Method for manufacturing a motor vehicle component for a motor vehicle and corresponding motor vehicle component

Abstract

The invention relates to a method for manufacturing a motor vehicle component (1) for a motor vehicle, wherein the motor vehicle component (1) comprises a first joining part (4) made of a first material and a second joining part (5) made of a second material different from the first material, which together at least partially surround a motor vehicle opening (2) and are joined together. It is provided that the joining is carried out by friction welding using a friction welding element (6). The invention further relates to a motor vehicle component (1) for a motor vehicle.

Description

The invention relates to a method for manufacturing a motor vehicle component, wherein the motor vehicle component comprises a first joining element made of a first material and a second joining element made of a second material different from the first material, which together at least partially surround a motor vehicle opening and are joined together. The invention further relates to a motor vehicle component for a motor vehicle. For example, German patent application DE 10 2014 001 230 A1 is known from the prior art. This document describes an elongated body support for a vehicle body, comprising a hollow profile and a half-shell that at least partially encloses this hollow profile, and in which at least one flange connection is provided for connecting the hollow profile to the half-shell. The hollow profile is designed as a closed hollow profile made of a high-strength or ultra-high-strength steel material, and the hollow profile is configured with a flange for forming the at least one flange connection, which is made of a material with a lower strength than the steel material of the hollow profile. Furthermore, German patent application DE 10 2010 046 318 A1 discloses an joining element for joining at least two adjacent joining parts, comprising a shaft and a head. The shaft is movable through at least one first joining part by a rotational and translational movement and can be pressed into a second joining part without penetrating it. The shaft is formed by the heat generated during pressing, resulting in a material-bonded connection with at least the second joining part. The shaft is provided with a radially circumferential bead, and the bead is arranged in a bead section of the shaft. In the state of the joining element being pressed into the second joining part, this bead is enclosed by the plasticized material of the first joining part. Furthermore, US patent 6,676,007 B2 discloses a method for fastening metallic elements to form a vehicle structure, comprising the following steps: providing a first metal element; bringing the first metal element into contact with a second metal element; providing a metallic fastener that is substantially rotationally symmetrical about a central axis and has an upper radially widened section, a lower radially widened section and a shank section arranged between them, forming a circumferential groove around the axis and the fastener; and rotating the fastener about the axis by means of a rotating drive device. The following steps are further provided: driving the fastener through the first metal element and into the second metal element during its rotation, thereby generating friction between the fastener, the first metal element, and the second metal element to melt at least section-by-section areas of the first and second metal elements and to form a flowable material that flows into the circumferential groove of the fastener, the fastener being driven only partially into the second metal element; and solidifying the flowable material within the circumferential groove to integrally join the flowable material, the fastener, the first metal element, and the second metal element, the flowable material metallurgically bonding at least with the first and second metal elements. The object of the invention is to propose a method for manufacturing a motor vehicle component for a motor vehicle which has advantages over known methods, in particular is uniformly usable, avoids special measures and enables high flexibility in production through a standardized joining technology concept. This is achieved according to the invention by a method for manufacturing a motor vehicle component for a motor vehicle with the features of claim 1. It is provided that the joining is carried out by friction welding using a friction welding element. Advantageous embodiments with expedient further developments of the invention are specified in the dependent claims. It should be noted that the exemplary embodiments described in the description are not limiting; rather, any variations of the features disclosed in the description, the claims, and the figures are possible. The method is used to manufacture the automotive component. The automotive component is preferably an integral part of the motor vehicle, but can, of course, also exist separately, particularly until the automotive component is mounted on and / or in the motor vehicle. Preferably, the automotive component is a body component, i.e., a part of the motor vehicle's body. The automotive component comprises at least the first joining part and the second joining part. Naturally, more joining parts are possible; in this case, the automotive component has at least one additional joining part besides the first and second joining parts. It should be noted that each of the joining parts can be a single piece or multiple pieces. For example, at least one of the joining parts consists of several parts, in particular several sheets, which are preferably joined together. The two joining parts, i.e., at least the first joining part and the second joining part, consist of different materials, namely the first joining part of the first material and the second joining part of the second material, the second material being different from the first material. Preferably, both materials are metals, i.e., the first material being a first metal and the second material being a second metal different from the first metal. The two joining parts encompass at least some of the vehicle opening, particularly together with at least one additional joining part. The vehicle opening is understood to be an opening manufactured in the vehicle component. For example, the vehicle opening may be in the form of a door opening. The vehicle opening can be designed to be open at the edge or closed at the edge. In the former case, it is only partially encompassed by the first joining part, the second joining part, and the optional at least one additional joining part. In the latter case, the first joining part, the second joining part, and the optional at least one additional joining part together completely encompass the vehicle opening, so that together they form an edge that continuously and completely delimits the vehicle opening. The two components are joined together by joining; optionally, at least one further component is also attached to the components by joining. Joining refers to a manufacturing technique according to DIN 8580. In particular, the components are permanently or at most conditionally detachably joined together by joining. The joining of the two components of the automotive part and / or the at least one further component