Method for welding an iron alloy component to an aluminum alloy component
Patent Information
- Authority / Receiving Office
- DE · DE
- Patent Type
- Patents
- Current Assignee / Owner
- GM GLOBAL TECHNOLOGY OPERATIONS LLC
- Filing Date
- 2021-04-30
- Publication Date
- 2026-08-06
AI Technical Summary
The challenge is to weld aluminum alloy components to steel components without forming brittle intermetallic aluminum/iron phases, which weaken the joint, while leveraging the weight advantages of aluminum and structural strength of steel in automotive applications.
A method involving machining and cleaning the mating surfaces of aluminum and steel components, applying a copper alloy layer, forming a weld groove with a tilt angle, and laser welding with a copper alloy filler to create a strong bond between the components.
This method forms a strong fusion bond between aluminum and steel components without brittle intermetallic phases, ensuring structural integrity and durability.
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Abstract
Description
INTRODUCTION
[0001] The present disclosure relates to a method for welding an aluminium alloy to steel.
[0002] The use of aluminum components in automobiles has become increasingly popular due to aluminum's weight advantages. However, certain components or parts of components, such as transmission interfaces or points of high stress concentration, must still be made of steel because steel inherently possesses a higher modulus of elasticity and greater mechanical strength, resulting in superior structural performance. The challenge for the industry lies in leveraging the advantages of both materials without incurring the disadvantages that arise from structurally joining them. Problems occur when aluminum and steel are welded directly together, such as the formation of brittle intermetallic aluminum / iron phases.
[0003] While current joining techniques fulfill their purpose, there is therefore a need for a new and improved method for welding aluminium components to steel components without the formation of brittle intermetallic aluminium / iron phases that weaken the weld joint. DESCRIPTION
[0004] According to several aspects of the present disclosure, a method for welding an iron alloy component to an aluminum alloy component comprises machining and cleaning a mating surface of the iron alloy component, machining and cleaning a mating surface on the aluminum alloy component, applying a layer of copper alloy material to the mating surface of the iron alloy component, forming a weld groove on at least one of the layers of copper alloy material applied to the mating surface of the iron alloy component and the mating surface of the aluminum alloy component, and laser welding the layer of copper alloy material applied to the mating surface of the iron alloy component and the mating surface of the aluminum alloy component to each other.
[0005] According to another aspect, forming a weld groove on the layer of copper alloy material applied to the mating surface of the iron alloy component and / or the mating surface of the aluminum alloy component further includes: machining the layer of copper alloy material applied to the mating surface of the iron alloy component and / or the mating surface of the aluminum alloy component at an inclined angle.
[0006] According to another aspect, the angle of inclination is greater than 0 degrees and less than or equal to 45 degrees.
[0007] According to another aspect, the laser welding of the layer of copper alloy material applied to the mating surface of the iron alloy component and the mating surface of the aluminum alloy component further includes: laser welding of the layer of copper alloy material applied to the mating surface of the iron alloy component and the mating surface of the aluminum alloy component by laser welding with a copper alloy filler material to join the layer of copper alloy material applied to the mating surface of the iron alloy component and the aluminum alloy component together.
[0008] According to another aspect, the chemical composition of the copper alloy filling material comprises approximately 50% to approximately 70% copper, zero to approximately 30% nickel, zero to approximately 10% aluminum, zero to approximately 10% iron, zero to approximately 8% manganese, zero to approximately 10% silicon and approximately 0.1% to approximately 0.5% titanium.
[0009] From another perspective, the layer of copper alloy material deposited on the mating surface of the iron alloy component and the copper alloy filler material have the same chemical composition.
[0010] From another perspective, the chemical composition of the layer of copper alloy material deposited on the mating surface of the iron alloy component has a lower nickel content than the chemical composition of the copper alloy filler material.
