Method and device for producing a metallurgical joint

Abstract

The invention relates to a method and a device for producing a metallurgical joint between two components, comprising the following steps: - pressing the first component and the second component by means of an actuator, - integrally metallurgically joining to one another the components to be pressed, by inputting energy into the opposite surface portions of the components (K1, K2) by means of energy transmission elements. In order to improve the contact between the components, at least one structural element tapered toward its free end is formed on at least one of the surface portions of the first and / or the second component (K1, K2) before the pressing. During the pressing and / or the metallurgical joining, the structural element (c) penetrates, by means of a contact face as part of its surface, into the opposite surface portion. During the penetrating, the shape of the structural element is maintained.

Description

[0001] METHOD AND DEVICE FOR PRODUCING A METALLURGICAL JOINT

[0002] The invention relates to a method and a device for producing a metallurgical bond between a first component made of a first metal and at least one second component made of a second metal. The invention also relates to a component for use in the method and for producing the metallurgical bond.

[0003] In the state of the art, various welding processes, such as butt welding, are generally known for the metallurgical joining of two metal components. Butt welding is divided into pressure butt welding and flash butt welding, with the following definitions (from "Compendium of Welding Technology," Volume 1: Welding Processes):

[0004] Butt welding: "The workpieces are heated at the butt surfaces and welded using force. Current and force are transferred via clamping jaws. Heating occurs through the contact resistance between the two parts to be welded. Therefore, a well-machined, plane-parallel butt surface is required to ensure a uniform current flow and thus uniform heating."

[0005] Flash butt welding: "The workpieces are heated at the butt surfaces by light contact through the formation of smoldering contacts, whereby molten material is ejected from the butt surfaces by metal vapor pressure (burning off), and welded by sudden compression under the application of force. Burning off can be preheated by repeated contact (reversing with individual current pulses) or by external heating. Current and force are transferred through contact jaws. In flash butt welding, in addition to the resistance heating, there is also combustion heat as well as the energy from smoldering arcs that form at the protruding contact points of the butt surfaces. The formation of smoldering spots is favored by a rough butt surface. This does not have to be plane-parallel either, because it is leveled by the burning off process.Liquid material (slag, metal) that is still in the welding gap from the burn-off process is pressed out during the sudden compression towards the end of the welding process and forms a burr on the surface."

[0006] Figures 10a and 10b illustrate the more familiar so-called projection welding. Figure 10a shows the components K1 and K2 involved in an initial situation before projection welding, while Figure 10b shows the components after projection welding.

[0007] DIN standards for projection welding:

[0008] DIN 8519

[0009] DIN EN 28167

[0010] DIN EN ISO 16432

[0011] DIN EN ISO 18278-1

[0012] DIN EN ISO 14327

[0013] Characteristic features of projection welding:

[0014] * The contour of the projection / bead (S1) is formed from a predominantly flat part (sheet metal or flat rail, sheet thickness <= 3.2 mm) using a deep-drawing, embossing, or forming process, creating a cavity within the projection. * The dimensions (height, outer diameter, interior space) of the projection (round, longitudinal, or ring projection) are derived from customer requirements and the material thickness in accordance with DIN standards.

[0015] * In the bonding process, the material is heated above its softening temperature during hot pressing to such an extent that it already enters a doughy state.

[0016] * In the actual joining phase, the two components undergo a fusion welding or

[0017] The previously formed contour (cavity) is leveled again. The projection collapses during welding, creating a flat connection in the form of a weld nugget (SWL).

[0018] * The dimensions of the projection and the customer-specific welding parameters (contact force, current, duration) determine the dimensions of the connection zone in the form of a weld nugget.

[0019] * The oxide and contamination layers present on the joining surface before the joining phase remain in the melt and can lead to corrosive layers.

[0020] * After the joining process, the two components lie completely or almost gap-free on top of each other.

[0021] The state of the art includes material-to-metal joints such as laser welding, electron beam welding of contact parts, resistance welding and soldering.

[0022] Flash butt welding and pressure butt welding, projection welding are generally known.

[0023] However, increasingly larger cross-sections when connecting contact materials are pushing existing processes to their limits:

[0024] Electron beam welding requires a vacuum and is complex and expensive. Resistance welding of aluminum and copper cannot currently be used to weld large surfaces because, once the current flows at a specific point, it no longer heats the remaining surface. Finally, ultrasonic ultrasonic welding or ultrasonic bonding is also well-known in the state of the art. In AI-US wire bonding (the first variant), which takes place at room temperature, an aluminum wire is pressed onto a solid surface made of an aluminum, gold, or copper layer using a bonding head, and the two are joined under ultrasonic influence. The ultrasonic generates the frictional heat required for the selective melting of the surfaces.

[0025] A second variant is called thermosonic bonding. Here, a gold or copper wire is pressed onto a surface made of aluminum, gold, or copper heated to approximately 300°C and bonded together under ultrasonic influences. Similar to the Joule bonding process, the bonding process also involves cold and / or hot forming, followed by the bonding process.

[0026] The invention is based on the object of developing a known method and a known device for producing a metallurgical connection and a component used therein in such a way that the contact between the components is improved.

[0027] This object of the invention is achieved with regard to the method by the method steps according to patent claim 1. It is characterized in that, before pressing, at least one structural element tapering towards its free end is formed on at least one of the surface sections of the first and / or the second component; that during pressing and / or during metallurgical joining, the structural element penetrates into the opposite surface section with a contact surface as part of its surface and with an actual immersion depth and with an actual energy and at least substantially retains its shape during penetration; and that the application of the contact force and / or the introduction of energy takes place until a desired immersion depth has been reached or a predetermined desired energy input has been introduced into the connection between the components.The target penetration depth can be assigned to a specific path marker. The path marker indicates a position along the path at which the structural element penetrates the mating component. The path marker can be an intermediate position along the path or the final station, i.e., the final depth along the path of the structural element. In the latter case, the target penetration depth is also called the total target penetration depth.

