16, which tapers towards the tip from the front inner surface 18a, can easily engage with the non-ferrous metal material 21. Moreover, since the foot 16 is cylindrical surrounding the imaginary axis A, the rigidity of the foot 16 can be made approximately uniform in the circumferential direction, while ensuring the rigidity of the foot 16 in the direction of the imaginary axis A. Thus, when the joint 10 is pressed into the non-ferrous metal material 21 from the foot 16 by pressing the joint surface 12, the foot 16 is less likely to bend or break, and the foot 16 can reliably engage with the non-ferrous metal material 21. As a result, the bonding strength between the non-ferrous metal material 21 and the joint 10 can be ensured.

[0062] It should be noted that, according to JIS Z 2244:2009 (ISO 6507-1 and ISO 6507-4), the Vickers hardness of the raw material for the joint 10 is set to 310–370 HV10, which is optimal for pressing into the non-ferrous metal material 21 made of aluminum alloy. If the Vickers hardness of the joint 10 is within this range, the foot 16 can be engaged into the non-ferrous metal material 21 of the aluminum alloy casting without buckling, and the foot 16 can be sufficiently plastically deformed radially outward within the non-ferrous metal material 21 during pressing.

[0063] The space inside the foot 16 of the connector 10 is almost entirely filled with non-ferrous metal material 21. As a result, the foot 16, which has undergone plastic deformation in the radially outward direction, becomes difficult to deform in the radially inward direction and recover. Therefore, the bonding strength between the non-ferrous metal material 21 and the connector 10 provided by the radially outward-extending foot 16 can be ensured.

[0064] Figure 1 The outer peripheral surface of the main body 11 of the pre-press-in connector 10 is formed by a parallel portion 14 and an inclined portion 15, without an inclined surface that faces the imaginary axis A away from the joint surface 12. Furthermore, a foot 16, including an outer peripheral surface 17 connected to the outer peripheral surface (parallel portion 14) of the main body 11, protrudes from the back surface 13 of the main body 11. As a result, compared to the case where the flange extending outward from the outer peripheral surface 17 of the foot 16 is located in the main body 11, the connector 10 can be easily pressed into the surface 22 of the non-ferrous metal material 21 up to the main body 11.

[0065] When the mating surface 12 is pressed to insert the connector 10 into the non-ferrous metal material 21 from the foot 16, a reaction force from the foot 16 along the imaginary axis A is applied to the main body 11. As a result, the outer periphery of the mating surface 12, pressed by the foot 16, tends to bulge between the drill punch and the clamp. However, the outer periphery of the main body 11 at the location where the outer periphery surface 17 of the foot 16 connects includes an inclined portion 15 connected to the outer periphery of the mating surface 12. Thus, the deformation of the main body 11 caused by the foot 16 pressing can be absorbed by the deformation of the inclined portion 15, which is nearly flush with the mating surface 12. Consequently, the mating surface 12 of the connector 10, pressed into the non-ferrous metal material 21, can be kept planar. In particular, even if the joint 10 is made of a relatively soft raw material of 310 to 370 HV10, the joint surface 12 of the joint 10 pressed into the non-ferrous metal material 21 can be kept flat by using the inclined portion 15. It should be noted that the inclined portion 15, which becomes flush with the joint surface 12, becomes part of the joint surface 12.

[0066] The boundary B2 (outer periphery of the joint surface 12) between the inclined portion 15 and the joint surface 12 is located further away from the imaginary axis A than the boundary B1 between the foot portion 16 and the back surface 13 of the main body portion 11. Therefore, when pressing the joint surface 12 to press the joint member 10 into the non-ferrous metal material 21 from the foot portion 16, the joint surface 12 can be pressed at a position extending the foot portion 16 along the imaginary axis A. As a result, the main body portion 11 of the joint member 10, pressed into the non-ferrous metal material 21, is less likely to sink into the inside of the foot portion 16.

[0067] Below, refer to Figure 3 The joint 1, in which the opposing component 2 is joined to the metal body 20 for welding, will be described. Figure 3 This is a cross-sectional view of joint 1. Figure 3 In, with Figure 1 , 2 Similarly, a cross-section including the imaginary axis A is shown. The opposing component 2 is a component made of ferrous metal, and the portion welded to the welding metal body 20 is formed in a plate shape.

[0068] To form the joint 1, firstly, a rust-preventive sealant (not shown) is applied to the surface 22 of the non-ferrous metal material 21 that overlaps with the counterpart component 2 and the mating surface 12 of the joint 10. This sealant is used to reduce galvanic corrosion between the joint 10 and the non-ferrous metal material 21, and between the non-ferrous metal material 21 and the counterpart component 2.

[0069] Next, the surface 22 of the non-ferrous metal material 21 is overlapped with the surface 22 of the other component 2. By spot welding the exposed joint 10 to the other component 2, a molten portion 4 is formed between the joint 10 and the other component 2, which are made of the same metal. In this way, a joint body 1 is formed by joining the non-ferrous metal material 21 and the other component 2 through the joint 10.

[0070] In this embodiment, direct resistance spot welding is used to weld the counterpart component 2 and the joint 10. In this direct resistance spot welding, current flows between a pair of electrodes 28 and 29 that sandwich the welding metal body 20 and the counterpart component 2 on both sides from the imaginary axis A of the joint surface 12. The tip of the electrode 28, which abuts against the counterpart component 2, is formed to be flat. Therefore, it is difficult for indentations created by the electrode 28 to remain on the counterpart component 2.

[0071] Since the back surface 23 of the cover portion 24 against which the electrode 29 rests is a plane perpendicular to the imaginary axis A, it is easy to control the pressure generated by the electrode 29 and the grounding area between the electrode 29 and the back surface 23. Since the cover portion 24 in the back surface 23 is raised relative to the surrounding parts, the cover portion 24 serves as an indicator of the position where the electrode 29 rests.

