Joining apparatus and joining method for friction stir welding and resistance welding

Abstract

A joining device and joining method for friction stir bonding and resistance welding. The joining device for joining a first component (3), an intermediate component (4) and a second component (5) stacked as a laminate assembly includes: a probe (12, 41); an anvil (11, 11b, 11c, 11d); a shoulder component (13, 13a, 61, 64, 68); a drive mechanism (14) configured to rotate the probe about a central axis and move the probe toward and away from the second component along the central axis; and a power source (15) electrically connected to the anvil and the shoulder component to conduct current through the laminate assembly via the anvil and the shoulder component.

Description

Technical Field

[0001] This invention relates to a joining device and a joining method for friction stir joining and resistance welding. Background Technology

[0002] Resistance welding and friction stir joining are known to be environmentally friendly processes for joining multiple sheet metal components because they emit relatively small amounts of gas and have a very small impact on air quality. Friction stir joining is particularly preferred because this process requires relatively little electricity.

[0003] When joining three or more sheet metal components made of different materials by resistance welding, a bonding agent is typically used to prevent electrolytic corrosion. However, it is difficult to prevent inherent defects in the bonding agent, and stable joint strength cannot be maintained for a long time without highly stringent preventative measures. When a high level of reliability is required, rivets must be used in conjunction.

[0004] Friction stir joining is suitable for joining two sheet metal components made of different materials, but it may not be suitable for joining three or more sheet metal components due to the limited range of materials that can be effectively stirred. For example, when an aluminum sheet component and a pair of steel sheet components are joined by friction stir joining, the upper two components (e.g., the aluminum sheet component and the steel sheet component) can be properly joined, but the third component or the bottom layer may be improperly joined to the other two components.

[0005] JP2005-111489A discloses a method for joining three or more metal components, including metal components made of different materials, by combining two joining techniques. According to this prior art, an aluminum component, a steel component, and a cladding component comprising aluminum and steel layers are joined together by friction stir bonding, whereby the aluminum component is bonded to the aluminum layer of the cladding component, and the steel component and the steel layer of the cladding component are simultaneously bonded using a thermosetting adhesive, which is cured by the frictional heat of the friction stir bonding. However, this method requires the presence of a cladding component in one of the components to be joined.

[0006] In the process disclosed in JP2007-237253A, a pair of components abut against each other and are joined together by friction stirring, and a third component is joined to the joint by means of fusion welding or resistance welding.

[0007] When three or more metal components made of different materials are involved, two or more different joining methods are required. According to existing technology, the entire joining process must be carried out in multiple steps and requires two or more different joining devices, resulting in extended production lines and significant investment.

[0008] In view of these problems in the prior art, the main objective of this invention is to provide a joining device and method for joining three or more components, including components made of different materials, wherein the joining device and method allow for a reduction in the time required for the joining process and a reduction in the cost of production equipment. This invention can help minimize the environmental impact on air and improve the energy efficiency of production equipment. Summary of the Invention

[0009] To achieve this objective, one aspect of the invention provides a joining device 1 for joining a first member 3, an intermediate member 4, and a second member 5 together, wherein the first member, the intermediate member, and the second member are conductive, extend along a predetermined main plane, and are stacked in this order as a laminated assembly 2, the joining device comprising:

[0010] Anvils 11, 11b, 11c, 11d, the anvils being configured to support a first surface provided by the first member of the laminate assembly, and including a conductive portion abutting against the first surface;

[0011] Probes 12 and 41 are configured to rotate about a central axis intersecting the main plane and to move toward and away from the second surface 7 provided by the second member of the laminating assembly at a position corresponding to the anvil.

[0012] Shoulder members 13, 13a, 61, 64, 68, the shoulder members having shoulder contact surfaces 24, 24a configured to press against the second surface 7 and through holes 20, 20a configured to receive the probe, the shoulder members being at least partially conductive;

[0013] Drive mechanism 14, the drive mechanism being configured to rotate the probe about the central axis and to move the probe toward and away from the second member along the central axis;

[0014] Power supply 15, electrically connected to the anvil and the shoulder member to conduct current through the laminating assembly via the anvil and the shoulder member; and

[0015] Control unit 16, the control unit is used to control the operation of the drive mechanism and the power supply, such that the first component and the intermediate component are joined together by resistance welding, and the second component and the intermediate component are joined together by friction stirring.

