Method for joining members and member connection structure

Abstract

The invention relates to a method for joining components, comprising the following steps: - providing a first component, in particular an aluminum die casting, wherein the first component has a joining region for the arrangement and fixing of a second component; - forming an adhesive layer at least locally on the joining region by means of a thermal spraying method; - fixing the second component on the adhesive layer by means of a joining by pressure welding.

Description

Technical Field

[0001] The present invention relates to methods for joining components, such as those used in body / vehicle manufacturing, and to component connection structures. Background Technology

[0002] Steel / aluminum joining structures are used in vehicle body manufacturing to keep the weight of components, parts, and structures low. Common joining or connection methods in this context include riveting, particularly (semi-hollow) stamping riveting, interlocking connections, (extrusion die) threaded connections, bonding, or combinations of these methods. A common thread among these methods is that they are not optimal in terms of cycle time and investment cost. Manufacturing costs are also typically high in order to produce sufficiently rigid and robust connections. Summary of the Invention

[0003] Therefore, the object of the present invention is to provide a method for joining components and a component connection structure that meets the highest mechanical requirements with optimized cycle time and low investment cost.

[0004] Therefore, the present invention proposes a method for joining components, the method comprising the following steps:

[0005] - Provide a first component, the first component being an aluminum die-cast component, wherein the first component has a mating area for setting and fixing a second component;

[0006] - An adhesive layer is formed at least partially on the bonding area by a thermal spraying method, wherein the adhesive layer extends along the bonding area and has a profile, structure or wave profile along the bonding area, wherein the adhesive layer has wave peaks, plateaus or field areas at regular intervals along the bonding area.

[0007] - The second component is fixed to the adhesive layer by means of pressure welding, wherein spot welding is performed in the region of the wave crest of the adhesive layer.

[0008] The present invention also proposes a component connection structure comprising a first component and a second component, the first component being made of aluminum, the first component and the second component being fixed to each other along a joint area, wherein the first component has at least partially an adhesive layer in the joint area, the adhesive layer being formed by a thermal spraying method, and the second component being fixed to the adhesive layer by pressure welding, wherein the adhesive layer alternately includes wave peaks and wave troughs along the joint area, and at least one welding point is provided on each of the wave peaks, the adhesive layer having wave peaks at regular intervals along the joint area.

[0009] According to the present invention, a method for joining components (particularly for joining at least two components of different materials) includes the following steps:

[0010] - Provide a first component, particularly an aluminum die-cast component, wherein the first component has a mating area for setting and fixing a second component;

[0011] - An adhesive layer is formed, at least locally, on the bonding area by thermal spraying;

[0012] - The second component is fixed to the adhesive layer by means of pressure welding.

[0013] In pressure welding, two workpieces or components to be joined are heated to their melting point and joined together by pressing them together. A particularly advantageous aspect is that no additional materials, such as welding wire, are required during pressure welding, thus saving costs. Furthermore, since no additional materials are needed (as in riveting), there is no significant increase in weight during the joining process. Advantageously, the welding duration is only a few milliseconds, allowing for very short cycle times in manufacturing.

[0014] In this context, a particularly advantageous method is resistance welding, especially resistance spot welding. Here, the two components are pressed together by two electrodes. An electric current heats the weld joint between the electrodes to the necessary temperature. The shape and strength of the weld core depend on three key welding parameters: current, time, and pressing pressure. In resistance spot welding, high energy is concentrated over a small area in the shortest possible time, and combined with pressure generated by pneumatics, hydraulics, servo motors, or electromagnetics, an unbreakable bond is created.

[0015] Another preferred welding method is capacitor discharge welding.

[0016] According to one embodiment, the electrodes of welding tools (particularly welding tools for resistance spot welding) are currently preferably equipped with welding caps of different shapes. According to one embodiment, a spherical welding cap is used on the aluminum side, while a flat welding cap is used on the steel side. It has been shown that this configuration yields optimized welding results. Indentations on the aluminum material can be advantageously avoided. Adhesion of the welding cap is also effectively prevented. Different cap shapes can also be used to achieve the desired purpose.