[0072] The front end of the electrode 29, which rests against the back surface 23 of the cover portion 24, is formed in a dome shape. Since the electrode 29 can press the portion inside the foot 16 of the non-ferrous metal material 21, the non-ferrous metal material 21 can be easily brought into close contact with the back surface 13 of the main body portion 11 of the connector 10. As a result, power can be easily supplied to the connector 10 from the electrode 29 through the non-ferrous metal material 21, thus stabilizing the resistance spot welding.

[0073] It should be noted that the joint 10 and the counterpart component 2 can also be welded by indirect, series, or parallel resistance spot welding. Alternatively, laser welding, arc welding, or gas welding can also be used to weld the joint 10 and the counterpart component 2. A protrusion can also be provided on a portion of the mating surface 12, or a protrusion can be provided on the counterpart component 2 to abut against the mating surface 12, for projection welding of the joint 10 and the counterpart component 2.

[0074] According to the joint 1 described above, the opposing component 2 is welded onto a portion of the joint 10 exposed from the surface 22 of the non-ferrous metal material 21, while the remaining portion of the joint 10 is not exposed from the non-ferrous metal material 21 and is embedded within the non-ferrous metal material 21. This reduces galvanic corrosion between the non-ferrous metal material 21 and the joint 10. Therefore, it is possible to suppress the increase in work steps and costs resulting from countermeasures against galvanic corrosion on the back surface 23 side of the non-ferrous metal material 21.

[0075] As described above, since the bulge of a portion of the mating surface 12 can be reduced by the inclined portion 15 connected to the outer periphery of the mating surface 12, the mating surface 12 can be easily brought into contact with the surface of the counterpart component 2. As a result, the welding strength between the joint 10 and the counterpart component 2 can be improved. Furthermore, since the mating surface 12 is approximately flush with the surface 22 of the non-ferrous metal material 21, when welding the counterpart component 2 and the joint 10 overlapping the mating surface 12, almost no gap is generated between the surface 22 of the non-ferrous metal material 21 and the counterpart component 2. Since the joint 10 is less susceptible to corrosion due to moisture or the like entering through the gap, the durability of the joint 10 can be improved. As a result, the bonding strength of the joint between the counterpart component 2 and the non-ferrous metal material 21 via the joint 10 can be improved. Furthermore, by applying a sealant between the surface 22 of the non-ferrous metal material 21 and the counterpart component 2, moisture is less likely to enter the joint 10 side from between them, making the joint 10 more resistant to corrosion.

[0076] The thickness T1 of the joint 10 in the region forming the molten portion 4 is preferably 0.8 to 2 times the thickness T2 of the counterpart component 2 in that region. It should be noted that the thicknesses T1 and T2 of each part in the region forming the molten portion 4 represent the thicknesses of each part before the formation of the molten portion 4. In particular, since the molten portion 4 tends to be largest in the central portion, at the central portion of the region forming the molten portion 4, the thickness T1 of the joint 10 is preferably 0.8 to 2 times the thickness T2 of the counterpart component 2. Figure 3 In the diagram, the contact surface between the joint 10 and the counterpart component 2 before the molten part 4 is formed is represented by a double-dotted line, and the surface of the counterpart component 2 before the indentation generated by the electrode 28 is represented by a dashed line.

[0077] If the thickness T1 is more than 0.8 times the thickness T2, the position and size of the molten portion 4 formed between the joint 10 and the counterpart component 2 can be appropriately adjusted, making it difficult for the molten portion 4 to reach the non-ferrous metal material 21. This ensures the strength of the joint 10 and the bonding strength between the joint 10 and the non-ferrous metal material 21. Furthermore, if the thickness T1 is less than twice the thickness T2, the force required to press the joint 10 into the non-ferrous metal material 21 until the joint surface 12 of the joint 10 and the surface 22 of the non-ferrous metal material 21 become approximately flush can be reduced, and the joint 10 can be made lighter.

[0078] Since the joint 10 is formed of low-carbon steel with a carbon content of less than 0.4% by mass, as described above, it is possible to avoid the joint 10 becoming too hard and brittle due to the heat effect generated during welding of the other component 2 and the joint 10. If the carbon content of the low-carbon steel is less than 0.2% by mass, the hardening of the joint 10 caused by the heat effect of welding can be sufficiently suppressed. As a result, since the weld cracks and reduction in toughness of the joint 10 caused by hardening during welding can be suppressed, the bonding strength of the joint 10 connecting the other component 2 and the non-ferrous metal material 21 can be ensured.

[0079] Below, refer to Figure 4A and Figure 4B The second embodiment will be described. In the first embodiment, the outer peripheral surface of the main body 11 of the connector 10 is formed by a parallel portion 14 and an inclined portion 15, and the outer peripheral surface 17 of the foot 16 is along the imaginary axis A. In contrast, in the second embodiment, the outer peripheral surface of the main body 31 of the connector 30 is formed by an inclined portion 32, and the outer peripheral surface 17 of the foot 34 is inclined relative to the imaginary axis A. It should be noted that the same reference numerals are used for parts that are the same as in the first embodiment, and the description is omitted below.

[0080] Figure 4A This is a cross-sectional view of the connector 30 in the second embodiment. Figure 4B This is a cross-sectional view of the joint 40 obtained by joining the other component 2 and the non-ferrous metal material 42 through the coupling member 30. It should be noted that... Figure 4B In the text, the components of electrodes 28 and 29 (see reference) are omitted. Figure 3 The diagram shows the indentation produced.

[0081] like Figure 4A As shown, the connector 30 has a circular plate-shaped main body 31 and a cylindrical foot 34 protruding from the main body 31, both integrally formed from low-carbon steel with a carbon content of less than 0.4% by mass. The connector 30 is formed to be symmetrical about an imaginary axis A. Figure 4A and Figure 4B The diagram shows a cross section including the imaginary axis A.