[0016] According to this aspect of the invention, since the anvil and shoulder members used for friction stir joining also serve as electrodes for resistance welding, equipment costs can be reduced, equipment size can be decreased, and the length of the production line can be shortened. Furthermore, since friction stir joining and resistance welding can be performed simultaneously, processing time can be reduced.

[0017] Preferably, the probe 41 includes a conductive central portion 42 and an electrically insulating jacket 43 disposed on the outer peripheral surface of the central portion.

[0018] Since the probe can consist of a conductive central section, usually made of metal, and an electrically insulating jacket, current is prevented from being conducted from the shoulder component to the probe, which can stabilize and improve the bonding quality and improve the electrical safety of the device. Meanwhile, the central section can be made of inexpensive materials.

[0019] Preferably, the shoulder members 61, 64 include annular portions 63, 67 made of electrically insulating material surrounding the through hole 20 and outer peripheral portions 62, 66 made of conductive material.

[0020] Therefore, the shoulder component can conduct current to the laminated assembly used for resistance welding without conducting it to the probe, thereby ensuring the quality of the joint and improving the electrical safety of the equipment.

[0021] Preferably, the shoulder member 64 includes an inner ring portion 65 made of conductive material surrounding the through hole 20, an outer ring portion 67 made of electrically insulating material surrounding the inner ring portion, and an outer peripheral portion 66 made of conductive material.

[0022] Therefore, the shoulder component can conduct current to the lamination assembly used for resistance welding without conducting it to the probe, thereby ensuring bonding quality and improving the electrical safety of the equipment. Furthermore, the portion of the shoulder component that slides into contact with the probe can be made of inexpensive and durable materials such as metals.

[0023] Preferably, the anvil 11 is provided with an anvil contact surface 17, which is configured to contact the first surface 6 of the laminating assembly 2, and the anvil contact surface has an outer peripheral profile located radially outside the inner peripheral profile of the shoulder contact surface.

[0024] Because the path of the current extends to the radially outer region, the molten core can extend in a radially outward direction, which can improve the bonding strength between the first member and the intermediate member.

[0025] Another aspect of the present invention provides a bonding method for joining a first component 3, an intermediate component 4, and a second component 5 together using a bonding device as defined above, wherein the first component, the intermediate component, and the second component are conductive, extend along a predetermined main plane, and are stacked in this order to form a laminated assembly 2. The bonding method includes the following steps: abutting anvils 11, 11b, 11c, and 11d against a first surface 6 of the laminated assembly 2, and abutting shoulder components 13, 13a, 61, 64, and 68 against a second surface 7 of the laminated assembly 2; and using a driving mechanism to rotate a probe around... While the central axis rotates, the probe is pushed from the second surface into the laminated assembly through the through-hole of the shoulder member to bond the second member and the intermediate member together by friction stirring, and the first member and the intermediate member are bonded together by resistance welding by conducting current through the laminated assembly between the shoulder member and the anvil using a power source; and the probe is pulled away from the laminated assembly through the through-hole, wherein the first member and the intermediate member are made of similar materials, and the second member is made of a material different from the materials of the first member and the intermediate member.

[0026] According to this aspect of the invention, since the anvil and shoulder members used for friction stir joining also serve as electrodes for resistance welding, equipment costs can be reduced, equipment size can be decreased, and the length of the production line can be shortened. Furthermore, since friction stir joining and resistance welding can be performed simultaneously, processing time can be reduced.

[0027] When resistance welding dissimilar materials, very brittle intermetallic compounds are often formed, resulting in a failure to achieve the desired bond strength. However, according to this aspect of the invention, the second and intermediate components are joined by friction stir bonding rather than resistance welding, thereby preventing such intermetallic compounds from reducing the bond strength.

[0028] Generally, the materials of the first and intermediate components are superior to those of the second component in terms of mechanical strength and electrical resistance. Components made of similar materials as used here mean they are alloys with the same main composition, while components made of different materials mean they are alloys with different main compositions.