[0017] Advantageously, the application of the adhesive layer enables the joining of different types or dissimilar materials. In particular, it allows for the seamless, for example, welding connections between aluminum and steel structures. Steel or iron / steel-based materials are advantageously used as the material for the adhesive layer. According to a preferred embodiment, austenitic (stainless) steel, and particularly preferred ferritic (stainless) steel, is used as the material for the adhesive layer. Currently, it is particularly preferred that cast components made of aluminum, especially die-cast aluminum components, are provided with the adhesive layer.

[0018] Thermal spraying is a surface coating method. Here, additional material, the so-called spray additive, is ablated, melted, or fused inside or outside the spray burner and accelerated in the gas stream as spray particles. The component surface remains unmelted. This results in a low heat load. Layers are formed because the spray particles, upon impact with the component surface, are more or less flattened depending on the process and material, primarily held in place by mechanical clamping, thus building the spray layer in layers. Energy carriers used for melting or fusion of the spray additive material include: electric arcs (arc spraying), plasma jets (plasma spraying), fuel-oxygen-flame or fuel-oxygen-velocity flame (conventional and high-velocity-flame spraying), rapidly preheated gases (cold gas spraying), and laser beams (laser beam spraying). The combination of thermal coating methods with pressure welding methods, particularly for joining different types of materials, enables exceptionally short cycle times and low investment costs.

[0019] Cold gas spraying has proven to be a particularly advantageous coating method. In this case, according to a preferred embodiment, the gas jet temperature exceeds 800°C. The preferred maximum temperature is in the range of 1200°C, and therefore, generally, the preferred temperature range is between about 800°C or above and about 1200°C. Tests have shown that temperatures in the range of about 1000°C are optimal for coating quality. Advantageously, cold gas spraying can achieve surfaces with optimal structure for downstream bonding processes.

[0020] According to a preferred embodiment, the method includes the following steps:

[0021] - An adhesive layer is formed extending along the bonding region, such that the adhesive layer has a profile, structure, or wavy profile along the bonding region;

[0022] - Spot welding, particularly resistance spot welding, is performed in the region of the wave crest of the adhesive layer.

[0023] Advantageously, the adhesive layer does not have a constant thickness or wall thickness along the bonding area. For the desired effect, the adhesive layer is thicker in the areas where the welding points are to be located (currently referred to as platforms, wave crests, or field areas), while the sections between these areas are preferably thinner. Therefore, coating material can be advantageously saved, thereby reducing weight and cost. Alternatively, the adhesive layer may also have a constant thickness along the bonding area. Further alternatively, the adhesive layer may be constructed locally along the bonding area. Thus, no adhesive layer is constructed between the aforementioned wave crests, etc.

[0024] The adhesive layer is designed to conform to the desired shape or structure of the joining area, such that in the area of ​​the weld point, the adhesive layer has a thickness of, for example, preferably about 500µm to 2500µm, particularly preferably about 800µm to 1500µm, and particularly preferably about 1000µm. In a top view, the adhesive layer in this area extends to about 20 x 20 mm. Depending on the type of components to be joined, these values ​​may be deviated upwards and downwards. However, it has been shown that the above measurements enable reliable manufacturing of a particular process. In this case, the decisive factor is the implementation of a welding method preferably performed automatically by at least one robot. This robot (currently particularly preferably a 6-axis or 7-axis industrial robot) has certain tolerances in the position of the weld point, especially due to its high movement speed, which can be advantageously compensated for by the size of the aforementioned platform, wave crest, or field area.

[0025] Preferably, the adhesive layer has wave crests, plateaus, or fields at a preferred regular interval along the bonding area. According to a preferred embodiment, the wave crests, plateaus, or fields are spaced, particularly regularly, relative to their centers in a range of about 40 mm to 70 mm, and particularly preferably in a range of about 55 mm to 60 mm. This spacing has proven advantageous in achieving mechanical target settings during body and vehicle manufacturing.