[0028] The target energy input can be assigned to a specific energy token. The energy token represents a specified amount of energy or a specified energy input that, when reached, should be input into the resulting connection of components. The energy token can be an intermediate energy input or a specified total energy input for the path of the structural element. In the latter case, the target energy input is also called the total target energy input.

[0029] The term "energy" refers to heat, i.e., thermal energy. This thermal energy is transferred into the components in various ways using energy transfer elements. Examples include fusion welding, in which an electric current is applied to the components using energy transfer elements in the form of electrodes; soldering, particularly brazing, in which heat is applied to the components using energy transfer elements in the form of electrodes or heating elements; or ultrasonic welding, in which ultrasonic vibrations are transferred to the components using energy transfer elements in the form of sonotrodes.

[0030] This energy concept of heat is distinguished here from the energy that is applied by a contact force.

[0031] The components can be, for example, busbars, flexible cables, for example stranded cables or strips, or connection elements (terminals). The structural elements according to the invention are then formed on the connection-side or connection-side ends or surface sections of the components. The surface sections with the structural elements can be formed and arranged at any position on the surfaces of the components, for example also on the end faces of the components. In the case of stranded cables or stranded strips, their strands can be compacted in sections. In the compacted sections, the structural elements can be formed as described in the paragraph after the next. The examples mentioned apply to all components, in particular to the first, second and / or a third component.

[0032] The method according to the invention advantageously achieves not only a long-lasting and resilient mechanical connection, but in particular also very good electrical conductivity at the contact surfaces between the connected components, even if these consist of different metals.

[0033] The structural element is a concrete physical part of a component and not merely a surface roughness of the component. The structural element is formed on at least one surface section of the component prior to pressing, for example, by cutting, sawing, punching, embossing (e.g., using a die), casting, laser cutting, or machining, in particular milling. The (total) height of the structural element is, for example, in the range of a few millimeters or a few centimeters.

[0034] The (total) height of the structural element is generally measured from the free end, i.e. the tip or highest point of the structural element, to its base / bottom on the respective component where it is formed. The penetration depth is that part of the height of the structural element with which the structural element, with its free end first, penetrates into the opposite component. The part of the surface of the structural element involved in this process is the contact area. If possible, the actual penetration depth can be measured directly within the scope of the method according to the invention. Alternatively, the actual penetration depth can also be determined indirectly as the difference between the originally known (total) height of the structural element and the measurable distance between the first and second components, which increasingly decreases during penetration.

[0035] As long as the components, or more precisely their opposing surface sections, do not touch over their entire surface after penetration, a deposit forms between them to absorb the slag created during the metallurgical joining. In other words: the deposit is formed by the remaining cavity between the spaced components after their inventive joining. The volume of the deposit should preferably be equal to or greater than the volume of the slag. The deposit serves to absorb as much of the slag created and squeezed out of the contact surface during the joining process as possible. If the deposit is overfilled, the slag is pushed out of the cavity laterally. There, its spread or distribution can optionally be specifically limited or defined by a mechanical barrier.This causes the slag to solidify into controlled structures, eliminating the need for rework. Alternatively, the squeezed-out slag can be reworked if necessary.

[0036] The term “slag” includes all residues that arise, in particular, during metallurgical joining, such as melting of the two components, oxides of the metals of the components, surface contamination of the components and, if applicable, melting of a solder.

[0037] The terms “immersion path” and “immersion depth” are used synonymously.

[0038] According to another embodiment, the two components can also be moved toward each other until no gap or hollow space remains between them. The contact area then increases accordingly; that is, the contact area encompasses not only the entire surface of the structural element, but also the portion of the surface sections of the components where the opposing components touch. The deposit is then eliminated, and all accumulating slag oozes outward or laterally toward the actual connection, as described at the end of the last paragraph.

[0039] In conventional butt welding, large, plane-parallel surfaces are typically joined together. In contrast, in the method according to the invention, structural elements tapering toward their free ends, e.g., conical or pyramid-shaped elements with initially small contact areas, penetrate the surface sections of opposing components, with the contact area expanding or enlarging during the process.

[0040] The known flash butt welding process utilizes surface roughness or smoldering contacts on the surfaces of the components involved at low contact forces, resulting in a burning process and a sudden upsetting process. In contrast, the method according to the invention provides for point-like and / or well-defined initial surfaces in the form of the free ends of the structural elements, preferably with a sufficiently constant contact force. Common to flash butt welding and the method according to the invention is that the melt is forced out of the contact area, thus leaving the melt core free of oxides and contamination.

[0041] Characteristic features of the inventive connection of components via structural elements:

[0042] * The contour of the structural elements, characterized by a taper towards their free end, is produced by a punching, embossing, laser cutting, machining, or casting process in a flat part of the first, second, and / or third component, without creating a cavity facing the later opposing component, as is the case with projection welding. In other places, the outer contour of the structural element can resemble a projection or bead. * During the cold forming process that takes place at the beginning of the joining process, the tapered ends of the structural elements destroy the oxide layers and force them out of the joining zone.

[0043] * In the hot pressing phase, which optionally follows the cold forming, the structural element is softened only to the extent that defined and desired initial surfaces are established between the tapered end of the structural elements and the counter component.

[0044] * In metallurgical bonding, the contours of the structural elements, especially their tapered free ends, are at least largely preserved. At most, they melt onto and into the mating component at their surface. The structural element tapers toward its free end, thus increasing the contact area during immersion.

[0045] * During the metallurgical joining phase, the two or more components are joined by a fusion weld, a brazing joint, or an ultrasonically welded joint, with the structural element melting into the mating component. In all three cases, a slag zone forms on the side flanks of the structural elements, which is collected in the zone and in any deposits between the opposing components.