[0029] Preferably, current is supplied between the shoulder member and the anvil before the probe reaches the intermediate member.

[0030] Because the current supplied between the shoulder member and the anvil causes a larger area of ​​the lamination assembly to soften, it facilitates the insertion of the probe into the lamination assembly and allows for faster insertion.

[0031] Alternatively, current may be supplied between the shoulder member and the anvil substantially simultaneously with or after the probe reaches the intermediate member.

[0032] Because the current softens the second member from the portion adjacent to the outer periphery of the probe (from which the hook begins to form) to the portion adjacent to the shoulder member, the tip of the hook can be guided in a radially outward direction. Furthermore, the portion of the intermediate member located directly above the anvil is preferentially softened, which further facilitates the formation of the hook in an advantageous manner.

[0033] Alternatively, current may be supplied between the shoulder member and the anvil substantially simultaneously with or after the probe reaches the first member.

[0034] Therefore, a ring-shaped molten nucleus can be formed in a stable manner, thereby improving the bonding strength.

[0035] Therefore, the present invention provides a joining device and joining method for joining three or more components, the components including those made of different materials, the joining device and joining method allowing for a reduction in the time required for the joining process and a reduction in the expenditure on production equipment. Attached Figure Description

[0036] Figure 1 This is a vertical cross-sectional view showing the joining device according to a preferred embodiment of the present invention;

[0037] Figure 2 This is a partial vertical cross-sectional view showing a modified example of the probe of the coupling device according to the present invention;

[0038] Figures 3A to 3D This is a partial cross-sectional view illustrating different embodiments of the shoulder member according to the present invention;

[0039] Figure 4A It shows Figure 1 The cross-sectional and plan views of the shoulder component of the connecting device are shown.

[0040] Figure 4B It shows something similar to Figure 4A The improved shoulder component is shown.

[0041] Figures 5A to 5D Here are cross-sectional views of different examples of coupling devices equipped with anvils:

[0042] Figures 6A to 6E These are diagrams illustrating different stages of the joining method according to a preferred embodiment of the present invention; and

[0043] Figures 7A to 7C This diagram illustrates different stages of the joining method according to a modified embodiment of the present invention. Detailed Implementation

[0044] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Figure 1 This is a vertical cross-sectional view of the joining device 1 and the laminated assembly 2 processed by the joining device 1 according to a preferred embodiment of the present invention. In the following description, the laminated assembly 2 extends along a horizontal plane (main plane), and the joining device 1 is applied downward in the vertical direction to the laminated assembly 2. However, this orientation is merely exemplary, and the invention can be applied to workpieces oriented in any desired direction and from any desired direction, such as laterally, upward, and obliquely, without departing from the scope of the invention.

[0045] The laminate assembly 2 includes a first member 3, an intermediate member 4, and a second member 5, all of which are composed of conductive plate members and are stacked in this order on a horizontal main plane. The laminate assembly 2 has a first surface 6 provided by the lower surface (bottom layer) of the first member 3 and a second surface 7 provided by the upper surface (top layer) of the second member 5. In another embodiment, the laminate assembly 2 further includes an additional member below the first member 3, which is made of the same or similar material as the first member 3.

[0046] In this embodiment, the first component 3 and the intermediate component 4 are made of the same or similar materials, while the second component 5 is made of a different or dissimilar material than the first component 3 and the intermediate component 4. The materials of the first component 3 and the intermediate component 4 have higher strength and higher electrical resistance than the material of the second component 5. For example, the first component 3 and the intermediate component 4 may be made of an iron alloy (steel), while the second component 5 may be made of an aluminum alloy, a magnesium alloy, or a copper alloy. Alternatively, the first component 3 and the intermediate component 4 may be made of a titanium alloy, while the second component 5 may be made of an aluminum alloy, a magnesium alloy, or a copper alloy. Furthermore, the first component 3 and the intermediate component 4 may be made of an aluminum alloy, while the second component 5 may be made of a copper alloy.