[0026] According to a preferred embodiment, the aforementioned spacing decreases or increases at least sectionally along the adhesive layer. Particularly preferably, the spacing within the functional critical range is about 15 mm to 25 mm, particularly about 20 mm.

[0027] According to embodiments of the coating method, the wave crests, platforms, or areas have a generally flattened cuboid shape, wherein, as previously described, the cuboid conforms to the destination and has a side length of approximately 20 x 20 mm and a height of approximately 1000 µm. Essentially, the adhesive layer preferably has a width in the range of approximately 10 mm to 30 mm, particularly preferably in the range of 15 mm to 25 mm, or for example, 20 mm. This automatically generates the aforementioned width of the "cuboid," the surface of which can be, for example, rectangular or square.

[0028] According to a preferred embodiment, the adhesive layer is relatively thin between the wave crests, plateaus, or field areas. Alternatively, the adhesive layer may also have a uniform or at least substantially uniform thickness along the bonding area, as described above. The area between the wave crests, plateaus, or field areas is currently referred to as a wave trough, gap, or pocket. According to a preferred embodiment, the thickness of the adhesive layer between the wave crests, plateaus, or field areas is in the range of about 200 µm to 2200 µm, particularly preferably about 600 µm to 1200 µm, and especially preferably about 700 µm.

[0029] The current thickness or height setting is an average value within the corresponding range.

[0030] According to a preferred embodiment, the height of the wave crest relative to the height of the wave trough is in the range of about 1.05 to 2.7, particularly preferably in the range of about 1.1 to 1.9, especially preferably in the range of about 1.3 to 1.6, and particularly preferably about 1.4 to 1.45.

[0031] Preferably, taking into account manufacturing tolerances, the wave crests and wave troughs have the same height along the adhesive layer.

[0032] According to a preferred embodiment, during coating, a profile, structural portion, or wavy profile is formed by adjusting the feed rate accordingly. Advantageously, the (coating) method includes the following steps:

[0033] - Use a coating tool (e.g., a spray gun) with a particularly constant feed rate v1 to form wave crests, platforms, or fields;

[0034] - Accelerate the coating tool to a feed rate v2, which is greater than v1, where less coating material is automatically applied due to the preferred continuous delivery of the coating material.

[0035] - Move at a feed rate v2;

[0036] - Slow down the coating tool to speed v1 to form the next wave peak.

[0037] As a result, transition zones appear between the wave crests and pouches or between the gaps, where the thickness of the adhesive layer increases or decreases. Depending on the method implementation, the thickness of the adhesive layer in the gaps, pouches, or valleys can be adjusted, for example, by selecting the appropriate nozzle and / or adjusting the moving speed v2 during coating.

[0038] According to one embodiment, the adhesive layer is formed intermittently or in sections along the bonding region. In this case, the adhesive layer is formed only in sections to create wave crests, platforms, or field areas. No adhesive layer is formed between them.

[0039] According to one embodiment, the profile, structural section, or wave contour is formed by masking the joint area sections. This can be particularly suitable if an intermittent adhesive layer is to be formed. The material deposited on the mask can be advantageously recycled or reused or transferred to other processes, thus requiring very little resource input.

[0040] According to one implementation, the method includes the following steps:

[0041] - An adhesive layer is formed by applying material to multiple lines arranged side by side (along the joint area).

[0042] The width of the adhesive layer (which, as previously described, is in the range of approximately 20 mm according to the preferred embodiment) can be formed in a single pass within a corresponding nozzle geometry. A flat nozzle with a corresponding width is advantageously used here. The smaller the width, the easier it is to achieve this. It has proven advantageous to use a nozzle geometry with a rectangular cross-section. The nozzle is aligned such that the long side of the rectangle is oriented transversely to the feed direction. The width of the rectangle determines the width of the adhesive layer. Alternatively, the adhesive layer can be formed by applying material in multiple lines arranged side-by-side. Here, a nozzle geometry with a rounded, particularly circular, cross-section (rounded nozzle) is preferred.