[0082] The main body 31 includes a mating surface 12, a back surface 13 opposite to the mating surface 12, and an outer peripheral surface connected to and surrounding the outer periphery of the mating surface 12. The outer peripheral surface of the main body 31 is formed by an inclined portion 32 that moves away from the imaginary axis A as it moves away from the mating surface 12. The inclined portion 32 is connected to the entire circumference of the outer periphery of the mating surface 12.

[0083] The foot 34 is a cylindrical portion protruding from the outer periphery of the back surface 13 of the main body 31. The outer peripheral surface 35 of the foot 34 is circumferentially connected to the inclined portion 32 of the main body 31. The outer peripheral surface 35 and the inner peripheral surface 36 of the foot 34 are surfaces that move away from the imaginary axis A as they move away from the joint surface 12, and gradually increase in diameter as they move towards the front end 37 of the foot 34, which is away from the main body 31. The wall thickness of the foot 34 decreases as it moves towards the front end 37. In a cross-section including the imaginary axis A, the outer peripheral surface 35 is formed as a straight line together with the inclined portion 32.

[0084] like Figure 4B As shown, a welding metal body 41 is formed by pressing the connector 30 into the non-ferrous metal material 42, and a molten portion 4 is formed between the connector 30 welded to the welding metal body 41 and the counterpart component 2 to manufacture the joint body 40. The non-ferrous metal material 42 is thicker than the non-ferrous metal material 21 in the first embodiment, except for this, its structure is the same as that of the non-ferrous metal material 21. The thickness of the non-ferrous metal material 42 is more than twice the dimension in the direction of the imaginary axis A from the joint surface 12 of the connector 30 to the front end 37. Therefore, even when the connector 30 is pressed into the non-ferrous metal material 42, the back surface 23 of the non-ferrous metal material 42 hardly bulges.

[0085] because Figure 4A The inner circumferential surface 36 of the foot 34, before being pressed in, gradually widens towards the front end 37, so that when the fitting 30 is pressed in, a radially outward force is applied from the non-ferrous metal material 42 toward the foot 34. Therefore, in Figure 4B In the welding metal body 41 shown, the foot 34, which is filled with non-ferrous metal material 42, undergoes plastic deformation by bending radially outward toward the front end 37. Since a hook portion is formed through the foot 34, and the hook portion includes an outer peripheral surface 35 facing the surface 22 of the non-ferrous metal material 42, it is possible to prevent the joint 30 from falling off the non-ferrous metal material 42.

[0086] Before being pressed in, the outer peripheral surface 35 of the foot 34 gradually widens towards the front end 37, and the connector 30 is pressed into the non-ferrous metal material 42 from its foot 34. At this time, by widening the outer peripheral surface 35, the component of the imaginary axis A in the reaction force of the foot 34 from the non-ferrous metal material 42 that is intended to help the joint surface 12 of the main body 31 to bulge can be reduced. As a result, the joint surface 12 can be easily kept flat.

[0087] Below, refer to Figure 5 The third embodiment will be described. In the first embodiment, the coupling body 1 with the hook portion was described, whereby the foot 16 undergoes plastic deformation as the coupling member 10 is pressed into the non-ferrous metal material 21, thereby forming the hook portion including the surface 22 facing the non-ferrous metal material 21. In contrast, in the third embodiment, the coupling body 50 obtained by joining the opposing member 2 and the non-ferrous metal material 42 by pressing in the coupling member 52, where the foot 54 undergoes almost no plastic deformation, will be described. It should be noted that the same reference numerals are used for parts that are the same as in the first and second embodiments, and the description is omitted below.

[0088] Figure 5 This is a cross-sectional view of the joint 50 in the third embodiment. Figure 5 In the text, the components of electrodes 28 and 29 (see reference) are omitted. Figure 3 The diagram shows the indentation produced. The joint 50 includes a mating part 2 and a welding metal body 51 obtained by pressing the joint 52 into a non-ferrous metal material 42. The joint 50 is manufactured by welding the mating part 2 onto the joint 52 of the welding metal body 51 to form a molten portion 4.

[0089] The connector 52 has a circular plate-shaped main body 11 and a cylindrical foot 54 protruding from the outer periphery of the back side 13 of the main body 11, both integrally formed from low-carbon steel with a carbon content of less than 0.4% by mass. The connector 52 is formed to be symmetrical about an imaginary axis A. Figure 5 The diagram shows a cross section including the imaginary axis A.

[0090] The inner circumferential surface 58 of the foot 54 is formed parallel to the imaginary axis A in a cross-section including the imaginary axis A, extending from the back surface 13 to the front end 59 of the foot. Therefore, when the connector 52 is pressed into the non-ferrous metal material 42, the foot 54 is less likely to expand radially outward. Since plastic deformation of the foot 54 is difficult to occur before and after pressing, the shearing of microscopic metallic structures caused by plastic deformation can be suppressed, ensuring the durability of the foot 54.

[0091] The outer surface of the foot 54 includes a first outer surface 55 and a second outer surface 56. The first outer surface 55 is circumferentially connected to the parallel portion 14 of the main body 11, and the second outer surface 56 is circumferentially connected to the front end 59 of the foot 54. The first outer surface 55 is formed parallel to the imaginary axis A in a cross-section including the imaginary axis A. The second outer surface 56 gradually expands in diameter as it moves away from the front end 59 away from the imaginary axis A. The first outer surface 55 and the second outer surface 56 are connected by a stepped surface that extends vertically from the end edge of the first outer surface 55 on the front end 59 side. The portion including this stepped surface is a hook portion 57.

[0092] When the joint 52 is pressed into the non-ferrous metal material 42, the second outer surface 56 receives a reaction force from the non-ferrous metal material 42 toward the radially inward side of the cylindrical foot 54. This makes it more difficult for the foot 54 to undergo plastic deformation before and after pressing, thus ensuring the durability of the foot 54. Furthermore, since the foot 54 has a hook portion 57, and this hook portion 57 includes a surface facing the non-ferrous metal material 42, it makes it difficult for the joint 52 to detach from the non-ferrous metal material 42.