[0047] The bonding device 1 includes: an anvil 11 configured to support a first surface 6 of the laminating assembly 2; a probe 12 positioned above the anvil 11; an annular shoulder member 13 positioned above the anvil 11 and surrounding the probe 12; a drive mechanism 14 for driving the anvil 11, the probe 12, and the shoulder member 13, as described below; a power source 15 for conducting current between the shoulder member 13 and the anvil 11, which insert the laminating assembly 2 therebetween; and a control unit 16 for controlling the operation of the drive mechanism 14 and the power source 15.

[0048] The anvil 11 is made of conductive material and has an anvil contact surface 17 that abuts against the first surface 6 of the laminate 2.

[0049] The probe 12 is disposed in the free end (lower end) portion of the rotatable member 18, which is rotatable about a central axis and has a shape that is rotationally symmetrical about the central axis. The probe 12 extends along the central axis and preferably has a cylindrical shape, the diameter of which is smaller than the diameter of the base portion 19 of the rotatable member 18. The probe 12 is made of a hard material such as steel, ceramic, or hard alloy.

[0050] like Figure 1 As shown, the shoulder member 13 has a rotationally symmetrical shape about a central axis. The shoulder member 13 includes: a probe support 21 having a through hole 20 centered on the central axis; a flange 22 extending radially outward from the probe support 21; and an annular sidewall 23 protruding downward from the lower surface of the probe support 21, concentric with the central axis. The probe 12 passes through the through hole 20. The upper end of the through hole 20 is formed as a tapered countersunk hole. The inner diameter of the lower part (main part) of the through hole 20 is slightly larger than the outer diameter of the probe 12, and the inner circumferential surface of the through hole 20 can slide in contact with the outer circumferential surface of the probe 12 when the probe 12 rotates about the central axis. The inner diameter of the sidewall 23 is substantially larger than the outer diameter of the probe 12, such that the inner circumferential surface of the sidewall 23 is concentrically separated from the outer circumferential surface of the probe 12. The inner circumferential surface of the sidewall 23 can be tapered towards its lower end, but can also be approximately parallel to the axial direction. The lower surface of the sidewall portion 23 forms a shoulder contact surface 24, which can abut against the second surface 7 of the laminate assembly 2. Therefore, the recess 25 is defined by the lower surface of the probe support portion 21 opposite to the second surface 7 of the laminate assembly 2 and the inner peripheral surface of the sidewall portion 23, and the recess 25 is recessed relative to the shoulder contact surface 24. The shoulder member 13 can be made of a hard material such as copper alloy (chromium copper, copper with dispersed alumina, tungsten copper alloy, etc.), conductive ceramic, hard alloy, etc.

[0051] like Figure 1 As shown, the drive mechanism 14 includes an anvil drive mechanism 27 for vertically moving the anvil 11, a rotation drive mechanism 28 for rotating the rotatable member 18 including the probe 12 about the central axis, a forward / backward drive mechanism 29 for moving the probe 12 forward / backward along the central axis, and a shoulder drive mechanism 30 for vertically moving the shoulder member 13.

[0052] Power supply 15 is electrically connected to a first terminal 31 and a second terminal 32. The first terminal 31 is electrically connected to an anvil 11, and the second terminal 32 is electrically connected to a shoulder member 13 (each via a sliding contact mechanism or a flexible cable). The anvil 11 is at least partially conductive, so that current can be supplied to the anvil contact surface 17 via the first terminal 31, and the shoulder member 13 is at least partially conductive, so that current can be supplied to the shoulder contact surface 24 via the second terminal 32.

[0053] The following will refer to Figures 6A to 6E describe Figure 1 The operating mode of the bonding device 1 shown in the diagram when processing the laminating assembly 2.

[0054] like Figure 6A As shown, the first component 3, the intermediate component 4, and the second component 5 are placed on the anvil 11, and the probe 12 and the shoulder component 13 are positioned above the second surface 7. The probe 12 and the shoulder component 13 move downward so that, under the control of the control unit 16, the laminating assembly 2 is pressed against the anvil 11 by using the drive mechanism 14, in preparation for friction stir point bonding and resistance spot welding, as described below.

[0055] like Figure 6B As shown, the anvil 11 presses the first surface 6 of the laminating assembly 2 from below, and the shoulder member 13 presses the second surface 7 of the laminating assembly 2 from above. When the laminating assembly 2 is pressed between the anvil 11 and the shoulder member 13, the probe 12 rotates about the central axis and advances into the laminating assembly 2 from the side of the second surface 7.