[0043] Preferably, the method includes the following steps:

[0044] - Adjust the trajectory offset when applying material in multiple lines to ensure that the adhesive layer has a uniform surface, especially in the width direction, i.e., transverse to the feed direction.

[0045] This advantageously avoids problems during welding. If the trajectory offset is too large, gaps of potentially unacceptable size appear between the individual applied lines, which can adversely affect the current between the electrodes during welding, particularly potentially causing weld spatter. It has proven advantageous to achieve a trajectory offset of approximately 1 mm when the nozzle diameter is approximately 8 mm. Preferred surface roughness values ​​will be mentioned later.

[0046] According to one embodiment, the adhesive layer is formed in a single pass. Alternatively, multiple passes are required. Therefore, the adhesive layer is formed, if necessary, layer by layer or in stages in the thickness direction.

[0047] Basically, the adhesive layer can include multiple layers or coatings. These layers / coatings can be applied or formed over multiple passes. The layers / coatings can include different materials or be composed of different materials.

[0048] According to one implementation, the method includes the following steps:

[0049] - An adhesive layer is formed by thermal spraying, especially cold gas spraying;

[0050] - The functional layer is preferably applied to the adhesive layer by thermal spraying, and in particular by cold gas spraying.

[0051] The functional layer is preferably constructed as a corrosion-protective layer. For this purpose, zinc or zinc compounds are preferably provided as the material. The functional layer is ideally a zinc layer.

[0052] Alternatively, the adhesive layer or the first component is oiled in this way.

[0053] According to one embodiment, an intermediate layer is formed between the adhesive layer and the first component. The intermediate layer can also be formed by a thermal spraying method, for example, particularly cold gas spraying. Preferably, the intermediate layer is designed to prevent contact corrosion between the first component and the adhesive layer. Preferably, the transfer of iron (Fe) into the aluminum (Al) material, which would be detrimental, is prevented because a brittle Fe-Al phase is avoided.

[0054] According to one implementation, the method includes the following steps:

[0055] - Additionally, the second component is secured to the joint area by means of adhesive bonding.

[0056] It should be mentioned at this point that, for example, the area where two components overlap is interpreted as the joining area. Therefore, the joining area can also be considered as a flange, flange segment, or flange region. The adhesive layer can extend around or along the entire joining area. Alternatively, the adhesive layer may be provided only in areas or portions of the joining area. For the application of the adhesive, this means that the adhesive can be configured to bond only the first and second components.

[0057] Particularly preferably, the adhesive is applied such that it also contacts the adhesive layer, thus providing a bond between the adhesive layer and the second component. This is particularly advantageous because the adhesive layer becomes roughened by the process, which is optimal for adhesive adhesion. The roughness, or the resulting increase in surface area, provides an optimal prerequisite for the use of the adhesive.

[0058] According to one implementation, the method includes the following steps:

[0059] - Apply adhesive to and / or next to the adhesive layer.

[0060] As previously mentioned, it is particularly recommended that the adhesive contact the adhesive layer. In this case, it is also particularly advantageous that the profile, structural portion, or wave profile of the adhesive layer, in addition to the wave crests, platforms, or areas used as welding sites as described above, also has wave troughs, pockets, or gaps located therebetween. These gaps or chambers can be optimally used as adhesive reservoirs, which are at least partially or partially filled with adhesive. Regarding the thickness of the adhesive layer in the wave trough regions, an optimal thickness of the adhesive layer in these regions can be advantageously set. According to a preferred embodiment, the thickness of the adhesive layer is about 200µm to 400µm, particularly about 300µm. Correspondingly, the height ratio of the wave troughs or wave crests to the wave troughs is constructed. Furthermore, the inherent advantages of the rough surface structure of the adhesive layer are also present. It should be mentioned here that this effect also occurs when the adhesive is laterally adhered to the adhesive layer. Accordingly, the adhesive can also be applied or placed next to the adhesive layer. Then, a corresponding distribution can be achieved when the components are pressed together.