to at least one of the components is preferably carried out by forming, in particular by folding and / or riveting, and / or welding. Embossing, in particular embossing for fixing, can also be used to join the two components. Particularly when designing a vehicle opening as a door, different joining methods are frequently used. These are due, for example, to the different material properties of the first and second joining parts along the edge defining the vehicle opening. Thus, different riveting methods are employed, such as self-piercing rivets, especially semi-tubular self-piercing rivets and / or grip self-piercing rivets. The various joining methods result in a complex and expensive manufacturing process for the automotive component. Therefore, according to the invention, joining is achieved by friction welding. In the friction welding process, a friction welding element is used to connect the two components. Optionally, at least one additional component is also joined to the components by friction welding. This means that the two components, and optionally the at least one additional component, are provided on the one hand, and the friction welding element on the other, and at least the two components are arranged relative to each other. The friction welding element is then used to join the components. In friction welding, the heat required for joining is generated by a mechanical relative movement of the friction welding element with respect to the parts being joined, specifically without the formation of a molten pool. The heat generated by this relative movement leads to a local plasticized zone in at least one of the parts being joined, in which a metallurgical bond is formed while maintaining a joining pressure acting on the friction welding element. For example, the friction welding element is set into rotation or an oscillating motion. The friction welding element penetrates one of the joining parts, in particular the first joining part, until it reaches the other joining part, in particular the second joining part, and comes into contact with it. It may also penetrate at least one further joining part. Due to the plasticized zone created by friction, a material-bonded connection forms between the friction welding element and the second component. Accordingly, after the joining process is complete, the friction welding element remains as an integral part of the joint on both joining parts. Friction welding using the friction welding element creates a form-fit and material-fit connection between the joining parts. Specifically, the friction welding element has a friction welding element head from which a friction welding element shaft extends. During friction welding, the friction welding element shaft penetrates the first joining part and establishes a connection to the second joining part and / or at least one further joining part. The friction welding element head rests against the first joining part, so that the first joining part is held between the friction welding element head and the second joining part and / or at least one further joining part, at least form-fit, and preferably also material-fit. The use of friction welding to join the two components and – optionally – at least one additional component together reduces the number of different joining processes and thus avoids special measures on the components that would otherwise be necessary to carry out the various joining processes, such as selectively softening one of the components. This results in high flexibility and cost-effective production of the automotive component. A further development of the invention provides that different metals are used as the first and second materials. The metals are preferably metal alloys, so that ultimately different metal alloys are present. For example, aluminum or an aluminum alloy is used as the first material and steel or a steel alloy as the second material, or vice versa. The use of the friction welding element for joining the two components made of the different materials enables a reliable connection even between dissimilar materials. The at least one further joining element consists, for example, of the first material, the second material, or a third material, which is preferably different from the first material and / or the second material. Therefore, components made of the same material can be joined to a component made of a different material using friction welding, as described. In particular, several components made of aluminum or an aluminum alloy are joined to a component made of steel or a steel alloy. A further development of the invention provides that the friction welding element is configured as a perpendicular welding element and that the friction welding is carried out as perpendicular element welding. Perpendicular element welding is also referred to as SRE welding. It is performed using the perpendicular welding element, which is designed, for example, in the manner described above, i.e., has the friction welding element head and the friction welding element shaft. The perpendicular welding element is driven into one of the parts to be joined by a rotary or oscillating movement and, due to the friction acting on its end face, creates the locally limited plasticized zone. The perpendicular welding element penetrates the part to be joined and comes into contact with the other part, with which a metallurgical bond is formed due to the frictional heat and the joining pressure.This ensures a reliable connection between the first joining part and the second joining part. A further development of the invention provides that the joining of the first and second components is carried out exclusively by friction welding or by friction welding combined with another joining method different from friction welding. Thus, in a first embodiment of the method, the two components can be joined only by friction welding, in particular only by vertical friction welding. This significantly reduces the variety of joining methods. However, the applicant has determined that a combination of friction welding with the other joining method is particularly advantageous in terms of cost. According to a second embodiment, friction welding or vertical friction welding therefore represents one joining method among several joining methods. In addition to friction welding, another joining process is used to connect the two parts. Naturally, joining the components is possible using any number of joining methods. Preferably, however, the two components are joined exclusively using at most two different joining methods, one of which is friction welding. In addition to friction welding, only one other joining method is used to connect the first component to the second. It is possible that the joining methods used to connect the components—i.e., friction welding and the other joining method—are of different natures. While friction welding creates a material-bonded connection, the other joining method may create a form-fit connection between the two components, preferably exclusively a form-fit connection.Both variants of the process enable cost-effective and simple production of the automotive component. A further development of the invention provides that folding is used as an additional joining method. At least in certain areas, the two joining parts are thus connected by folding. For