[0056] like Figure 6C As shown, the tip of probe 12 is inserted into the second member 5, causing the second member 5 to deform, displacing material from it into the recess 25 of the shoulder member 13. Due to the frictional heat generated by rotating probe 12, the material surrounding the second member 5 becomes a plastic fluid, creating an annular plastic fluid region around probe 12. Once the tip of probe 12 reaches the intermediate member 4, control unit 16 causes current to flow between shoulder member 13 and anvil 11. The position of the tip of probe 12 can be detected or managed by the downward stroke of probe 12, the insertion pressure (insertion load) of probe 12 into laminating assembly 2, the rotational load of probe 12, or any combination thereof.

[0057] like Figure 6D As shown, when current flows between the shoulder member 13 and the anvil 11, the probe 12 continues to rotate and move further downward, and the tip of the probe 12 inserts into the intermediate member 4. As a result, the resistance heat generated in the first member 3 and the intermediate member 4 and the frictional heat generated by the rotation of the probe 12 cause a melting zone 34 to be formed in or between the first member 3 and the intermediate member 4. At the same time, a portion of the material of the second member 5 and the intermediate member 4 near the probe 12 plastically flows. In particular, the portion of the material that is further pushed away from the probe 12 is cooled and becomes relatively less fluid, but is pushed away from the probe 12 under pressure from the larger fluid portion of the material. As a result, a hook 35 is formed in the portion of the intermediate member 4 surrounding the probe 12, protruding radially outward and upward. The hook 35 thus has a crown-like shape that opens toward its front end (upper end) and extends obliquely into or weds into the material of the second member 5.

[0058] like Figure 6E As shown, control unit 16 (see...) Figure 1 The current supply between the shoulder member 13 and the anvil 11 is stopped, and the probe 12 is retracted along the axis while rotating. Furthermore, the anvil 11 and the shoulder member 13 move away from the laminating assembly 2. When the current stops and the probe 12 is removed, the melting zone 34 (see...) Figure 6D The solidification forms a molten core 33, which firmly bonds the first member 3 and the intermediate member 4 together. Furthermore, since the hook 35 is formed in the second member 5 and the intermediate member 4, which have been plastically flowed by the rotation of the probe 12, the second member 5 and the intermediate member 4 are also firmly bonded together.

[0059] Figures 7A to 7C Shown by using Figure 1 The connecting device 1 shown is for use with Figures 6A to 6E The joining process is performed in a slightly different manner than shown. In this case, as... Figure 7A As shown, current is supplied between the shoulder member 13 and the anvil 11 before or simultaneously with the tip of the probe 12 contacting the second surface 7 of the laminating assembly 2. Because resistive heat generated by the current is produced over a wider area of ​​the laminating assembly 2 (the region of the second member 5 adjacent to the probe 12 and the shoulder member 13), and the size of the portion of the second member 5 softened by resistive heat is increased, the probe 12 can be inserted into the laminating assembly with lower resistance and / or at a higher speed.

[0060] like Figure 7B As shown, when current is supplied immediately before the tip of probe 12 reaches the intermediate member 4 of the laminating assembly 2, resistive heating softens the portion of the second member extending from the outer periphery of the probe (generating the hook 35 from the outer periphery to the shoulder contact surface 24), allowing the tip of the hook 35 to be guided radially outward (for better anchoring of the hook 35). Furthermore, the portion of the intermediate member 4 located directly above the anvil 11 is actively softened, thereby actively generating the hook 35 and preventing softened material from flowing into the interface between the first member 3 and the intermediate member 4. Figure 7C This illustrates the case where current supply begins when the tip of probe 12 has advanced beyond the interface between the second member 5 and the intermediate member 4. In this case, a similar current supply can be obtained from... Figure 7B The advantages obtained from the implementation shown are as follows.