[0061] According to one implementation, the method includes the following steps:

[0062] Apply the adhesive point by point to the crests of the wave.

[0063] Here, it is advantageous to apply the appropriate amount of adhesive to the crests. This does not preclude the possibility of applying a smaller amount of adhesive, for example, by dripping, during application.

[0064] Particularly preferably, the adhesive is applied in a straight line and continuously along the adhesive layer. In this case, the movement speed is preferably slowed down in the trough areas, because more adhesive is retained there to meet the destination.

[0065] According to a preferred embodiment, pre-distribution of the adhesive is achieved by setting or positioning the components close to each other. This eliminates the need for separate steps for distributing the adhesive. Instead, the adhesive is applied to the desired locations so that it can be further distributed when the components are joined.

[0066] According to one implementation, the method includes the following steps:

[0067] - The adhesive is ultimately distributed by introducing force when welding the components.

[0068] This induction force is an implicit component of the pressure welding method, so it is advantageous that no separate or individual method steps are required here.

[0069] According to one embodiment, viewed along the joint area, the adhesive joint is designed to completely seal the joint area on one side (K1 adhesive joint). Alternatively, the adhesive joint or multiple adhesive joints are configured to completely seal the joint area on both sides (K2 adhesive joint). Consistent with the desired outcome or according to a preferred embodiment, the adhesive layer is completely embedded in the adhesive, in other words, encapsulated in or encapsulated (in) the adhesive. The final configuration of the adhesive joint is determined by the application of the adhesive.

[0070] According to one embodiment, a one-component adhesive or a two-component adhesive is used. Preferably, structural adhesives are used. One-component adhesives require heat to cure. They do not cure after welding. Instead, they can cure, for example, during a subsequent painting process. Two-component adhesives cure in air. This provides greater flexibility in the materials used, particularly in the design of the components, allowing for a high degree of freedom.

[0071] According to one implementation, the method includes the following steps:

[0072] - Provide a first component having a surface-treated section;

[0073] - By forming an adhesive layer and partially removing the surface treatment portion during the formation of the adhesive layer.

[0074] The surface treatments discussed can be KTL layers (cathode immersion coating), passivation, or, for example, laser cleaning or laser activation, on the component surface. It has been shown that, in particular, the aforementioned types of "coatings" can be removed or exfoliated by thermal spraying. In other words, no type of surface treatment "interferes" with the application of the adhesive layer, where, particularly in cold gas spraying, a gas temperature preferably above 800°C, and especially preferably around 1000°C, is effective.

[0075] Alternatively, components that are initially at least partially exposed or uncoated are joined and then subsequently fed to a coating method, where this is, for example, for corrosion protection. According to one embodiment, the method includes the following steps:

[0076] - After joining the components, a surface treatment is applied to the first component.

[0077] The present invention also relates to a component connection structure comprising a first component, particularly aluminum, and a second component, particularly steel, fixed to each other along a joint area. The first component has at least partially an adhesive layer in the joint area, the adhesive layer being formed by a thermal spraying method, and the second component is fixed to the adhesive layer by pressure welding. Advantageously, the first component, made of aluminum, is provided with a steel coating / adhesive layer by a spraying method for connection to a suitable second component made of steel in a subsequent process by pressure welding, particularly resistance spot welding. Particularly preferably, the first component is an aluminum die-cast component. It may include surface treatments such as KTL coating, passivation, or laser activation / laser cleaning.