[0046] The heating process is different due to the newly invented contour of the structural elements, which does not widen towards the free end, but rather tapers. Due to the smaller cross-section of the tapered end of the structural element, an energy, and possibly current, concentration occurs at the beginning of the metallurgical joining process, thus resulting in a strong heating, ideally combined with local melting, which is important for the start of welding or soldering. The advantage is that the shape or contour of the

[0047] Structural element, the heat flow can be well controlled during welding or soldering. As the joining process progresses, the two components approach each other and, due to the structural element-specific shape, the contact zone expands. The resulting changes in energy inputs, such as currents, required for optimal heat development are adjusted continuously or in sections. The input energy or the immersion distance, i.e., immersion depth, can be used as criteria for the control process. The joining process is terminated when a specific immersion distance is reached and / or a specific amount of energy has been input.

[0048] After the joining process, a gap preferably remains between the two components - here referred to as depot - in which the melt solidifies, unless it has been squeezed out laterally from the two components joined according to the invention.

[0049] By melting into the counter component, only the materials of the components are joined together in the connection zone without oxides or contamination.

[0050] After joining according to the invention, the internal contact area between the components is enlarged by the structural elements provided according to the invention, compared to a butt / flat joining of the components. The enlarged contact area advantageously significantly improves the mechanical contact and electrical conductivity between the components.

[0051] Differences between the known welding of projections and the joining of the metallic components via structural elements according to the invention, for example by fusion welding:

[0052]

[0053]

[0054] The pressing and the metallurgical joining can take place one after the other. Alternatively, the metallurgical joining can also take place while the components are being pressed together using the contact pressure. According to one embodiment of the method according to the invention, the first and the second component can also be connected to one another via a third component by the metallurgical connection. For this purpose, the third component has at least two surface sections and is used or arranged as a connecting member, also called a bridge component, for connecting the first and the second component. One of the surface sections of the third component then lies opposite the surface section of the first component during pressing and when producing the metallurgical connection, and the other of the surface sections of the third component then lies opposite the surface section of the second component.The bridge component, like the other components, can be rigid, e.g., a busbar, or flexible, e.g., a cable section, particularly a cable strand or a stranded wire. Alternatively, the cable section or stranded wire can also be rigid.

[0055] Alternatively, the metallurgical bond can also connect the third component only to the second (or to the first) component if the third component only faces the second (or only the first) component. In this case, the third component is also connected to the first (or second) component indirectly, i.e. via the second (or via the first) component. The first component is then an intermediate component in that it can be arranged between the third and the second component. Alternatively, the second component can be an intermediate component in that it can be arranged between the third and the first component. For this purpose, the third component has at least one surface section in both cases.In addition to a first surface portion, with which the second (or first) component faces the first (or second) component, at least one second surface portion is formed on the second (or first) component, with which the second (or first) component faces the surface portion of the third component during pressing and during the production of the metallurgical connection. The following applies to both alternatives for the third component: Before pressing, at least one structural element can be formed on at least one of the surface portions of the third component.During the pressing and / or metallurgical bonding with a contact surface as part of its surface, the structural element then penetrates into the opposite surface section of the first and / or second component with an actual immersion depth and with an actual energy until a predetermined target immersion depth or a predetermined target energy input is reached. In these cases too, the tapered contour of the structural element is at least substantially retained during the penetration. Alternatively or in addition to the variant in which the structural element is formed on the surface section of the third component, the structural element can also be formed on the first and / or second component for penetration into the third component.

[0056] According to a further embodiment, an at least single-layer auxiliary material, for example in the form of a solder in a soldered connection, a coating and / or a foil, can be applied to at least one of the surface sections of the first, second and / or third component and / or to the surface of the structural element before the pressing, between the pressing and the metallurgical joining or during the metallurgical joining or can be introduced between the structural element and the opposite surface.

[0057] The application of the solder is particularly advantageous for the soldered joint because a preferably eutectic melt forms between the solder layer and the opposing component, with a melting point significantly below the lowest melting temperature of both metals from which the components are made. The intermetallic phases should be ductile. The goal is for the opposing component to melt only in the area of ​​the melting zone. The metallic remainder of the components, including the structural element, remains solid and thus dimensionally stable. Pressing can be performed by cold pressing alone, cold pressing followed by hot pressing, or simply by hot pressing the components together.

[0058] During cold and / or hot pressing, a static component of the contact force can be at least temporarily superimposed with a dynamic component, for example, in the form of a periodic oscillation of the contact force. This would have the advantage that the dynamic component loosens and displaces contaminants on the contact surfaces.

[0059] According to the invention, cold pressing is terminated when one of the following cold pressing shutdown criteria is met:

[0060] - The actual immersion depth has reached the predetermined target immersion depth; and / or

[0061] - the actual cold pressing time exceeds a specified target cold pressing time.

[0062] During optional hot pressing, the components are subjected to heat using energy transfer elements. The energy input during hot pressing, if it occurs, represents the first part of the total energy input; a second part of the total energy input occurs during the subsequent metallurgical joining phase. If hot pressing is not performed, the total energy input only occurs during metallurgical joining.

[0063] The (heat) energy introduced into the joint during hot pressing has at least a static component, which can optionally be additionally superimposed or modulated with a periodic component of energy. Modulating the energy input, for example, by current, leads to alternating heating and cooling of the contact surface between the structural element of one component and the opposite surface section of another component into which the structural element penetrates. Since the expansion coefficients of, for example, pure metal and its oxide are very different (Al: 22 ppm to 8 ppm), a temperature change creates a shearing movement that leads to the desired detachment of an oxide layer at the contact surfaces. Additional modulation of the contact force enhances this mechanism.

[0064] The penetration of the structural element into the opposing surface section can begin during hot pressing, provided that hot pressing is performed. The penetration of the structural element does not have to begin during the creation of the metallurgical bond.

[0065] Hot pressing is typically terminated when one of the following hot pressing shutdown criteria is met:

[0066] - The actual immersion depth has reached the predetermined target immersion depth; and / or

[0067] - An actual hot pressing time has reached a specified target hot pressing time; and / or

[0068] - The actual energy introduced into the resulting joint during hot pressing has reached a specified hot pressing target energy value.