[0093] Below, refer to Figure 6 The fourth embodiment will be described. In the first embodiment, the coupling body 1, which uses a foot 16 protruding from the outer periphery of the back surface 13 of the main body 11, was described. In contrast, in the fourth embodiment, the coupling body 60, which uses a footless coupling member 62, will be described. It should be noted that the same reference numerals are used for parts that are the same as in the first and second embodiments, and the descriptions are omitted below.

[0094] Figure 6 This is a cross-sectional view of the joint 60 in the fourth embodiment. Figure 6 In the text, the components of electrodes 28 and 29 (see reference) are omitted. Figure 3 The diagram shows the indentation produced. The joint 60 includes a mating part 2 and a welding metal body 61 obtained by pressing the joint 62 into a non-ferrous metal material 42. The joint 60 is manufactured by welding the mating part 2 onto the joint 62 of the welding metal body 61 to form a molten portion 4.

[0095] The connector 62 has a cylindrical main body 63 and a plurality of hook portions 65 protruding from a parallel portion 14 that serves as the outer peripheral surface of the main body 63. These portions are integrally formed from low-carbon steel with a carbon content of less than 0.4% by mass. The connector 62 is formed to be symmetrical about an imaginary axis A that is orthogonal to the engagement surface 12 of the main body 63. Figure 6 The diagram shows a cross section including the imaginary axis A.

[0096] The main body portion 63 is thicker than the main body portion 11 in the first embodiment, except that it is constructed the same as the main body portion 11. It should be noted that... Figure 6 The inclined portion 15 at the corner of the joint surface 12 and the outer peripheral surface of the main body 63 is shown (see reference). Figure 1 As the joint 62 is pressed into the non-ferrous metal material 42, it deforms and becomes flush with the joint surface 12.

[0097] The hook portion 65 is formed in the portion of the connector 62 that is filled with the non-ferrous metal material 42. When the connector 62 is filled with the non-ferrous metal material 42, the hook portion 65 includes a surface facing the surface 22 of the non-ferrous metal material 42, which makes it difficult for the connector 62 to fall off the non-ferrous metal material 42.

[0098] Compared to the connectors 10, 30, and 52 with feet 16, 34, and 54 in the first to third embodiments, connector 62 has a simple shape such as a cylinder. Therefore, connector 62 can be easily manufactured. Furthermore, connector 62 does not require a design that takes into account the bending of the feet.

[0099] Below, refer to Figure 7A and Figure 7B The fifth embodiment will now be described. In the first embodiment, the case where the main body 11 of the connector 10 is in the shape of a circular plate was described. In contrast, in the fifth embodiment, the case where a through hole 82 is formed in the radial center of the main body 81 of the connector 80, making the main body 81 in the shape of an annular plate, will be described. It should be noted that the same reference numerals are used for parts that are the same as in the first embodiment, and the description is omitted below. Figure 7A This is a cross-sectional view of the connector 80 in the fifth embodiment. Figure 7B This is a cross-sectional view of the joint 70. Figure 7B In the text, the components of electrodes 28 and 29 (see reference) are omitted. Figure 3 The diagram shows the indentation produced.

[0100] like Figure 7A As shown, the connector 80 has an annular plate-shaped main body 81 and a cylindrical foot 83. The main body 81 has a through hole 82 formed in the radial center, and the foot 83 protrudes from the main body 81. They are integrally formed from low-carbon steel with a carbon content of less than 0.4% by mass. The connector 80 is formed to be symmetrical about an imaginary axis A. Figure 7A and Figure 7B The diagram shows a cross-section including the imaginary axis A. Additionally, in... Figure 7A and Figure 7B In the middle, the boundary 87 between the main body 81 and the foot 83 is represented by a double-dotted line.

[0101] The main body 81 includes a mating surface 12 and a parallel portion 14 that is connected to the outer periphery of the mating surface 12 and surrounds the imaginary axis A. A through hole 82 opens in the mating surface 12 and communicates with the inner side (imaginary axis A side) of the foot portion 83.

[0102] The foot 83 is a cylindrical portion protruding from the side of the main body 81 opposite to the mating surface 12. The outer peripheral surface 17 of the foot 83 is circumferentially connected to the parallel portion 14 of the main body 81. The inner peripheral surface of the foot 83 facing the imaginary axis A gradually widens towards the front end 19 of the foot 83, which is away from the main body 81. The inner peripheral surface of the foot 83 includes: a first inner surface 84 that is circumferentially connected to the annular front end 19; a second inner surface 85 that extends circumferentially from the first inner surface 84 toward the main body 81; and a third inner surface 86 that connects the circumference of the second inner surface 85 to the circumference of the inner wall surface of the through hole 82 of the main body 81.

[0103] like Figure 7B As shown, a welding metal body 71 is formed by pressing the joint 80 into a non-ferrous metal material 21, and a molten portion 4 is formed between the joint 80 welded to the welding metal body 71 and the counterpart component 2, thereby manufacturing the joint 70. Because Figure 7A The first inner surface 84, the second inner surface 85, and the third inner surface 86 of the foot 83 before pressing in gradually increase in diameter towards the front end 19, so that a radially outward force is applied from the non-ferrous metal material 21 towards the foot 83 when the fitting 80 is pressed in. Therefore, in Figure 7B In the welding metal body 71 shown, the foot 83, which is filled with non-ferrous metal material 21, undergoes plastic deformation such that its outer peripheral surface 17 bends radially outward toward the front end 19. Since a hook portion is formed through this foot 83, and this hook portion includes the outer peripheral surface 17 facing the surface 22 of the non-ferrous metal material 21, it is possible to make the joint 80 difficult to detach from the non-ferrous metal material 21.