[0078] According to a preferred embodiment, the first component is a cast component, sheet metal, and / or profile, preferably made of a light metal such as aluminum. Preferred cast components are particularly structural components, such as spring supports, longitudinal beams, or cast joints (e.g., the A-pillar of a motor vehicle). Furthermore, cast components of the type discussed can also be the complete frame, rear body, or front compartment of a motor vehicle. The first component can also be the housing of an energy storage device, particularly a high-voltage storage device housing, preferably, especially the upper or lower portion of such a housing.

[0079] According to a preferred embodiment, the adhesive layer extends along the bonding region and has a profile, structural portion, or wave portion along the bonding region, preferably with at least one weld point formed at each wave crest. Preferably, the adhesive layer alternately includes wave crests and wave troughs along the bonding region, with one or at least one weld point provided at each wave crest.

[0080] According to a preferred embodiment, the surface of the adhesive layer, or particularly the surface of the wave crest, has a Sa value preferably greater than 5µm, particularly preferably between 5µm and 35µm, and even more preferably between 5µm and 15µm. The Sa value (average arithmetic height) is the amount of height difference at each point compared to the arithmetic mean of the surface. This ensures a reliable welding process. In particular, it ensures that the current path is not obstructed by any voids or gaps.

[0081] Preferably, the Sdr value of the adhesive layer is at least 5%, particularly preferably in the range of 10% to 30%, and even more preferably about 12% to 20%. This parameter is a percentage of the additional area of ​​the defined range due to the surface characteristics of the adhesive layer compared to an absolutely flat defined range. For example, the Sdr value of an untreated die-cast component is preferably in the range of 2%.

[0082] According to a preferred embodiment, the components are bonded at least sectionally along the joint area, particularly along the adhesion area. Preferably, the adhesive is in contact with the adhesion layer. An advantage used here is that the adhesion layer has a roughness greater than that of the first component.

[0083] Furthermore, the advantages and features mentioned in the method are similarly and correspondingly applicable to component connection structures or vice versa. Attached Figure Description

[0084] Further advantages and features can be derived from the following description of embodiments of the method for joining components or component connection structures with reference to the accompanying drawings.

[0085] In the attached diagram:

[0086] Figure 1 A schematic diagram illustrating an implementation of the method flow;

[0087] Figure 2 This diagram shows the two components before they are joined.

[0088] Figure 3 Showing the result after engagement Figure 2 The known components;

[0089] Figure 4 A schematic diagram showing a cross-section of the adhesive layer;

[0090] Figure 5 A schematic cross-sectional view of the adhesion layer as viewed along the feed direction is shown. Detailed Implementation

[0091] Figure 1 A schematic diagram illustrates an embodiment of the method flow for joining two components 10 and 20. The first component 10 is schematically shown. An adhesive layer 30 is applied to the joining area 26 of the first component 10 by a thermal coating method or a spraying method (see coating tool 70). An adhesive 40, which has been pre-distributed to the joining area 26 when positioning the second component 20, is applied directly to the adhesive layer 30. Subsequently, the two components 10 and 20 are joined by pressure welding, currently particularly resistance spot welding (see two weld caps 60). By introducing force (see arrows pointing to each other), the two components 10 and 20 are pressed against each other during welding, where the adhesive 40 is further distributed, and it is now advantageous that the adhesive layer 30 is completely encapsulated. It can be seen that the weld caps 60 are constructed differently. The lower weld cap 60, which rests against the first component 10, preferably aluminum, is implemented as a spherical shape, while the upper weld cap 60, which rests against the second component 20, preferably steel, is constructed as a planar or flat shape. This embodiment has proven advantageous because it avoids indentations on the aluminum side. Furthermore, adhesion of the weld cap 60 can be effectively prevented. The final illustration shows the removal of the weld cap 60, as indicated by the two arrows. The two components 10 and 20 are now joined by the weld point 50 and the adhesive 40. It can be seen that the adhesive 40 adheres both to the adhesive layer 30 (where it adheres particularly circumferentially) and to both components 10 and 20.