[0069] During pressing and metallurgical joining with the at least one structural element, the components can be arranged opposite one another at the end or at least partially overlapping one another.

[0070] During hot pressing and / or metallurgical joining, the electrodes can function not only to generate and transmit the current, but also as actuators for applying the contact force. This would have the advantage that the electrodes do not lose force during the joining process.

[0071] During hot pressing and / or during metallurgical joining, the contact force of the actuators, preferably of the electrodes if these also serve to apply the contact force, is always greater than zero. The contact force is adjusted or varied depending on the changing contact area. Since the joining process takes place in a very short time, specifically within a few tenths of a second, and the contact force must be maintained within a defined force range during this time, the dynamics of the typically used actuators or force controllers are generally insufficient. Force fluctuations lead to changes in surface resistance and consequently to overheating or insufficient heat. In addition to the actuator, the invention therefore provides a spring device which compensates for the fluctuations in force with the necessary dynamics.

[0072] In addition, certain metals, such as aluminum, exhibit a very strong tendency to oxidize. After cold pressing and / or hot pressing, the oxide surface layers are broken / destroyed, and an initial energy channel, such as a current channel, is created between the components. If, during a transition from pulse to pulse or during penetration of the structural element, the energy transfer element were briefly released without force or even lifted off, reoxidation would occur immediately, and a slight offset would cause the surface roughness with increased surface resistance to reappear. This would be highly detrimental to the expressly desired good electrical conductivity between the components connected to one another according to the invention, particularly in their contact surfaces.

[0073] According to a further exemplary embodiment, when the desired penetration depth is reached, a check is carried out to determine whether the energy applied up to that point lies within predefined limits, or after a predetermined amount of energy has been applied, a check is carried out to determine whether the penetration depth lies within predefined limits for the desired penetration depth. Both test methods are optional and serve for quality control purposes. Ideally, the connection produced using the method according to the invention meets both criteria, i.e. the desired penetration depth is reached and neither too little nor too much energy has been applied to the connection. If one of the conditions is still not met, a correction can still be made. This means that the penetration depth or the energy applied is corrected again in order to meet the corresponding specifications. This is advantageous for achieving the desired good electrical conductivity between the metallurgically joined components.Applying a protective gas to the joining area during pressing and / or during metallurgical joining offers the advantage of protecting the resulting joint between the two components from oxygen or harmful substances. This is also beneficial for achieving the desired good electrical conductivity between the metallurgically bonded components.

[0074] The first metal of the first component, the second metal of the second component and the third metal of the third component may be different or the same metals or metal alloys.

[0075] Preferably, the first metal from which the first component is made is copper or a copper alloy, and the second metal from which the second component is made is aluminum or an aluminum alloy. Both metals have very good electrical conductivity.

[0076] In particular, the shape of the structural elements according to the invention also assists in the inventive pressing and / or metallurgical joining of the components using ultrasonic US. Instead of current being introduced into the components using electrodes, ultrasound is then introduced into the components using sonotrodes to heat their contact surfaces.

[0077] Specifically, the structural elements enable a quality of connection that would not be achievable with a flat contact zone on the components without structural elements, as is known from the state of the art:

[0078] 1. With a completely flat contact surface between the two components, the oxide and contamination layers on both surfaces, with the exception of the edge zone, are not squeezed out. Instead, they remain in an undefined manner in the joint zone, disrupting and interrupting the joint formation (state of the art). 2. These contamination zones reduce the strength of the joint, increase the contact resistance, and can serve as a source of subsequent corrosion damage during operation (state of the art).

[0079] 3. The shape of the structural elements according to the invention allows a velocity transformation of the sonotrode-side contact surface of the component to be achieved.

[0080] This means that the ultrasonic motion of the sonotrode is transformed into a larger lateral and / or axial movement of the "tip" of the structural element. This heats it up.

[0081] 4. The shape and dimensions of the structural elements are preferably adapted to the selected US frequency and coupling type.

[0082] 5. Number, shape and dimensions determine the strength and volume resistance.

[0083] The above-mentioned object of the invention is further achieved by the device according to claim 29 and by the component according to claim 33. The advantages of these solutions correspond to the advantages previously mentioned with reference to the method according to the invention.

[0084] The device preferably has a cutting, sawing, machining, laser, punching, or embossing device, in particular a die, for forming the structural element on the surface portion of the first, second, and / or third component. The implementation of at least one of these devices in the device for producing a metallurgical bond offers the advantage that the process of forming the structural elements can take place within the device. The implementation is optional, which is expressed by the claiming of these devices as a dependent claim. Alternatively, the device for forming the structural element can also be provided outside the device for producing a metallurgical bond. In terms of time, the formation of the structural element always takes place before and independently of the pressing of the components in a separate operation.Further advantageous embodiments of the method according to the invention and the device according to the invention are the subject of the dependent claims.

[0085] The description includes 10 figures, where

[0086] Figure 1 shows various embodiments for the tapered free end of the structural element;

[0087] Figure 1 a shows various embodiments for the formation of holes in the structural elements and / or in the components on which the structural elements are formed;

[0088] Figure 2 shows various embodiments for the arrangement of the structural elements between a first and a second component;

[0089] Figure 3 shows a cohesive metallurgical connection between the first and the second metallic component realized according to the method according to the invention;

[0090] Figure 4a, a third component as

[0091] 4b and 4c connecting member between a first and a second component, wherein the third component has at least two surface sections on which, for example, structural elements are formed for penetrating the first and the second component;

[0092] Figure 5a shows an exemplary temporal relationship between different and 5b method steps of the method according to the invention;

[0093] Figure 6 shows the arrangement of the components and electrodes at the beginning of the joining process according to the invention by means of fusion welding; Figure 7 shows the arrangement of the electrodes and components after carrying out the method according to the invention by producing a fusion welded connection,

[0094] Figure 8 shows the arrangement of the electrodes and components at the beginning of the connection process according to the invention by soldering;

[0095] Figure 9 shows the connection of the components according to the invention after the soldering process has been carried out; and

[0096] Figures

[0097] 10a and

[0098] 10b shows or illustrates the projection welding process known from the prior art.