[0011] According to another aspect, laser welding of the layer of copper alloy material applied to the mating surface of the iron alloy component and the mating surface of the aluminum alloy component by laser welding with a copper alloy filler material to join the layer of copper alloy material applied to the mating surface of the iron alloy component and the aluminum alloy component, furthermore includes: focusing a laser welding laser beam on the copper alloy filler material during the laser welding process to avoid overheating of the mating surface of the aluminum alloy component.
[0012] According to another aspect, the process further includes inserting the iron alloy component and the aluminum alloy component into a holder to hold the iron alloy component and the aluminum alloy component relative to each other, before the layer of copper alloy material deposited on the mating surface of the iron alloy component and the mating surface of the aluminum alloy component are joined together by laser welding.
[0013] According to another aspect, the method further includes moving the device relative to a laser welding machine and holding the laser welding machine in place while the layer of copper alloy material applied to the mating surface of the iron alloy component and the mating surface of the aluminum alloy component are welded together.
[0014] According to another aspect, the process also includes moving a laser welding machine relative to the fixture and holding the fixture in place while the layer of copper alloy material deposited on the mating surface of the iron alloy component and the mating surface of the aluminum alloy component are welded together.
[0015] According to another aspect, the deposition of a layer of copper alloy material on the mating surface of the iron alloy component involves the deposition of a layer of copper alloy material on the mating surface of the iron alloy component by a laser deposition process.
[0016] According to several aspects of the present disclosure, a motor vehicle part comprises an iron alloy component with a machined mating surface, a layer of copper alloy material applied to the mating surface of the iron alloy component, an aluminum alloy component with a machined mating surface, a weld groove formed on at least one of the mating surfaces of the iron alloy component and the aluminum alloy component, and a copper alloy filler material laser-welded between the copper alloy layer applied to the mating surface of the iron alloy component and the aluminum alloy component, connecting them.
[0017] According to another aspect, the weld groove includes an inclined angle that is incorporated into at least one of the layers of copper alloy material applied to the mating surface of the iron alloy component and the mating surface of the aluminum alloy component.
[0018] According to another aspect, the angle of inclination is greater than 0 degrees and less than or equal to 45 degrees.
[0019] According to another aspect, the chemical composition of the copper alloy filling material comprises approximately 50% to approximately 70% copper, zero to approximately 30% nickel, zero to approximately 10% aluminum, zero to approximately 10% iron, zero to approximately 8% manganese, zero to approximately 10% silicon and approximately 0.1% to approximately 0.5% titanium.
[0020] From another perspective, the layer of copper alloy material deposited on the mating surface of the iron alloy component and the copper alloy filler material have the same chemical composition.
[0021] From another perspective, the chemical composition of the layer of copper alloy material deposited on the mating surface of the iron alloy component has a lower nickel content than the chemical composition of the copper alloy filler material.
[0022] According to another aspect, the layer of copper alloy material is deposited on the mating surface of the iron alloy component by a laser deposition process.
[0023] According to several aspects of the present disclosure, a motor vehicle part comprises an iron alloy component with a machined mating surface, a layer of copper alloy material applied to the mating surface of the iron alloy component by laser deposition, an aluminum alloy component with a machined mating surface, a weld groove defined by an angle of inclination of less than or equal to approximately 45 degrees and incorporated into at least one of the layers of copper alloy material applied to the mating surface of the iron alloy component and the mating surface of the aluminum alloy component, and a copper alloy filler material laser-welded between the layer of copper alloy material deposited on the mating surface of the iron alloy component and the mating surface of the aluminum alloy component, thus joining them together.wherein the chemical composition of the copper alloy filling material contains approximately 50% to approximately 70% copper, 0% to approximately 30% nickel, 0% to approximately 10% aluminum, 0% to approximately 10% iron, 0% to approximately 8% manganese, 0% to approximately 10% silicon, and approximately 0.1% to approximately 0.5% titanium.