[0104] about Figure 7AThe foot 83 shown before pressing, in a cross-section including the imaginary axis A, has an inclination angle relative to the imaginary axis A that increases in the order of the second inner surface 85, the third inner surface 86, and the first inner surface 84. Furthermore, the axial dimension of the third inner surface 86 is greater than the sum of the axial dimensions of the first inner surface 84 and the second inner surface 85. Thus, since the axial dimension of the portion of the foot 83 with increased wall thickness is ensured by the third inner surface 86, the foot 83 is less likely to bend during pressing. Additionally, the tip 19 of the foot 83, which tapers towards the tip from the first inner surface 84, can easily engage with the non-ferrous metal material 21. Furthermore, due to the inclination angle, the foot 83 at the second inner surface 85 is more likely to bend radially outward relative to the foot 83 at the third inner surface 86, making it less likely for the foot 83 to detach from the non-ferrous metal material 21.

[0105] Since the foot 83 is formed as a cylinder that completely surrounds the imaginary axis A, when the connector 80 is pressed into the non-ferrous metal material 21 from the foot 83, if there is no through hole 82 on the main body 81, air may sometimes remain between the main body 81 and the non-ferrous metal material 21 on the inner side of the foot 83. It should be noted that even without the through hole 82, if the connector 80 is pressed into the non-ferrous metal material 21 in a vacuum, no air can remain between the main body 81 and the non-ferrous metal material 21 after pressing.

[0106] In this embodiment, since the through hole 82 opening at the joint surface 12 communicates with the inside of the foot 83, even if the joint 80 is not pressed into the non-ferrous metal material 21 in a vacuum, it becomes difficult for air to remain between the main body 81 and the non-ferrous metal material 21 after pressing. Therefore, when welding the opposing component 2 against the joint surface 12 and the joint 80, the thermal movement from the joint 80 to the non-ferrous metal material 21 is less likely to be hindered by air between the main body 81 and the non-ferrous metal material 21. Consequently, the cooling of the joint 80 during welding is stable, and the shape and size of the molten portion 4 between the joint 80 and the opposing component 2 are stable. As a result, the welding strength between the joint 80 and the opposing component 2 can be improved.

[0107] Since the inner wall of the through hole 82 is circumferentially connected to the third inner surface 86 of the foot 83, when the connector 80 is pressed into the non-ferrous metal material 21, the main body 81 around the through hole 82 becomes difficult to be pressed by the non-ferrous metal material 21 inside the foot 83, making it difficult for a portion of the mating surface 12 to bulge. As a result, the mating surface 12 of the connector 80, which has been pressed into the non-ferrous metal material 21, can easily come into contact with the surface of the other component 2, thus improving the welding strength between the connector 80 and the other component 2.

[0108] The inner wall surface of the through hole 82 is parallel to the imaginary axis A in the cross-section including the imaginary axis A. Therefore, when the joint 80 is pressed into the non-ferrous metal material 21 by pressing the joint surface 12 with a punch or the like, the axial force of the imaginary axis A applied from the foot 83 through the main body 81 to the punch or the like can be made nearly uniform throughout the entire joint surface 12. As a result, the joint 80 is less likely to bend during pressing. Furthermore, since the inner wall surface of the through hole 82, which is parallel to the imaginary axis A, is less likely to experience the axial force of the imaginary axis A from the non-ferrous metal material 21, a portion of the joint surface 12 becomes less prone to bulging.

[0109] Below, refer to Figure 8A and Figure 8B The sixth embodiment will be described. In the fifth embodiment, the case where the inner wall surface of the through hole 82 is parallel to the imaginary axis A in a cross-section including the imaginary axis A was described. In contrast, in the sixth embodiment, the case where the inner wall surface of the through hole 94 is inclined towards the imaginary axis A in a cross-section including the imaginary axis A as it moves toward the foot 83 will be described. It should be noted that the same reference numerals are used for parts that are the same as in the first and fifth embodiments, and the descriptions are omitted below. Figure 8A This is a cross-sectional view of the connector 92 in the sixth embodiment. Figure 8B This is a cross-sectional view of the joint at 90°. Figure 8B In the text, the components of electrodes 28 and 29 (see reference) are omitted. Figure 3 The diagram shows the indentation produced.

[0110] like Figure 8A As shown, the connector 92 has an annular plate-shaped main body 93 and a cylindrical foot 83. The main body 93 has a through hole 94 formed in the radial center, and the foot 83 protrudes from the main body 93. They are integrally formed from low-carbon steel with a carbon content of less than 0.4% by mass. The connector 92 is formed to be symmetrical about an imaginary axis A. Figure 8A and Figure 8B The diagram shows a cross-section including the imaginary axis A. Additionally, in... Figure 8A and Figure 8B In the middle, the boundary 95 between the main body 93 and the foot 83 is represented by a double-dotted line.

[0111] The main body 93 includes a mating surface 12, an inclined portion 15 connected to the outer periphery of the mating surface 12, and a parallel portion 14 connecting the inclined portion 15 to the outer peripheral surface 17 of the foot 83. A through hole 94 opens in the mating surface 12 and communicates with the inner side (imaginary axis A side) of the foot 83.

[0112] The inner wall surface of the through hole 94 is not parallel to the imaginary axis A in the cross-section including the foot 83, but slopes towards the imaginary axis A. The lower end of the inner wall surface of the through hole 94 is circumferentially connected to the third inner surface 86 of the foot 83. The upper end of the inner wall surface of the through hole 94 is connected to the outer periphery of the mating surface 12. As a result, the mating surface 12 with the through hole 94 retains a linear portion formed by the outer periphery.

[0113] like Figure 8B As shown, a welding metal body 91 is formed by pressing the connector 92 into the non-ferrous metal material 21, and a molten portion 4 is formed between the connector 92 welded to the welding metal body 91 and the counterpart component 2 to manufacture a joint body 90. Similar to the fifth embodiment, since the foot portion 83, which is filled with the non-ferrous metal material 21, forms a hook portion, it is difficult for the connector 92 to detach from the non-ferrous metal material 21. Furthermore, through the through hole 94 formed in the main body portion 93, air is less likely to remain between the main body portion 93 and the non-ferrous metal material 21 after pressing.