[0061] Figure 2 A modified embodiment of the present invention is shown, which is similar to... Figure 1 The difference in the illustrated embodiment lies in the structure of probe 12. In this modified description, corresponding components are indicated by the same reference numerals, and their descriptions are not repeated to avoid redundancy. Figure 2 In the modified embodiment shown, probe 41 extends along the central axis and has a... Figure 1 The illustrated embodiment has a similar cylindrical shape, but differs in that it includes a probe conductive portion 42 and a probe insulating portion 43 made of an electrically insulating material. The probe 41 slides in contact with the inner peripheral surface of the through-hole 20 of the shoulder member 13 at the outer peripheral surface of the probe insulating portion 43. Therefore, current flow between the probe 41 and the shoulder member 13 is prevented, thereby improving the energy efficiency of resistance welding.

[0062] Figure 3A It shows in Figure 1 The shoulder member 13 used in the illustrated embodiment, while Figure 3B and Figure 3C Different variations are shown. Figure 3A The shoulder component 13 shown is made entirely of conductive material. Figure 3B In the case of the shoulder member 61 shown, its outer peripheral portion 62, including the flange 22 and the annular sidewall portion 23, is made of a conductive material, and its central annular portion 63, including the probe support portion 21 with the through hole 20 formed therein, is made of an electrically insulating material. The second terminal 32 slides in contact with the outer peripheral surface of the conductive flange 22, and the probe 12 is electrically insulated from the flange 22 by the probe support portion 21.

[0063] exist Figure 3C In the case of the shoulder member 64 shown, its outer peripheral portion 66, including the flange 22 and the annular sidewall portion 23, is made of a conductive material, and its central portion, including the probe support portion 21 with the through hole 20, includes an outer ring portion 67 made of an electrically insulating material and an inner ring portion 65 made of a conductive material. Therefore, the inner ring portion 65 defining the through hole 20 is made of a conductive material such as metal, but the inner ring portion 65 is electrically insulated from the outer peripheral portion 66 of the shoulder member 64 by the outer ring portion 67. The second terminal 32 again slides in contact with the outer peripheral surface of the conductive flange 22, and the probe 12 is electrically insulated from the flange 22 by the outer ring portion 67 of the probe support portion 21.

[0064] Figure 3D The shoulder component 68 shown is Figure 3C The shoulder member shown is similar, and its outer peripheral portion 69, including the flange 22 and the annular sidewall portion 23, is made of a conductive material. Its central portion, including the probe support portion 21 with the through-hole 20, includes an outer ring portion 70 made of an electrically insulating material and an inner ring portion 65 made of a conductive material. In this case, the outer ring portion 70 has an increased radial thickness to occupy a larger portion of the annular sidewall portion 23, thereby improving the rigidity and mechanical strength of the annular sidewall portion 23 by appropriately selecting the material of the outer ring portion 70.

[0065] exist Figure 2 , Figure 3A , Figure 3B and Figure 3C In the modified embodiment shown, the conductive part can be made of copper alloy (e.g., chromium copper, copper with dispersed alumina, tungsten copper alloy, etc.), conductive ceramic material, hard alloy, etc., and the electrically insulating part can be made of insulating ceramic material, Bakelite (registered trademark) (phenolic resin), mica, etc.

[0066] The friction stirring joint performed by the aforementioned jointing device 1 is a friction stirring point joint, and the shoulder contact surface 24 of the shoulder member 13 contributes to a good appearance of the joint point. Figure 4A Showing more details Figure 1 The shoulder member 13 of the connecting device 1 shown.

[0067] Figure 4B An alternative embodiment of the shoulder member 13a is shown. Figure 4B In, with Figure 4A Corresponding components are indicated by the same reference numerals, each number followed by the letter "a". In this case, the sidewall portion 23a is U-shaped, such that the recess 25a has an opening on one side, which is defined by a pair of mutually parallel straight sections of the sidewall portion 23a on the rear side of the shoulder member 13a relative to the direction of travel of the shoulder member 13a relative to the laminating assembly 2 during in-line joining. According to this embodiment, by using an assembly with Figure 4B The joining device 1 of the shoulder member 13a shown causes the laminating assembly 2 to move relative to the joining device 1 along a horizontal line, allowing the laminating assembly 2 to be advantageously joined along the line. Although Figure 4A The shoulder member 13 shown can be used for frictional stirring engagement along a line, but Figure 4B The embodiment shown is advantageous because the open side of the recess 25a allows the laminating assembly 2 to move relative to the bonding device 1 with relatively little resistance. The sidewall portion 23a may also include a pair of parallel portions extending along the relative movement between the laminating assembly 2 and the bonding device 1.