[0024] Further areas of application will become apparent from the description presented here. It goes without saying that the description and specific examples serve only for illustration and are not intended to limit the scope of this disclosure. List of characters
[0025] The drawings described here are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way. Fig. Figure 1 is a perspective view of an automotive part according to an exemplary embodiment of the present disclosure; Fig. 2 is a section view along line 2-2 in Fig. 1; Fig. Figure 3 is an enlarged view of part of Fig. 2, as indicated by the dashed circle labeled Fig. 3 in Fig. 2 displayed; Fig. 4 is an enlarged view similar to Fig. 3, before welding the aluminum alloy component and the iron alloy component together; and Fig. Figure 5 is a flowchart showing a method for welding an iron alloy component to an aluminum alloy component according to an exemplary embodiment. DETAILED DESCRIPTION
[0026] The following description is merely exemplary and is not intended to limit the present disclosure, application, or use. Referring to Fig. 1 and Fig. 2 comprises an automotive part 10, an iron alloy component 12 welded to an aluminum alloy component 14. As in Fig. 1 and Fig. As shown in Figure 2, automotive part 10 is a hub with a gear welded to it. The hub is made of an aluminum alloy to save weight. The gear is made of steel to ensure the strength and durability required for the meshing.
[0027] Referring to Fig. In section 3, the aluminum alloy component 14 has a machined mating surface 16 and the iron alloy component 12 has a machined mating surface 18. The mating surfaces 16, 18 of the iron alloy component 12 and the aluminum alloy component 14 are surfaces that have been machined and washed to weld the iron alloy component 12 and the aluminum alloy component 14 together at the corresponding mating surfaces 16, 18.
[0028] The mating surface 18 of the iron alloy component 12 contains a layer of copper alloy material 20 applied to it. A weld seam 22 is formed on at least one of the layers of copper alloy material 20 applied to the mating surface 18 of the iron alloy component 12 and the mating surface 16 of the aluminum alloy component 14. A copper alloy filler material 24 is laser-welded between and joins the layer of copper alloy 20 applied to the mating surface 18 of the iron alloy component 12 and the mating surface 16 of the aluminum alloy component 14.
[0029] The layer of copper alloy material 20 bonds well with the iron alloy component 12 and ensures a strong connection between the mating surface 18 of the iron alloy component 12 and the layer of copper alloy material 20. In an exemplary embodiment, the layer of copper alloy material 20 is applied to the mating surface 18 of the iron alloy component 12 by laser deposition.
[0030] The chemical composition of the copper alloy filler material 24 contains approximately 50% to approximately 70% copper, 0% to approximately 30% nickel, 0% to approximately 10% aluminum, 0% to approximately 10% iron, 0% to approximately 8% manganese, 0% to approximately 10% silicon, and 0.1% to approximately 0.5% titanium. This high-nickel copper alloy filler material 24 fills the weld groove 22 and bonds well with both the layer of copper alloy material 20 applied to the mating surface 18 of the iron alloy component 12 and the mating surface 16 of the aluminum alloy component 14, thereby forming a strong fusion bond between the iron alloy component 12 and the aluminum alloy component 14.
[0031] Referring to Fig. 4. Before welding, the weld groove 22 contains an inclined angle 26, which is incorporated into at least one of the layers of copper alloy 20 applied to the mating surface 18 of the iron alloy component 12 and the mating surface 16 of the aluminum alloy component 14. The weld groove 22 creates a gap between the layer of copper alloy material 20 applied to the mating surface 18 of the iron alloy component 12 and the mating surface 16 of the aluminum alloy component 14, to allow the copper alloy filler material 24 to bond with the entire area of the layer of copper alloy material 20 applied to the mating surface 18 of the iron alloy component 12 and the mating surface 16 of the aluminum alloy component 14. In an exemplary embodiment, the inclination angle 26 is greater than 0 degrees and less than or equal to 45 degrees.