[0099] The invention is described in detail below with reference to the figures in the form of exemplary embodiments. In all figures, identical technical elements are designated by identical reference numerals.

[0100] The invention aims to connect at least two metallic components K1, K2, K3 to one another. To achieve this connection as effectively as possible, structural elements c according to the invention are formed on a surface portion of at least one of the components to be connected. The structural elements c are intended to penetrate into the opposing component within the scope of the inventive method in order to improve the connection.

[0101] The structural element is a 3-dimensional geometric object that tapers towards a free end. It is, for example, in the form of a tooth (see Figure 11), a cone (see Figure 11VI), a truncated cone (see Figure 1V), a pyramid (see Figure 1VII), a truncated pyramid (see Figure 1VII), a sphere or a spherical segment (see Figure 111), a horizontal cylinder, a horizontal cylinder segment, in particular a half-cylinder (see Figure 11ll), a column (see Figure 11V), or in the form of any combination of these objects, whereby the objects can then optionally also be arranged one above the other.

[0102] Particularly preferred are structural elements c that have inclined lateral surfaces at their tapered free end. This is the case, for example, with cones or pyramids and their truncated ends. In the joining method according to the invention, the tapering or inclined lateral surfaces initially generate a very high surface pressure at the specified force due to the initially small surface area. This is helpful for reliably squeezing slag constituents, such as free melt, oxides, and contaminants, out of the melt zone. Therefore, the free end of the structural element c is preferably tapered in the form of a point or an approximately rounded shape.

[0103] The structural elements c, regardless of their contour, can be manufactured using the devices mentioned above in the general part of the description.

[0104] The structural element c and the end region of the component K1, K2, K3, on which the structural element is formed, are preferably formed from solid material.

[0105] According to Fig. 1a, holes 40, also in the form of blind holes, or other artificial deformations, e.g. dents, can also be formed in or on the structural element c or the end region of the component K1, K2, K3. The holes 40 or corresponding blind holes can be formed according to Figures 1a I), II), III) in the form of an elongated hole, one or more circular holes or a triangle. The current must flow around the holes 40, whereby the current conduction is changed and the current density and thus the heat development in the edge region of the holes is increased; compared to the design of the structural elements without holes, the holes result in additional local heating. In this respect, through targeted placement and design of the holes or deformations, a desired heat distribution in the structural element or the end region of the component - which differs from the heat distribution without holes and deformations - can be achieved.

[0106] This is particularly clear in Fig. 1a IV, where the formation of several structural elements c is shown as an example using a component K1. Through the small holes 40 in component K1 near the structural elements c, the current is forced to divert to the current paths between the small holes 40, symbolized by the bold arrows in these intermediate regions. The current density and thus also the heat generation are thereby significantly increased in this intermediate region; at the same time, the heat flow from the later connection zone, where the structural elements have penetrated into the counter component, back into component K1 is reduced. The large hole 40' in the hinterland of the component is a mounting hole for the component.

[0107] Also advantageous is the provision of optional flow channels 45, which connect the part of the surface of the structural elements intended for penetration into the mating component with the holes 40 or blind holes. This makes it possible for the holes or blind holes to function as additional depots into which slag generated during the joining process can flow through the flow channels.

[0108] Figure 2I) shows linearly arranged structural elements c, some of which are also designed in the form of a circumferential and closed ring. Figure 2II) shows linearly arranged structural elements c arranged in a star shape. Figure 2I1I) shows individual structural elements c arranged in a row. Figure 2IV) shows different individual elements arranged in a row between the first component K1 and the overlapping second component K2.

[0109] The first component K1 and the second component K2 overlap in Figure 2 as an example. The annular arrangement according to Figure 2I), which should be circumferentially closed but not necessarily circular, offers the advantage that its surrounding structure in the form of a sealing collar prevents the escape of slag or melt. Free melt, oxides, and contaminants collect as slag in the deposit. Without the annular arrangement of the structural elements, there is a risk that the slag will also solidify in an area outside the connection zone and then have to be removed in an additional operation.

[0110] According to Figure 3, the first component K1 and the second component K2—as an alternative to the overlapping arrangement shown in Figure 2—can also face each other and be connected to each other according to the present invention. For this purpose, at least one structural element c according to the invention is formed on the end face of at least component K2, which penetrates into the first component K1 within the scope of the connection method according to the invention.

[0111] The structural elements c shown in Figure 3 are formed, for example, in a tooth-shaped manner on the second component K2. They are pressed into the first component K1 by means of actuators with a contact force F1, F2. In the embodiment shown here, the electrodes E1, E2 of the components K1, K2 are formed independently of the actuators and contact the components K1 and K2 at a different location.

[0112] In general, a spatial and temporal decoupling of the two processes "forming the structural element" and "pressing" is advantageous. In a single press system for embossing or punching the structural element, which is decoupled from the device according to the invention for producing the metallurgical connection, the first component is first inserted, a preferably heated die is placed on top of it, and finally an actuator, for example the upper electrode, presses the die, preferably with temperature, force, and / or displacement monitoring, into the surface section of the first component, thereby forming the structural element there. The die is then removed. Optionally, the second component is subsequently inserted into the single press system, and the embossing process with the die is repeated to form a structural element on the surface section of the second component. Pressing is then initiated.The feature that the structural element remains intact during hot pressing and during the creation of the metallurgical bond, particularly during penetration into the surface portion of the opposing component, does not preclude the possibility that the surface of the structural element may melt slightly during the penetration process. However, this still allows the structural element to retain its geometric shape, at least substantially.