[0068] Figures 5A to 5D Different current patterns depending on the configuration of the anvil 11 are shown. The arrows in these figures indicate the flow of current. The anvil 11 and probe 12 are typically cylindrical in shape and positioned coaxially.

[0069] Figure 5A The anvil 11 shown has a diameter that is substantially the same as or slightly larger than that of the probe 12. Due to the relatively small contact area between the laminating assembly 2 and the anvil 11, the laminating assembly 2 receives relatively strong and stable pressure from the anvil 11, and current flows through a relatively limited area of ​​the laminating assembly 2.

[0070] Figure 5B The anvil 11b shown has a large diameter between the inner and outer diameters of the shoulder contact surface 24 (sidewall portion 23). Because current flows through a relatively large area (relatively large radial range) of the laminating assembly 2, a relatively large melt nugget 33 is generated.

[0071] Figure 5C The anvil 11c shown includes a central portion 71 and an outer peripheral portion 72. The central portion 71 is made of a material that is more rigid or harder than the outer peripheral portion 72. According to this embodiment, the deformation of the anvil 11c can be reduced when pressed against the laminate assembly 2. The outer contour of the central portion 71 can be larger than the inner contour of the shoulder contact surface 24.

[0072] Figure 5D The anvil 11d shown includes a central portion 71 and an outer peripheral portion 72. The central portion 71 is made of a material with less rigidity or hardness than the outer peripheral portion 72. According to this embodiment, the outer peripheral portion 72 preferentially presses against the laminating assembly 2, such that current preferentially flows through the radially outer region (or the annular region around the central axis) of the laminating assembly 2.

[0073] The various features and advantages of the above-described embodiments will be discussed below.

[0074] In the aforementioned joining device 1, the anvil 11 and probe 12 used for friction stir bonding can also be used as electrodes for resistance spot welding. Compared to using a friction stir bonding device and a resistance spot welding device separately, the cost and size of the joining device 1 can be minimized. In particular, by using the aforementioned joining device 1, the length of the production line can be reduced, and the necessary investment can be decreased. Furthermore, since friction stir bonding and resistance spot welding can be performed simultaneously, the time required for the manufacturing process can be reduced.

[0075] When resistance welding dissimilar materials, very brittle intermetallic compounds are often formed, resulting in a failure to achieve the desired bond strength. In the above embodiment, since the second component 5 and the intermediate component 4, which may be made of different materials, are joined by friction stir bonding instead of resistance welding, this reduction in bond strength due to intermetallic compounds is prevented.

[0076] In the above embodiment, the frictional heat generated by the probe 12 during the friction stirring and joining of the intermediate component 4 and the first component 5 helps the resistance welding of the intermediate component 4 and the first component 3, and can reduce the energy consumption of resistance welding.

[0077] In resistance welding, it is known that if the molten region 34 cools too quickly, the toughness of the weld nugget 33 may decrease. In the aforementioned embodiment, since the probe 12 remains rotating and is pulled out from the lamination assembly 2 after the current for resistance welding is stopped, the frictional heat generated by the probe 12 is conducted to the molten region 34, thereby preventing the molten region 34 from cooling too quickly and preventing a decrease in the toughness of the weld nugget 33.

[0078] exist Figure 2 , Figure 3B and Figure 3C In the illustrated embodiment, the probe 12 (41) is electrically insulated from the peripheral portion of the shoulder member 13, which is connected to the power supply 15 via the second terminal 32. Therefore, the electrical safety measures for the coupling device 1 can be simplified. Figure 3C In the embodiment shown, the shoulder member 68 includes an inner ring portion 65 that can conduct electricity and can be made of a highly wear-resistant metal material.