[0032] In one exemplary embodiment, the layer of copper alloy material 20 deposited on the mating surface 18 of the iron alloy component 12 and the copper alloy filler material 24 have the same chemical composition. In another exemplary embodiment, the chemical composition of the layer of copper alloy material 20 deposited on the mating surface 18 of the iron alloy component 12 has a lower nickel content than the chemical composition of the copper alloy filler material 24. A higher nickel content in the copper alloy filler material 24 increases the strength and weldability between the layer of copper alloy material 20 on the mating surface 18 of the iron alloy component 12 and the mating surface 16 of the aluminum alloy component 14.
[0033] In Fig.Figure 4 shows a flowchart illustrating a method 100 for welding an iron alloy component to an aluminum alloy component. Starting with block 110, the method 100 comprises machining and cleaning a mating surface 18 on the iron alloy component 12, and in block 112, machining and cleaning a mating surface 16 on the aluminum alloy component 14. In block 114, the method comprises depositing a layer of copper alloy material 20 onto the mating surface 18 of the iron alloy component 12. In an exemplary embodiment, depositing the layer of copper alloy material 20 onto the mating surface 18 of the iron alloy component 12 comprises depositing the layer of copper alloy material 20 onto the mating surface 18 of the iron alloy component 12 by a laser deposition process.Further to block 116, the process 100 includes forming a weld groove 22 on at least one of the layers of copper alloy material 20 applied to the mating surface 18 of the iron alloy component 12 and the mating surface 16 of the aluminum alloy component 14.
[0034] In one exemplary embodiment, the weld groove 22 is formed by machining at least one of the layers of copper alloy material 20, which is applied to the mating surface 18 of the iron alloy component 12 and the mating surface 16 of the aluminum alloy component 14, at an inclined angle 26. In another exemplary embodiment, the inclination angle 26 is greater than 0 degrees and less than or equal to 45 degrees.
[0035] Further to block 118, process 100 includes laser welding of the layer of copper alloy material 20, which is applied to the mating surface 18 of the iron alloy component 12 and the mating surface 16 of the aluminum alloy component 14.
[0036] In an exemplary embodiment, the iron alloy component 12 and the aluminum alloy component 14 are laser-welded with a copper alloy filler material 24 to join the layer of copper alloy material 20 applied to the mating surface 18 of the iron alloy component 12 and the aluminum alloy component 14.
[0037] In another exemplary embodiment, the chemical composition of the copper alloy filler material 24 comprises about 50% to about 70% copper, zero to about 30% nickel, zero to about 10% aluminum, zero to about 10% iron, zero to about 8% manganese, zero to about 10% silicon, and about 0.1% to about 0.5% titanium. The layer of copper alloy material 20 deposited on the mating surface 18 of the iron alloy component 12 and the copper alloy filler material 24 may have the same chemical composition, or alternatively, the chemical composition of the layer of copper alloy material 20 deposited on the mating surface 18 of the iron alloy component 12 may have a lower nickel content than the chemical composition of the copper alloy filler material 24.
[0038] During the welding of the layer of copper alloy material 20 applied to the mating surface 18 of the iron alloy component 12 and the mating surface 16 of the aluminum alloy component 14, a welding laser is focused on the copper alloy filler material 24 during the laser welding process. This is done to prevent overheating of the mating surface 16 of the aluminum alloy component 14.To ensure that the iron alloy component 12 and the aluminum alloy component 14 remain correctly aligned with each other during welding, the method 100 may further include inserting the iron alloy component 12 and the aluminum alloy component 14 into a device to hold the iron alloy component 12 and the aluminum alloy component 14 relative to each other before the layer of copper alloy material 20 applied to the mating surface 18 of the iron alloy component 12 and the mating surface 16 of the aluminum alloy component 14 are laser-welded together.
[0039] In block 122, the device can be adapted to move relative to a stationary welding machine, wherein the method 100 comprises moving the device relative to the laser welding machine and holding the stationary laser welding machine while the layer of copper alloy material 20 applied to the mating surface 18 of the iron alloy component 12 and the mating surface 16 of the aluminum alloy component 14 are welded together.