[0092] Figure 2 The second component 20 and the first component 10 are shown schematically. Along the first component 10, the adhesive layer 30 extends along the bonding region 26. The adhesive layer 30 is formed by a thermal spraying process. For this purpose, the adhesive layer 30 is applied by traveling along the direction of movement V through the bonding region 26 using a suitable tool. This can be done in multiple layers, which are applied in an overlapping manner. Preferably, the desired thickness of the adhesive layer 30 is formed in a single pass. The width of the adhesive layer 30, measured transversely to the direction of movement V, can be achieved by traveling through multiple parallel lines or tracks, where multiple layers can also be applied in an overlapping manner. Alternatively, the width can be adjusted in a single pass, depending on the selection of the appropriate nozzle. Depending on the desired outcome, the adhesive layer 30 is designed along the direction of movement V to form a profile, structure, or wave profile. This wave profile includes wave peaks 34 and wave troughs 36. In the region of the wave peaks 34 (see the shaded area), the thickness of the adhesive layer 30 is greater than the thickness in the wave troughs 36. According to a preferred embodiment, the thickness of the adhesive layer 30 in the region of the wave crest 34 is approximately 1000 µm. In the wave trough 36 therebetween, the thickness of the adhesive layer 30 is lower than this value or, depending on the method, even close to 0. The function of the structural portion is particularly due to… Figure 3 It is clear. Wave crest 34, also known as a platform or field area, has a preferred side length of 20x20mm in the top view. The spacing between adjacent wave crests 34 is, for example, approximately 60mm relative to their center.

[0093] Figure 3 Showing basically from Figure 2 The known simplified diagram shows that component 20 is now fixed to the joint area 26 of the first component 10. This fixing is achieved by means of a joint using pressure welding (currently preferably, in particular, resistance spot welding). Welding point 50 (see also...) Figure 2 The weld point 50 is positioned on the wave crest 34. As previously mentioned, the wave crests 34 are spaced approximately 60 mm apart, and the side length of this "area" is preferably approximately 20 x 20 mm. The size of this area or wave crest 34 allows for reliable positioning or alignment during the welding process. The spacing of this area or wave crest 34 is designed to achieve the mechanical target value for the connection. Particularly advantageously, adhesive bonding is used in addition to welding to join components 10 and 20. The adhesive can ideally extend into or be positioned in the wave trough 36. Due to the roughness or porosity of the adhesive layer 30, and due to application by spraying, optimized adhesion, or rather, adhesive clamping, can be achieved, which improves the strength of the component connection structure.

[0094] Figure 4A cross-section of the adhesive layer 30 disposed on the first member 10 is shown schematically along the direction of movement V of the coating tool. The wave profile, including wave peaks 34 and wave troughs 36, is schematically illustrated. In the region of wave peaks 34, the wall thickness of the adhesive layer 30 is significantly greater than that in between. This is achieved, for example, by increasing the moving speed of the coating tool in the region of wave troughs 36. It can be clearly seen that this method minimizes the size of the adhesive layer 30 in the region of wave troughs 36, significantly reducing weight and material costs, and thus significantly reducing the method cost. With further adjustments to this method, it can also be implemented such that no coating material is present in the region of wave troughs 36 when desired. Then, the adhesive layer 30 is constructed precisely only in the region of wave peaks 34. However, regarding the above-described bonding method, the presence of at least a thin adhesive layer 30 in the region of wave troughs 36 provides significant advantages because its roughness or porosity increases the surface area in this region, which greatly benefits the adhesive bonding structure.

[0095] Figure 5 A cross-section of the adhesive layer 30 is schematically shown. The adhesive layer 30 is currently formed by a plurality of lines 31 arranged side by side. It can be seen that gaps 32 are formed between these lines 31. The further apart the lines 31 are, the larger the gaps 31 become. If welding is now performed on such a structure (see [reference needed]),... Figure 1 In particular, welding spatter may occur. This problem arises especially when the electrode is positioned in or on the area of ​​"gap 31". Advantageously, the method is implemented by adjusting the trajectory or line misalignment and / or appropriately selecting the nozzle diameter to form a uniform surface over the entire area of ​​the adhesive layer 30, currently particularly in the width direction, so that the weld point can be set so-called "arbitrarily".