[0114] When the joint 92 is pressed into the non-ferrous metal material 21, the linear residue near the joint surface 12 formed by the through hole 94 is flattened, and the width of the joint surface 12 is slightly enlarged. Nevertheless, the width of the joint surface 12 is narrow enough that, during spot welding, as with projection welding, the current is concentrated on the narrow joint surface 12 in contact with the counterpart component 2. As a result, during welding, the radial heating center is stable, and the heat generation is nearly uniform throughout the circumferential direction. Consequently, since the molten portion 4 between the joint 92 and the counterpart component 2 can be homogenized throughout the circumferential direction, the bonding strength between the joint 92 and the counterpart component 2 can be improved.

[0115] Below, refer to Figure 9A and Figure 9B The seventh embodiment will now be described. In the first embodiment, the case where the back surface 13 of the main body 11 is concave was described. In contrast, in the seventh embodiment, the case where the back surface 103 of the main body 11 is convex will be described. It should be noted that the same reference numerals are used for parts that are the same as in the first embodiment, and the description will be omitted below. Figure 9A This is a cross-sectional view of the connector 102 in the seventh embodiment. Figure 9B This is a cross-sectional view of the joint 100. Figure 9B In the text, the components of electrodes 28 and 29 (see reference) are omitted. Figure 3 The diagram shows the indentation produced.

[0116] like Figure 9AAs shown, the back surface 103 of the main body portion 11 of the connector 102 is formed as a convex shape that bulges toward the side opposite to the joint surface 12 as it moves toward the radial center (imaginary axis A). Except for the shape of the back surface 103, the connector 102 is constructed in the same way as the connector 10 in the first embodiment.

[0117] like Figure 9B As shown, a welding metal body 101 is formed by pressing the connector 102 into the non-ferrous metal material 21, and a molten portion 4 is formed between the connector 102 welded to the welding metal body 101 and the counterpart component 2 to manufacture a joint body 100. Since the foot 16 is formed into a cylindrical shape that surrounds the imaginary axis A, after pressing the connector 102 into the non-ferrous metal material 21, air may sometimes remain between the back surface 103 of the main body 11 on the inner side of the foot 16 and the non-ferrous metal material 21.

[0118] However, since the back surface 103 is convex, air accumulates between the periphery of the convexity (the side of the foot 16) and the non-ferrous metal material 21, and the central portion of the convexity (the radial center of the back surface 103) easily adheres to the non-ferrous metal material 21. Therefore, when welding the opposing component 2 and the joint 102 against the joint surface 12, heat can easily move from the joint 102 to the non-ferrous metal material 21. Consequently, the cooling of the joint 102 during welding is stable, and the shape and size of the molten portion 4 between the joint 102 and the opposing component 2 are stable. As a result, the welding strength between the joint 102 and the opposing component 2 can be improved.

[0119] Furthermore, in the joint 102, since the through holes 82 and 94 are not opened on the joint surface 12 as in the fifth and sixth embodiments, the molten portion 4 is more easily increased compared to the case where the through holes 82 and 94 are present. As a result, the welding strength between the joint 102 and the other component 2 can be improved.

[0120] Preferably, the convex shape of the back surface 103 and the welding conditions are set such that the molten portion 4 is located radially inward than the periphery of the contact portion between the back surface 103 of the joint 102 and the non-ferrous metal material 21. This allows the heat from the portion where the molten portion 4 is to be formed (the radially central portion of the joint 102) generates the most heat during welding of the joint 102 and the counterpart component 2 to easily move towards the non-ferrous metal material 21. As a result, the cooling of the joint 102 during welding is more stable, and the shape and size of the molten portion 4 between the joint 102 and the counterpart component 2 are more stable.

[0121] The present invention has been described above based on embodiments, but it is not limited to the above-described manner. It is readily understood that various modifications and variations can be made without departing from the spirit of the invention. For example, it is not limited to the case where the portion of the counterpart component 2 that is welded to the connecting parts 10, 30, 52, 62, 80, 92, 102 is plate-shaped. If it can be welded to the connecting parts 10, 30, 52, 62, 80, 92, 102, the shape of the counterpart component 2 can be freely set. Furthermore, it is not limited to the case where the portion of the non-ferrous metal materials 21, 42 that is pressed into the connecting parts 10, 30, 52, 62, 80, 92, 102 is plate-shaped. If the forming of the connecting bodies 1, 40, 50, 60, 70, 90, 100 includes a predetermined surface facing the counterpart component 2, the shape of the non-ferrous metal materials 21, 42 can be freely set. Alternatively, the joints 10, 30, 52, 62, 80, 92, and 102 can be pressed into two or more overlapping non-ferrous metal materials to obtain the portion.

[0122] In the above description, the case where the joint 10 is formed from a raw material having a Vickers hardness suitable for pressing into an aluminum alloy non-ferrous metal material 21 has been explained. However, the Vickers hardness of the raw material of the joint 10 can be appropriately changed depending on the raw material of the metal forming the non-ferrous metal material 21. Furthermore, the case where the joint 10 is formed from low-carbon steel, which is relatively easy to weld, has been explained, but this is not a limitation. Depending on the welding method, the joint 10 can also be formed from steel with a carbon content of more than 0.4% by mass.

[0123] In the above description, the case where the mating surface 12 is planar has been explained, but it is not necessarily limited to this. Depending on its relationship with the other component 2, the mating surface may also be formed as a curved surface, etc. In the case where the mating surface is curved, the imaginary axis A is an axis orthogonal to the tangent plane at a predetermined position of the curved surface. In addition, protrusions or recesses may be provided on a portion of the mating surface 12.

[0124] If the couplings 10, 30, 52, 62, 80, 92, and 102 have hook portions when pressed into non-ferrous metal materials 21 and 42, and these hook portions include a surface (prescribed surface) 22 facing the non-ferrous metal materials 21 and 42, then the shapes of the main bodies 11, 31, 63, 81, 93, and the feet 16, 34, 54, and 83 can be appropriately modified. For example, the surface of the square flat main body can be used as the coupling surface 12, and a hook portion can be provided at the front end of the foot protruding from the center of the back of the main body to form the coupling.