this purpose, one of the joining parts is formed, particularly at its edge, so that the other joining part is positively engaged and held between two sections of the joining part formed by the folding. In particular, one of the joining parts has one or more folding wings extending from a base body of the joining part. The folding wings are formed relative to the base body, in particular bent over, i.e., folded, so that a fold is formed. The other joining part is then positively engaged between the base body and the folding wing. In particular, an edge of this other joining part engages between the base body and the folding wing. Folding enables an extremely cost-effective joining of the two components, even over long distances. It therefore represents an ideal complement to friction welding. For example, the plan is to join the two components along the edge of the vehicle opening alternately by folding and friction welding. Folding allows large areas of the components to be fastened together quickly and cost-effectively. Friction welding provides a final, secure bond with high dimensional accuracy and positional precision. Accordingly, the advantages already described are achieved. Folding can also be supplemented by adhesive bonding. In this case, folded areas of the components are joined not only by folding but also by adhesive bonding. A further development of the invention provides that one of the joining parts has spaced-apart folded wings which are formed to engage behind the other joining part. Between the folded wings of one joining part is a mounting flange of the other joining part, to which the first joining part is attached by friction welding using the friction welding element. The first joining part thus has the folded wings, which extend, in particular, from a base body of the first joining part. Specifically, the folded wings are arranged at an edge of the base body, i.e., they originate from the edge. The folded wings are spaced apart from each other and are connected to each other exclusively via the base body. They are designed and formed, more precisely bent, to engage behind the other joining part. The other joining part is then positively locked between the base body and the folded wings of the first joining part. The mounting flange of one joining part is positioned between the folded edges of the other joining part; the folded edges thus accommodate the mounting flange in one direction. The mounting flange is designed and configured to create a joint between the joining parts. For this purpose, the friction welding element is arranged on it and connects the mounting flange to one joining part. The joining parts are materially bonded to each other by means of the friction welding element. On both sides of the friction welding element, the connection between the joining parts is positively locked, specifically purely positively locked, by means of the folded edges. However, it may be possible to use an adhesive in addition to the folding process to achieve a material-bonded connection between the joining parts, even in the folded joint area. In this case, the adhesive is applied specifically between the folded flap and the base body of one joining part, where it interacts with the other joining part. In any case, a reliable and durable bond between the joining parts is achieved, resulting in the advantages already described. The bonding effect achieved with the adhesive is preferably part of the joint created by the folding process. Therefore, the bonding effect performed in addition to the folding should not be considered a separate joining method. A further development of the invention provides that a seal is arranged on the first joining part and the second joining part such that it overlaps the friction welding element. Such a design is particularly suitable if the vehicle opening is a door opening of the vehicle. The seal serves, for example, to interact with a locking element, such as a door, which is mounted so as to be displaceable relative to the vehicle component. In particular, the vehicle component and the locking element are components of the vehicle body, and the locking element is mounted so as to be displaceable on the vehicle component, in particular by means of a hinge. The locking element can be arranged in different positions relative to the vehicle component, closing the vehicle opening to varying degrees in each position. For example, a first position is the closed position. In this position, the locking element completely closes the vehicle opening. Preferably, it also interacts with the seal around its entire circumference, or at least almost entirely, to ensure a reliable and tight seal. In a second position, which can also be described as the open position, the locking element at least partially releases the vehicle opening. As previously explained, the friction welding element remains attached to the two components after they are joined. In particular, it protrudes beyond the components, resulting in a protrusion. This is normally undesirable, as it detracts from the visual appearance of the automotive component. Therefore, the friction welding element, and especially the protrusion it forms, is concealed by the gasket. For this purpose, the seal is applied to the joining parts in such a way that the friction welding element is overlapped by the seal. Preferably, the protrusion formed by the friction welding element is completely located within the seal or completely overlapped by the seal. This offers an aesthetic advantage. Furthermore, the friction welding element, or rather its protrusion, serves as a positive-locking retainer for the seal, ensuring that it is held securely and reliably on the joining parts. A further development of the invention provides that a push-fit seal with a plug-in receptacle is used as the seal, which, in cross-section, is enclosed by several legs of the push-fit seal. The push-fit seal is understood to be a seal that is pushed or plugged onto the joining parts, in particular a common edge of the joining parts. Accordingly, the push-fit seal has the plug-in receptacle, which is designed and configured to receive the edge of the joining parts. The plug-in receptacle is defined by the legs of the plug-in seal. Specifically, two of the legs are spaced apart from each other, preferably parallel to each other, and connected only by a further leg. For example, the first-mentioned legs are each angled relative to the further leg, thus forming an angle with it that is greater than 0° and less than 180°. Preferably, the angle is at least 60° and at most 120°, at least 75° and at most 105°, or approximately or exactly 90°. For example, the legs are thus arranged in an essentially U-shape. This facilitates easy installation of the seal. A further development of the invention provides that the seal consists of a seal with a stiffening component made of a stiffening material, which is embedded within a sealing component made of a sealing material. The seal thus comprises both the stiffening component and the sealing component. The stiffening material of the stiffening component has a higher strength than the sealing material of the sealing component. In particular, the sealing material is in the form of an elastomer, for example, rubber or the like. Preferably, a metal, such as steel or spring steel, is used as