[0113] Figure 4a illustrates an embodiment in which the first component K1 and the second component K2 are connected to one another via a third component K3 arranged between them in the form of an intermediate component. On the upper side of the third component K3, a one-piece structural element c in the form of a circumferential ring is formed according to Figure 4I). On the underside of the third component, individual structural elements c are formed, for example, according to Figure 4III, distributed over the circumference. Figure 4II) shows a cross-sectional view of the third component K3. Finally, Figure 4IV) illustrates the overlapping arrangement of the first component K1 and the second component K2 with the third component K3 arranged therebetween.The structural elements c just shown with reference to Figures 4I), II), and III) are shown in Figure 4IV), as they penetrate into the first component K1 and the second component K2 according to the method according to the invention, thus ensuring a good, integral metallurgical connection between all components involved, in particular also good electrical conductivity between these components. The design of the third component K3 in the form of a ring shown here in Fig. 4a is merely exemplary; the third component could equally well be designed as a body with any other geometric shape.

[0114] In contrast to Fig. 4a, Fig. 4b illustrates an embodiment in which the first component K1 and the second component K2 are connected to one another via the third component K3 in the form of a parallel bridge component. On the underside of the third component K3, a first and a second surface section are each formed with structural elements c. In Fig. 4b I), the structural elements c on the first surface section are initially only placed on the first component K1, and the structural elements on the second surface section are initially only placed on the second component K2.

[0115] Fig. 4b II) shows how the structural elements c penetrate into the first component K1 and the second component K2 according to the method according to the invention, thus ensuring a good, cohesive metallurgical bond between all components involved, in particular also ensuring good electrical conductivity between these components. The structural elements of the third component K3, for example, do not completely penetrate into the first and second components K1, K2, so that an intermediate space remains in each case as a depot 10 for escaping slag.

[0116] The bridge component according to Fig. 4b enables, for example, the connection of two flat components K1, K2 made of the same or different materials.

[0117] Fig. 4c shows a further exemplary embodiment for the third component K3, namely as a serial bridge component. The structural elements c are formed here on the end faces of the bridge component K3. Fig. 4c I shows a plan view of the components K1, K3 and K2 before application of the method according to the invention. Fig. 4c II shows in a horizontal section and also in a plan view how the structural elements c of the third component K3 have penetrated into the opposite surface sections of the first and second components K1, K2 after completion of the method according to the invention. The remaining deposits 10 can also be seen. In this exemplary embodiment, the design of the third (bridge) component K3 as a flexible stranded band is particularly preferred, wherein the strands of this strip are compacted at the free ends; the compacted regions at the free ends are designated by the reference symbol c10.The following material pairing is preferred: The first and second components are made of aluminum or an aluminum alloy, and the third (bridge) component is made of copper or a copper alloy. Fig. 4c III shows a longitudinal section through the components K1, K3, and K2 connected according to the invention.

[0118] Both Figures 5a and 5b illustrate the temporal progression of various physical parameters during the implementation of the method according to the invention. These parameters are the contact force, the current, the immersion depth, the (heat) energy introduced into the joint, and the size of the contact area between the structural elements and the mating component into which the structural elements penetrate.

[0119] Explanations of the parameters in detail:

[0120] Contact pressure:

[0121] An electromotive, pneumatic, or hydraulic actuator generates the contact force required to establish good contact between components K1, K2, K3 and the energy transfer elements on the one hand, and between the components on the other. The modulation of the contact force, optionally superimposed on a static contact force during the cold and / or hot pressing phase, serves to destroy the oxide and contamination layers and to form a reproducible contact surface. Furthermore, the contact force, in combination with the additional heat energy input, for example, via electricity, controls the heating of the contact surface between the structural element and the opposing component.

[0122] Electricity

[0123] The current generates the heat required for each process step during the hot pressing phase and the metallurgical joining phase. Optional modulation during the hot pressing phase creates a superimposed additional temperature change that enhances the detachment of the oxide layer. During the metallurgical joining phase, the current is adjusted to the changing conditions. By increasing the contact area during the joining process, the current level required to generate the required heat changes. This adjustment can occur continuously or intermittently. These changes in force and / or current depend on the immersion distance or the applied energy.

[0124] Immersion depth:

[0125] Starting from the initial contact height of the structural elements e with the counter component, the immersion depth, i.e. the immersion path, increases continuously until a predetermined target immersion depth is reached. The immersion path or immersion depth is divided into several segments, i.e. sections, for which different or identical energy input levels, for example current, and contact force levels are set. The transitions between the individual segments are marked in the figures by drawn levels or milestones. The milestones each represent predetermined immersion depths that are less than or equal to the predetermined maximum target immersion depth. Alternatively, the milestones can also each represent predetermined energy levels that are to be reached at individual stages of the immersion path; in these cases, the milestones are also referred to as energy milestones.When a distance or energy threshold is reached, certain quality control procedures can be performed, as described below. Regardless of whether such control procedures are performed, upon reaching a specified (total) target penetration depth or a specified (total) target energy input, the input of further energy is stopped, in particular, the power is switched off, and a cooling process is initiated.

[0126] Contact surface:

[0127] As the bonding process progresses, the contact area increases.

[0128] In chronological order, the process according to the invention is divided into the following process steps: cold pressing, hot pressing (optional), metallurgical joining and cooling, as can be seen in Figures 5a and 5b.

[0129] The time sequences in Figures 5a and 5b are purely schematic and merely exemplary representations. They apply regardless of whether the metallurgical bond is created using the process according to the invention by fusion welding, brazing, or ultrasonic welding as the method for energy input. Actual time sequences may differ from those shown in the figures.

[0130] Figures 5a and 5b differ in the rows for the energy curve and the immersion depth curve for different quality control methods. In Fig. 5a, the temporal progression of the applied energy shows the position of energy corridors for the specified immersion depth markers. In Fig. 5b, the temporal progression of the immersion depth shows the position of the height corridors for specified energy markers of the applied energy. Both control methods can be implemented as open-loop or closed-loop control.