[0096] List of reference numerals

[0097] 10 First Component

[0098] 20 Second Component

[0099] 26 joint areas

[0100] 30 Adhesion Layers

[0101] 31 routes and tracks

[0102] 32 gap

[0103] 34 wave peaks and plateaus

[0104] 36 Wave Valley

[0105] 40 adhesive layers

[0106] 50 welding points

[0107] 60 welding cap

[0108] 70 Coating Tools

[0109] V. Movement direction, feed direction

Claims

1. A method for joining components, the method comprising the following steps: - Provide a first component (10), the first component (10) being an aluminum die-cast component, wherein the first component (10) has a mating area (26) for setting and fixing the second component (20). - An adhesive layer (30) is formed at least partially on the bonding area (26) by a thermal spraying method, wherein the adhesive layer (30) is formed extending along the bonding area (26) such that the adhesive layer (30) has a wavy profile along the bonding area (26), wherein the adhesive layer (30) has wavy peaks (34) at regular intervals along the bonding area (26). - The second component (20) is fixed to the adhesive layer (30) by means of pressure welding, wherein spot welding is performed in the region of the wave crest (34) of the adhesive layer (30).

2. The method according to claim 1, wherein, The method includes the following steps: - An adhesive layer (30) is formed by cold gas spraying.

3. The method according to claim 1 or 2, wherein, The ratio of the height of the wave crest (34) to the height of the wave trough (36) is in the range of 1.05 to 2.

7.

4. The method according to claim 1 or 2, wherein, The wave profile is formed when the adhesion layer (30) is formed by adjusting the feed rate.

5. The method according to claim 1 or 2, wherein, The method includes the following steps: - The adhesive layer (30) is formed by applying material to multiple lines arranged side by side.

6. The method according to claim 1 or 2, wherein, The method includes the following steps: - Additionally, the second component (20) is fixed to the joint area (26) by means of adhesive bonding.

7. The method according to claim 6, wherein, The method includes the following steps: - Apply the adhesive (40) to the adhesive layer (30) and / or to the side of the adhesive layer.

8. The method according to claim 7, wherein, The method includes the following steps: - The adhesive (40) is distributed by setting or positioning the first component (10) and the second component (20) and by introducing force during pressure welding.

9. The method according to claim 1 or 2, wherein, The method includes the following steps: - Provide a first component (10) having a surface-treated section; - The surface treatment portion is partially removed by forming an adhesion layer (30) and during the formation of the adhesion layer.

10. A component connection structure comprising a first component (10) and a second component (20), the first component being made of aluminum, the first component and the second component being fixed to each other along a joint area (26), wherein, The first component (10) has at least partially an adhesive layer (30) in the joint area (26), the adhesive layer being formed by a thermal spraying method, and the second component (20) is fixed to the adhesive layer (30) by pressure welding, wherein the adhesive layer (30) alternately includes wave peaks (34) and wave valleys (36) along the joint area (26), and at least one welding point (50) is provided on each of the wave peaks (34), the adhesive layer (30) having wave peaks (34) at regular intervals along the joint area (26).

11. The component connection structure according to claim 10, wherein, The surface of the adhesion layer (30) has a Sa value in the range of 5µm to 30µm.

12. The component connection structure according to claim 10 or 11, wherein, The first component (10) and the second component (20) are bonded together at least partially along the joint area (26).

13. The component connection structure according to claim 10 or 11, wherein, The second component is made of steel.

14. The component connection structure according to claim 12, wherein, The first component (10) and the second component (20) are bonded together along the adhesive layer (30).

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