the stiffening material. The stiffening component is completely embedded within the sealing component; consequently, the sealing component completely incorporates the stiffening component. Such a design of the seal enables a reliable hold on the components to be joined. The invention further relates to a motor vehicle component, in particular manufactured according to the explanations within this description, wherein the motor vehicle component comprises a first joining element made of a first material and a second joining element made of a second material different from the first material, which together at least partially surround a motor vehicle opening and are joined together by joining. It is provided that the joining is friction welding using a friction welding element. The advantages of such a design of the motor vehicle component and such a manufacturing process have already been mentioned. Both the motor vehicle component and the method for manufacturing it can be further developed according to the explanations within this description, so reference is made to these in this respect. The features and combinations of features described in the description, in particular those described in the following figure description and / or shown in the figures, can be used not only in the combinations specified, but also in other combinations or individually, without departing from the scope of the invention, in particular the scope of the claims. Thus, embodiments that are not explicitly shown or explained in the description and / or the figures, but which emerge from or can be derived from the explained embodiments, particularly within the scope of the claims, are also to be considered as encompassed by the invention. The invention is explained in more detail below with reference to the exemplary embodiments shown in the drawing, without limiting the invention. Figure 1 shows a schematic representation of a motor vehicle component in a first view, Figure 2 shows a schematic representation of the motor vehicle component in a second view, and Figure 3 shows a schematic sectional view of the motor vehicle component, which, in addition to two joining parts and a friction welding element, has a seal. Figure 1 shows a schematic representation of a motor vehicle component 1, which encompasses at least a portion, preferably completely, of a vehicle opening 2. Accordingly, the motor vehicle component 1 forms an opening edge 3 that delimits the vehicle opening 2, in particular continuously. The motor vehicle component 1 has a first joining element 4 and a second joining element 5, which is arranged behind the first joining element 4 and is only partially visible. It can be seen that at least the second joining element 5 is multi-part and consists of several elements. In particular, the second joining element 5 has several sheets which are connected to one another. The two joining parts 4 and 5 are attached to one another by joining. In the case of a multi-part design of the second joining part 5, for example, only one of the elements of the second joining part 5 is directly connected to the first joining part 4 by joining. The joining is carried out according to one or more joining methods. In any case, it is carried out by friction welding, using a friction welding element 6. Preferably, the joining parts 4 and 5 are joined to one another exclusively by friction welding using several friction welding elements 6. In the illustrated embodiment, however, it is provided that the joining in a first area 7 is carried out by friction welding and in at least one or more second areas 8 by folding. This means that one of the joining parts 4 and 5, preferably the first joining part 4, has a folded flap 9 in each of the second areas 8, which is formed or bent to create a folded recess. The other joining part 4 and 5, in the illustrated embodiment the second joining part 5, is received in the folded recess with a component edge 10. Preferably, several first areas 7 and several second areas 8 are provided around the circumference of the vehicle opening 2, with the first areas 7 and the second areas 8 alternating, so that a first area 7 is always located between several second areas 8 and / or a second area 8 is located between several first areas 7. Fig. 2 shows a schematic representation of the motor vehicle component 1 in a different view, namely from the rear. Here, the folded wings 9 of the first joining part 4, located in the second areas 8, are clearly visible. It is also evident that the component edge 10 of the second joining part 5 is positively engaged by the folded wings 9. The folded wings 9 are spaced apart from one another on the first joining part 4. Between them lies the first area 7, in which the second joining part 5 has a mounting flange 11, which is designed as a projection and engages between the folded wings 9. The at least one friction welding element 6 of the first area 7 is attached to the mounting flange 11. For this purpose, the friction welding element 6 extends through the first joining part 4 and is materially bonded to the mounting flange 11 of the second joining part 5. This ensures a reliable fastening of the joining parts 4 and 5 to each other. Figure 3 shows a further schematic cross-sectional view of the automotive component 1. Visible is the friction welding element 6, which has a friction welding element head 12 and a friction welding element shaft 13 extending from the friction welding element head 12. After joining the components 4 and 5 using the friction welding element 6, the friction welding element head 12 overlaps the first component 4, so that it is positively locked between the friction welding element head 12 and the second component 5. After joining the components 4 and 5, a seal 14 is applied to them. This is done such that the seal 14 overlaps the friction welding element 6, preferably completely. The seal 14 is a push-fit seal with a plug-in receptacle 15, which is bounded by legs 16, 17, and 18. The legs 16, 17, and 18 are preferably arranged in a U-shape relative to each other, as shown here. The seal 14 also has a stiffening component 19, which is embedded in a sealing component 20. The stiffening component 19 and the sealing component 20 are made of different materials, with the stiffening material of the stiffening component 19 having a higher strength than the sealing material of the sealing component 20. The stiffening component 19 is preferably essentially U-shaped. The sealing component 20, which receives the stiffening component 19, has a different shape; in particular, it has several sealing ribs and / or sealing projections which at least partially abut the joining parts 4 and 5 in a sealing manner. Preferably, at least one of the sealing projections abuts each of the joining parts 4 and 5 to ensure a reliable retention of the seal 14 on them. REFERENCE MARK LIST: 1 Motor vehicle component 2 Motor vehicle opening 3 Opening edge 4 1st joining part 5 2nd joining part 6 Friction welding element 7 1st area 8 2nd area 9 Rebated wing 10 Component edge 11 Mounting flange 12 Friction welding element head 13 Friction welding element shaft 14 Seal 15 Plug-in receptacle 16 Leg 17 Leg 18 Leg 19 Stiffening component 20 Sealing component QUOTES INCLUDED IN THE DESCRIPTION This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature DE 10 2014 001 230 A1