[0131] Fig. 5a illustrates, particularly in the rows for the parameters immersion depth and energy, an immersion depth-controlled quality control process. It comprises the following substeps: a) Checking and determining that the structural element c of the first component K1 reaches a first milestone upon penetrating the second or third component K2, K3; b) Checking at the first milestone whether the actual energy introduced into the connection created by the penetration up to that point is within a target corridor for a target energy input assigned to the first milestone; c') If so: Continuing the penetration process up to a subsequent milestone, and repeating step b there for the subsequent milestone;and c") In the case of a control system, if no: adjusting at least one manipulated variable such that when the subsequent path marker is reached, a target energy input specified for the subsequent path marker is expected to be reached, and then: carrying out step c') with the adjusted manipulated variables; or c") In the case of a control system, if no: determining the difference between the actual energy input and the target energy input at the first path marker as the energy control deviation, adjusting at least one manipulated variable in accordance with the energy control deviation such that the energy control deviation is expected to be zero at the subsequent path marker, and then: carrying out step c') with the adjusted manipulated variable.;

[0132] In this immersion-depth-controlled quality control process, energy is the control variable. The control variables can be the contact force, the current level, the amplitude, or the frequency of the sonotrode when using the ultrasonic welding process, or the soldering temperature. In the case of a control system, the correction value for the control variable is a fixed value from a table.

[0133] The distance between the waypoints, and thus the number of control points and the correction values ​​of the manipulated variables, are determined during process optimization. The distance can vary from waypoint to waypoint, but is preferably equidistant.

[0134] The process steps b) to c') or c") are repeated for the subsequent milestones until a final (total) target penetration depth is reached.

[0135] When the cut-off mark corresponding to the final target penetration depth is reached, the current is switched off and the total energy fed in is checked to ensure it is within the target range. If the total energy is outside this range, the welded part is not automatically released.

[0136] Fig. 5b illustrates the energy-controlled quality control method, particularly in the rows for the parameters immersion depth and energy. It comprises the following sub-steps: a) Checking and determining that the structural element c of the first component K1 reaches a first energy mark upon penetrating the second or third component K2, K3, which represents a predetermined amount of energy that is to be introduced at the first energy mark into the connection created by the penetration; b) Checking at the first energy mark whether the actual immersion path traveled up to that point is within a target corridor for a desired immersion path assigned to the first energy mark; c') If so: Continuing the penetration process up to a subsequent energy mark, and repeating step b) there for the subsequent energy mark;and c") In the case of a control system, if no: adjusting at least one manipulated variable such that when the subsequent energy mark is reached, a subsequent target immersion path specified for the subsequent energy mark is expected to be reached, and then: carrying out step c') with the adjusted manipulated variables; or c") In the case of a control system, if no: determining the difference between the actual immersion path and the target immersion path at the first energy mark as the immersion path control deviation, adjusting at least one manipulated variable in accordance with the immersion path control deviation such that the immersion path control deviation is expected to be zero at the subsequent energy mark; and then: carrying out step c') with the adjusted manipulated variable.;

[0137] In this energy-controlled quality control process, the immersion depth is the control variable. The control variables can be the contact force, the current level, the amplitude, or the frequency of the sonotrode when using the ultrasonic welding process (US), or the temperature during soldering. In the case of a control system, the correction value for the control variable is a fixed value from a table.

[0138] The distance between the energy markers, and thus the number of control points and the correction values ​​of the manipulated variables, are determined during process optimization. The energy distance can vary from energy marker to energy marker, but is preferably always the same.

[0139] The process steps a) to c') or c") are repeated for the subsequent energy marks until a total target energy mark has been reached.

[0140] When the cut-off energy level, i.e., the specified total target energy, is reached, the current is switched off and the immersion distance traveled is checked to determine whether it is within the target range. If the total immersion distance is outside this range, the welded part is not automatically released.

[0141] In addition, multi-channel control systems can be configured with the controlled variables: immersion distance and energy, and with the manipulated variables: contact force and current, IIS amplitude, and / or soldering temperature. Here, the controlled variables are continuously read at very short, equal intervals, and the optimal manipulated variables are determined and adjusted using a complex control algorithm. When the shutdown condition (total target immersion depth or total target energy) is reached, the respective energy transfer element is deactivated, and the controlled variables are checked to ensure they have reached the target range. If the conditions are satisfactory, they are automatically released.

[0142] The joining process according to the invention with the metallurgical joining of the components in the form of fusion welding is explained in more detail below with reference to Figures 6 and 7.

[0143] Figure 6 shows the arrangement at the beginning of the joining process (fusion welding):

[0144] *Electrode E1 contacts the first component K1 with the surface AO

[0145] *On / at the first component K1 is the two-level structural element with the exemplary levels or waypoints:

[0146] *A1 : Base area of ​​the structural element

[0147] *A2: Intermediate area at the level of the depot

[0148] *A3: Connection surface between stage 1 and stage 2 of the structural element, preferably at the cut-off height of the hot pressing

[0149] *A4: Intermediate surface, preferably at the cut-off height of the cold pressing

[0150] *St: Start height: Zero point of the measured value penetration depth

[0151] *Electrode E2 contacts the second component K2 with the surface A5

[0152] Figure 7 shows the result after carrying out the method according to the invention for producing a metallurgical joint, as shown in its time sequence in Figs. 5a and 5b. Fig. 7 shows the result of a fusion welded joint according to the invention, for the case where the melting temperature of the second metal of the second component K2 is lower than the melting temperature of the first metal of the first component K1. Between the structural element c and the second component K2, a melt SM consisting of the second metal and a mixture of the first and second metals forms. The slag SL, consisting of the melt of the structural element c with the second component K2 as well as the oxides and contaminants on the surfaces, is pressed outside the melt zone into the depot 10.

[0153] Due to the tapered shape and the resulting smaller contact area of ​​the planes near the zero point, the temperature of the structural element is higher in the direction of the second component K2 than in the direction of the first component K1. Melting therefore occurs at the tip of the structural element facing the second component.