[0079] The present invention has been described with reference to specific embodiments, but the invention is not limited to these embodiments and can be modified in various ways without departing from the scope of the invention. The joining between the second member and the intermediate member is not limited to resistance spot welding, but can also be other forms of resistance welding. Various features of various embodiments can be combined without departing from the scope of the invention. For example, Figures 5A to 5D The anvil shown can be used with Figures 3A to 3D Any shoulder components shown and Figure 1 and Figure 2 Any probe combination shown. Timing of current supply between shoulder member 13 and anvil 11 ( Figure 6D The timing can coincide with the time at which probe 12 arrives at the first component 3 or a short time after that timing. Therefore, annular weld nuggets can be produced in a stable manner, thereby improving the bonding strength.

Claims

1. A joining device for joining a first component, an intermediate component, and a second component together, the first component, the intermediate component, and the second component being conductive, extending along a defined main plane, and stacked in this order as a laminated assembly, the joining device comprising: An anvil, the anvil being configured to support a first surface of the laminate assembly provided by the first member, and including a conductive portion abutting against the first surface; A probe configured to rotate about a central axis intersecting the main plane and to move toward and away from the second surface provided by the second member of the laminating assembly at a position corresponding to the anvil; A shoulder member having a shoulder contact surface configured to press against the second surface and a through hole configured to receive the probe, the shoulder member being at least partially conductive; A drive mechanism configured to rotate the probe about the central axis and to move the probe toward and away from the second member along the central axis; A power source, electrically connected to the anvil and the shoulder member, to conduct current through the laminating assembly via the anvil and the shoulder member; as well as A control unit is provided for controlling the operation of the drive mechanism and the power supply, such that the first component and the intermediate component are joined together by resistance welding, and the second component and the intermediate component are joined together by friction stirring. The control unit controls the drive mechanism by rotating the probe about the central axis and moving the probe forward / backward along the central axis. The control unit also controls the power supply by conducting current through the laminating assembly via the anvil and the shoulder member. The control unit is configured to control the operation of the drive mechanism and the power supply to simultaneously perform resistance welding of the first member and the intermediate member, and friction stirring bonding of the second member and the intermediate member.

2. The coupling device according to claim 1, wherein, The probe includes a conductive central portion and an electrically insulating jacket disposed on the outer peripheral surface of the central portion.

3. The coupling device according to claim 1, wherein, The shoulder member includes an annular portion made of an electrically insulating material surrounding the through-hole and an outer peripheral portion made of a conductive material.

4. The coupling device according to claim 1, wherein, The shoulder member includes an inner ring portion made of conductive material surrounding the through hole, an outer ring portion made of electrically insulating material surrounding the inner ring portion, and an outer peripheral portion made of conductive material.

5. The coupling device according to claim 1, wherein, The anvil is provided with an anvil contact surface configured to contact the first surface of the laminating assembly, and the anvil contact surface has an outer peripheral profile located radially outside the inner peripheral profile of the shoulder contact surface.

6. A bonding method for joining a first member, an intermediate member, and a second member together using a bonding device as defined in claim 1, wherein the first member, the intermediate member, and the second member are conductive, extend along a predetermined main plane, and are stacked in this order as a laminated assembly, the bonding method comprising the steps of: The anvil rests against the first surface of the laminating assembly, and the shoulder member rests against the second surface of the laminating assembly; While the probe is rotated about the central axis by using a drive mechanism, the probe is pushed from the second surface into the lamination assembly through the through hole of the shoulder member to join the second member and the intermediate member together by friction stirring. And by using a power source to conduct current through the lamination assembly between the shoulder member and the anvil to join the first member and the intermediate member together by resistance welding. as well as The probe is pulled away from the laminate assembly through the through-hole. The first component and the intermediate component are made of similar materials, and the second component is made of a different material than the first component and the intermediate component.

7. The joining method according to claim 6, wherein, The first component and the intermediate component are made of similar materials, and the second component is made of a different material than the first component and the intermediate component, and the materials of the first component and the intermediate component are higher than the materials of the second component in terms of mechanical strength and electrical resistance.

8. The joining method according to claim 6, wherein, Before the probe reaches the intermediate member, current is supplied between the shoulder member and the anvil.

9. The joining method according to claim 6, wherein, Current is supplied between the shoulder member and the anvil at the same time or after the probe reaches the intermediate member.

10. The joining method according to claim 6, wherein, At the same time or after the probe reaches the first component, current is supplied between the shoulder component and the anvil.

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