[0040] Alternatively, going to block 124, the apparatus can be stationary and the laser welding machine can be adapted to move relative to the apparatus, wherein method 100 comprises moving the laser welding machine relative to the apparatus and holding the apparatus stationary while the layer of copper alloy material 20 applied to the mating surface 18 of the iron alloy component 12 and the mating surface 16 of the aluminum alloy component 14 are welded together.
[0041] A method for welding an iron alloy component to an aluminum alloy component of the present disclosure offers the advantage of forming a strong fusion bond between the iron alloy component 12 and the aluminum alloy component 14, which does not contain brittle intermetallic aluminum / iron phases that would form if the iron alloy component 12 were welded directly to the aluminum alloy component 14.
[0042] The description of the present revelation is merely exemplary, and variations that do not deviate from the core of the present revelation are to be considered within the scope of the present revelation. Such variations are not to be considered a deviation from the spirit and scope of the present revelation.
Claims
[1] A method of welding a ferrous alloy component to an aluminum alloy component, comprising: Machining and cleaning a mating surface on the ferrous alloy component; Machining and cleaning a mating surface on the aluminum alloy component, Depositing a layer of a copper alloy material on the mating surface of the iron alloy component; Forming a weld groove on at least one of the layers of copper alloy material applied to the mating surface of the iron alloy component and the mating surface of the aluminum alloy component; and Laser welding the layer of copper alloy material deposited on the mating surface of the iron alloy component and the mating surface of the aluminum alloy component to each other. [2] The method according to claim 1, wherein forming a weld groove on the layer of copper alloy material applied to the mating surface of the iron alloy component and / or the mating surface of the aluminum alloy component further comprises: machining the layer of copper alloy material applied to the mating surface of the iron alloy component and / or the mating surface of the aluminum alloy component at an inclined angle. [3] The method of claim 2, wherein the angle of inclination is more than 0 degrees and less than or equal to 45 degrees. [4] The method according to claim 3, wherein laser welding the layer of copper alloy material deposited on the mating surface of the iron alloy component and the mating surface of the aluminum alloy component together comprises: laser welding the layer of copper alloy material deposited on the mating surface of the iron alloy component and the mating surface of the aluminum alloy component together by laser welding with a copper alloy filler material to join the layer of copper alloy material deposited on the mating surface of the iron alloy component and the aluminum alloy component together. [5] The method of claim 4, wherein the chemical composition of the copper alloy filler material comprises: from about 50% to about 70% copper; from zero to about 30% nickel; from zero to about 10% aluminum; from zero to about 10% iron; from zero to about 8% manganese; from zero to about 10% silicon; and from about 0.1% to about 0.5% titanium. [6] The method of claim 5, wherein the layer of copper alloy material deposited on the mating surface of the iron alloy component and the copper alloy filler material have the same chemical composition. [7] The method of claim 5, wherein the chemical composition of the layer of copper alloy material deposited on the mating surface of the iron alloy component has a lower nickel content than the chemical composition of the copper alloy filler material. [8] The method according to claim 4, wherein laser welding the layer of copper alloy material deposited on the mating surface of the iron alloy component and the mating surface of the aluminum alloy component by laser welding with a copper alloy filler material to join the layer of copper alloy material deposited on the mating surface of the iron alloy component and the aluminum alloy component together, further comprises: focusing a laser welding laser beam on the copper alloy filler material during the laser welding process to avoid overheating of the aluminum alloy mating surface. [9] The method of claim 4, further comprising: placing the iron alloy component and the aluminum alloy component in a fixture to hold the iron alloy component and the aluminum alloy component relative to each other before joining the layer of copper alloy material deposited on the mating surface of the iron alloy component and the mating surface of the aluminum alloy component by laser welding. [10] The method of claim 9, further including moving the fixture relative to a laser welding machine and holding the laser welding machine stationary while welding the layer of copper alloy material deposited on the mating surface of the iron alloy component and the mating surface of the aluminum alloy component together.
Citation Information
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