[0125] In the first to third, fifth to seventh embodiments described above, the feet 16, 34, 54, and 83 of the connecting members 10, 30, 52, 80, 92, and 102 were described as cylindrical with an imaginary axis A as the center, but this is not a limitation. The feet 16, 34, and 54 may also be provided intermittently around the imaginary axis A. In this case, even without the through holes 82 and 94, air can be expelled from between the main body portions 11, 31, 81, and 93 and the non-ferrous metal material 21 from between the intermittently provided feet 16, 34, and 54.

[0126] Alternatively, the feet 16, 34, 54, and 83 can be formed into a cylindrical shape. Plate-shaped feet 16, 34, and 54 can also be positioned on both sides separated by an imaginary axis A. Preferably, the outer peripheral surfaces of the main body portions 11, 31, 81, and 93 at the locations where they connect to the outer peripheral surfaces 17 and 35 (first outer surface 55) of the feet 16, 34, 54, and 83 have inclined portions 15 and 32 connected to the mating surface 12. Thus, when the joint is pressed into the non-ferrous metal material 21 and 42, the deformation of the main body portions 11, 31, 81, and 93 caused by the feet 16, 34, 54, and 83 can be absorbed by the deformation of the inclined portions 15 and 32.

[0127] Alternatively, the inclined portions 15 and 32 connected to the mating surface 12 may not be provided regardless of the presence or absence of feet 16, 34, and 54. Alternatively, flanges extending radially outward relative to feet 16, 34, 54, and 83 may be provided on the main body portions 11, 31, 81, and 93. In this case, since the outer side of the portion of the main body portions 11, 31, 81, and 93 pressed by feet 16, 34, 54, and 83 during pressing has a flange, it is difficult for the outer periphery of the mating surface 12 to penetrate between the punch and the clamp.

[0128] In the above method, the case where the joints 10, 30, 52, 62, 80, 92, and 102 are pressed into the non-ferrous metal materials 21 and 42 until the joint surface 12 becomes flush with the surface 22 of the non-ferrous metal materials 21 and 42 is described, but it is not necessarily limited to this. The joints 10, 30, 52, 62, 80, 92, and 102 may also protrude more than 1 mm from the surface 22.

[0129] In the fifth and sixth embodiments described above, the inner wall surfaces of the through holes 82 and 94 provided in the main body portions 81 and 93 are connected to the inner surface (third inner surface 86) of the foot portion 83 around the entire circumference, and no back surface 13 remains on the inner side of the foot portion 83 (see reference). Figure 1The following situations (e.g.,) have been described, but are not necessarily limited to this. Through holes may also be formed on the main body portions 81 and 93 such that the inner wall surface of the through hole is not connected to the inner surface of the foot portion 83, and the back surface 13 remains on the inner side of the foot portion 83. In this case, multiple through holes may be formed on the main body portions 81 and 93. Alternatively, through holes may be formed on the main body portions 11, 31, and 63 of the connectors 10, 30, 52, and 62 in the first to fourth embodiments.

[0130] For example, such as Figure 10 As shown, a connecting member 110 with a through hole 111 provided in the radial center of the main body 11 can also be formed. The connecting member 110 is constructed identically to the connecting member 10 in the first embodiment, except that it has a through hole 111 formed in the main body 11. The through hole 111 opens at the mating surface 12 and opens at the back surface 13 in a manner communicating with the inside of the foot 16. The inner diameter of the through hole 111 is constant along the entire axial direction of the imaginary axis A and is smaller than the inner diameter of the foot 16. The inner diameter of this through hole 111 is set to the minimum size that can be formed when upsetting the connecting member 110 (for example, about 2 mm). Therefore, the connecting member 110 with the through hole 111 can be formed by upsetting, and when the connecting member 110 with the through hole 111 is welded to the other component 2, the influence of the through hole 111 on the formation of the molten portion 4 can be minimized.

[0131] Furthermore, the through holes 82, 94, and 111 are not limited to opening at the mating surface 12. They can also be opened on the outer peripheral surfaces (parallel portion 14, inclined portion 15, 32) of the main body portions 11, 31, 63, 81, and 93, or on the outer peripheral surfaces 17 and 35 of the feet 16, 34, 54, and 83. The closer the opening is to the mating surface 12, the less likely air will remain between the main body portions 11, 31, 63, 81, and 93 and the non-ferrous metal material 21 after being pressed in.

[0132] Furthermore, if the through hole is connected to the inner side of the feet 16, 34, 54, and 83, the through hole can also be made to open on the inner circumferential surface of the feet 16, 34, 54, and 83 (the inner surface 18a of the front end, the inner surface 18b of the base end, the first inner surface 84, etc.). It should be noted that the closer the opening is to the back surface 13 and the boundaries 87 and 95, the less likely air will remain between the main body 11, 31, 63, 81, and 93 and the non-ferrous metal material 21 after being pressed in.

[0133] In the seventh embodiment described above, the back surface 103 of the main body 11 was generally formed as a convex shape that bulges toward the side opposite to the mating surface 12 as it moves toward the radial center (imaginary axis A), but this is not a limitation. A convex back surface 103 may also be provided on the main body 31 or the like in the second embodiment. Furthermore, it is sufficient that a portion of the back surface of the main body 11, 31 bulges toward the side opposite to the mating surface 12 relative to its surrounding area. For example, a convex portion including a flat surface perpendicular to the imaginary axis A may be formed by making a portion of the back surface of the main body 11, 31 bulge in a stepped manner.