[0002] DE 10 2010 046 318 A1

[0003] US 6,676,007 B2

[0004]

Claims

Method for manufacturing a motor vehicle component (1) for a motor vehicle, wherein the motor vehicle component (1) has a first joining part (4) made of a first material and a second joining part (5) made of a second material different from the first material, which together encompass a motor vehicle opening (2) at least partially and are joined together, characterized in that the joining is carried out by friction welding using a friction welding element (6). Method according to claim 1, characterized in that different metals are used as the first material and as the second material. Method according to one of the preceding claims, characterized in that the friction welding element (6) is provided as a perpendicular friction welding element and the friction welding is carried out as perpendicular friction element welding. Method according to one of the preceding claims, characterized in that the fastening of the first joining part (4) and the second joining part (5) to each other is carried out exclusively by friction welding or by friction welding and a further joining method different from friction welding. Method according to one of the preceding claims, characterized in that folding is used as a further joining method. Method according to one of the preceding claims, characterized in that one of the joining parts (4, 5) has spaced-apart folded wings (9) which are formed to engage behind the other joining part (4, 5), wherein a fastening flange (11) of the other joining part (5) is located between the folded wings (9) of one joining part (4), to which one joining part (4) is attached by friction welding using the friction welding element (6). Method according to one of the preceding claims, characterized in that a seal (14) is arranged on the first joining part (4) and the second joining part (5) such that it overlaps the friction welding element (6). Method according to one of the preceding claims, characterized in that a plug-in seal with a plug-in receptacle (15) is used as the seal (14), which in cross-section is enclosed by several legs (16, 17, 18) of the plug-in seal. Method according to one of the preceding claims, characterized in that the seal (14) is a seal (14) with a stiffening component (19) made of a stiffening material which is embedded in a sealing component (20) made of a sealing material. Motor vehicle component (1) for a motor vehicle, in particular manufactured according to one or more of the preceding claims, wherein the motor vehicle component (1) has a first joining part (4) made of a first material and a second joining part (5) made of a second material different from the first material, which together encompass a motor vehicle opening (2) at least partially and are attached to one another by joining, characterized in that the joining is friction welding using a friction welding element (6).

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