Claims

1. A method of manufacturing a bonded body for manufacturing a bonded body obtained by joining a partner member made of a ferrous metal with a non-ferrous metal material including a prescribed surface facing the partner member, the method characterized by, have: The pressing process involves pressing a ferrous metal fitting into the designated surface of the non-ferrous metal material; and In the welding process, a molten portion is formed between the exposed portion of the joint, which has been pressed into the non-ferrous metal material, and the other component. The joining member prior to the pressing-in process includes: The main body includes a mating surface and an outer peripheral surface. The mating surface is formed as a plane orthogonal to an imaginary axis, and the outer peripheral surface is connected to the outer peripheral edge of the mating surface and surrounds the imaginary axis. as well as The foot portion includes an outer surface connected to the outer peripheral surface and protrudes from the body portion from the side opposite to the mating surface in a manner located around the imaginary axis and away from the imaginary axis. Prior to the pressing process, the outer peripheral surface of the main body is formed by at least one of a parallel portion and an inclined portion, and does not have an inclined surface that faces the imaginary axis away from the mating surface. The parallel portion is parallel to the imaginary axis in a cross-section including the imaginary axis, and the inclined portion moves away from the imaginary axis away from the mating surface. After the pressing process, a portion of the joint, including the mating surface, is exposed from the designated surface, while the remaining portion of the joint is embedded in the non-ferrous metal material and not exposed. The remaining portion of the connector has a hook portion, the hook portion including a surface facing the designated surface.

2. The method for manufacturing the joint according to claim 1, characterized in that, The manufacturing method includes a heating step, in which the portion of the non-ferrous metal material to be pressed into the joint by the pressing step is heated before the pressing step.

3. A metal body for welding, characterized in that, have: Non-ferrous metal materials, including specified surfaces; and A connector made of low-carbon steel, wherein the carbon content of the low-carbon steel is below 0.4% by mass. The coupling member includes: The main body includes a mating surface and an outer peripheral surface. The mating surface is formed as a plane orthogonal to an imaginary axis, and the outer peripheral surface is connected to the outer peripheral edge of the mating surface and surrounds the imaginary axis. as well as The foot portion includes an outer surface connected to the outer peripheral surface and protrudes from the body portion from the side opposite to the mating surface in a manner located around the imaginary axis and away from the imaginary axis. The outer peripheral surface of the main body is formed by at least one of a parallel portion and an inclined portion, and has no inclined surface that faces the imaginary axis away from the joint surface. The parallel portion is parallel to the imaginary axis in a cross-section including the imaginary axis, and the inclined portion moves away from the imaginary axis away from the joint surface. A portion of the joint member, including the mating surface, is exposed from the designated surface, while the remaining portion of the joint member is pressed into the designated surface in a manner that conceals it within the non-ferrous metal material. The remaining portion of the connector has a hook portion, the hook portion including a surface facing the designated surface.

4. A coupling made of a ferrous metal, said coupling being pressed into a predetermined surface of a non-ferrous metal material and welded to a counterpart component made of a ferrous metal, said coupling being characterized in that... It has a main body and feet. The main body includes a mating surface and an outer peripheral surface. The mating surface is formed as a plane orthogonal to an imaginary axis. The outer peripheral surface is connected to the outer peripheral edge of the mating surface and surrounds the imaginary axis. The foot includes an outer surface connected to the outer peripheral surface and protrudes from the side of the main body opposite to the mating surface in a manner located around the imaginary axis and away from the imaginary axis. The outer peripheral surface of the main body is formed by at least one of a parallel portion and an inclined portion, and there is no inclined surface that moves away from the joint surface toward the imaginary axis. The parallel portion is parallel to the imaginary axis in a cross section including the imaginary axis, and the inclined portion moves away from the imaginary axis as it moves away from the joint surface.

5. The coupling according to claim 4, characterized in that, The outer peripheral surface at the location where the outer surface of the foot is connected includes the inclined portion connected to the outer peripheral edge of the mating surface.

6. The coupling according to claim 5, characterized in that, The main body includes a back surface, which is the side opposite to the mating surface, and extends from the foot towards the imaginary axis. The boundary between the inclined portion and the mating surface is located further away from the imaginary axis than the boundary between the back surface and the foot.

7. A coupling made of a ferrous metal, said coupling being pressed into a predetermined surface of a non-ferrous metal material and welded to a counterpart component made of a ferrous metal, said coupling being characterized in that... It has a main body and feet. The main body includes a mating surface and an outer peripheral surface. The mating surface is formed as a plane orthogonal to an imaginary axis. The outer peripheral surface is connected to the outer peripheral edge of the mating surface and surrounds the imaginary axis. The foot includes an outer surface connected to the outer peripheral surface and protrudes from the body portion from the side opposite to the mating surface in a manner located around the imaginary axis. The outer peripheral surface is formed by at least one of a parallel portion and an inclined portion. The parallel portion is parallel to the imaginary axis in the cross-section including the imaginary axis. The inclined portion moves away from the imaginary axis as it moves away from the mating surface. The foot is formed as a cylinder that completely surrounds the imaginary axis. The through hole at the joint surface, the outer peripheral surface, or the outer surface communicates with the inside of the foot.

8. A coupling made of a ferrous metal, said coupling being pressed into a predetermined surface of a non-ferrous metal material and welded to a counterpart component made of a ferrous metal, said coupling being characterized in that... It has a main body and feet. The main body includes a mating surface and an outer peripheral surface. The mating surface is formed as a plane orthogonal to an imaginary axis. The outer peripheral surface is connected to the outer peripheral edge of the mating surface and surrounds the imaginary axis. The foot includes an outer surface connected to the outer peripheral surface and protrudes from the body portion from the side opposite to the mating surface in a manner located around the imaginary axis. The outer peripheral surface is formed by at least one of a parallel portion and an inclined portion. The parallel portion is parallel to the imaginary axis in the cross-section including the imaginary axis. The inclined portion moves away from the imaginary axis as it moves away from the mating surface. The foot is formed as a cylinder that completely surrounds the imaginary axis. The main body includes a back surface, which is the side opposite to the mating surface, and extends from the foot towards the imaginary axis. At least a portion of the back side is formed to be convex.

9. The coupling according to any one of claims 4 to 8, characterized in that, The foot is cylindrical, surrounding the imaginary axis.

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