[0154] Temperature estimates for the pairing of copper (K1) and aluminum (K2): Temperature in the melt zone: 548°C, melting temperature for copper 1084°C and aluminum 660°C. Only the narrow melt zone becomes liquid. The mixing ratio of the melt, based on weight, is approximately 33% copper and approximately 67% aluminum (eutectic).

[0155] The joining process according to the invention with the metallurgical joining of the components in the form of (hard) soldering is explained in more detail below with reference to Figures 8 and 9.

[0156] Connection process: soldering

[0157] Figure 8 shows the arrangement at the beginning of the connection process (soldering):

[0158] *Electrode E1 contacts the first component K1 with the surface AO *On / at the component K1 is the two-stage structural element c with the exemplary levels or waypoints

[0159] *A1 : Base area of ​​the structural element

[0160] *A2: Intermediate surface at the level of the depot *A3: Connection surface between stage 1 and stage 2 of the structural element, preferably at the cut-off height of the hot pressing

[0161] *A4: Intermediate surface, preferably at the cut-off height of the cold pressing *Start height: Zero point of the measured value penetration depth

[0162] *Electrode E2 contacts the second component K2 with the surface A5 *The first component K1 is coated with a solder LB.

[0163] Figure 9 shows the result after carrying out the method according to the invention for producing a metallurgical joint, as shown in its time sequence in Figs. 5a and 5b. The result results from the soldering used according to the invention to introduce heat energy into the resulting joint in the event that the melting temperature of the K2 material is lower than the melting temperature of the K1 material. The structural element c is coated here with a solder LB. Alternatively, the solder can also be supplied separately as an insert (paste, foil, strip). In addition to the preferred hard solder, soft solder can also be used.

[0164] A melt of the solder and the K2 material forms between the structural element c and the second component K2. The slag, consisting of the melt of the solder with the countercomponent K2, as well as the oxides and contaminants on the surfaces, is forced into the depot 10 or outside the joint zone.

[0165] Due to the tapered shape and the resulting smaller area of ​​the planes near the zero point, the temperature of structural element c is higher toward the second component K2 than toward the first component K1. Melting therefore occurs at the K2-soapy tip.

[0166] The solder on the higher-melting material of structural element c on the first component K1 forms a eutectic fusion bond with the second metal of component K2. Ductile intermetallic phases can form in the second, larger-area bond zone caused by the structural element. Regardless of the method chosen for introducing the heat energy (fusion welding, ultrasonic welding, or soldering), the following applies:

[0167] Due to the structural element tapering towards its free end, an initially small contact and contact surface becomes a large contact surface during the joining process, ie the increasing penetration.

[0168] - The number of structural elements and their arrangement can be freely chosen.

[0169] - Several components can be connected to each other - the structural elements are formed on at least one surface section of the joining partners, i.e. the components.

[0170] In the embodiments according to Figures 6, 7, 8 and 9, the structural element and the first components are each made of higher-melting metal than the second (counter) component.

[0171] The energy transfer elements, in particular the electrodes E1 and E2, serve here as actuators for applying the contact force.

[0172] Alternatively, the actuators can also be designed independently or in addition to the energy transmission elements, analogous to Figure 3.

[0173] List of reference symbols:

[0174] A1 Area=Level=Waymark=Height

[0175] A2 Area=Level=Waymark=Height

[0176] A3 Area=Level=Waymark=Height

[0177] A4 Area=Level=Waymark=Height

[0178] A5 Area=Level=Waymark=Height c Structural element c10 Compact area

[0179] E1 Energy transfer element, e.g. first electrode

[0180] E2 Energy transfer element, e.g. second electrode

[0181] F1 contact force

[0182] F2 contact force

[0183] K1 first component

[0184] K2 second component

[0185] K3 third component

[0186] LB solder coating

[0187] Sl bead

[0188] SL slag

[0189] SM melt

[0190] St starting height

[0191] SWL welding lens

[0192] 10 Depot

[0193] 20 Control device

[0194] 40 holes, also blind holes

[0195] 40' mounting hole

[0196] 45 flow channel

Claims

Patent claims:

1. A method for producing a metallurgical connection between a first component (K1) made of a first metal and at least one second component (K2) made of a second metal, wherein the first and the second component (K1, K2) each have at least one surface section with which they face each other, comprising the following steps: - pressing the first and the second component (K1, K2) together with the aid of an actuator which exerts a contact force (F1, F2) greater than zero on the components, optionally with additional input of energy with the aid of energy transmission elements, and - materially bonding the components (K1, K2) to be pressed together by introducing energy into the opposing surface sections of the components with the aid of the energy transfer elements; characterized in that, before the pressing, at least one structural element (c) tapering towards its free end is formed on at least one of the surface sections of the first and / or the second component (K1, K2); that the structural element (c) penetrates into the opposing surface section during the pressing and / or during the metallurgical joining with a contact surface as part of its surface and with an actual immersion depth and with an actual energy and at least substantially retains its shape during the penetration;and that the application of the contact force and / or the introduction of the energy takes place until a desired immersion depth has been reached or a predetermined desired energy input has been introduced into the connection of the components (K1, K2); 2. Method according to claim 1, characterized in that the structural element is formed from solid material.

3. Method according to one of the preceding claims, characterized in that the structural element (c) is a 3-dimensional geometric object, for example in the form of a tooth, a cone, a truncated cone, a pyramid, a truncated pyramid, a sphere or a sphere segment, a horizontal cylinder, a horizontal cylinder segment, in particular a half cylinder or any desired combination of these objects, optionally also arranged one above the other.

4. Method according to one of the preceding claims, characterized in that the free end of the structural element (c) is designed in the form of a non-planar, preferably pointed contour.

5. Method according to one of the preceding claims, characterized in that a single structural element (c) or a plurality of structural elements (c) are formed or arranged on the surface section, for example in the form of a rectilinear, star-shaped, curvilinear or closed annular arrangement or in any combination of these arrangements.

6. Method according to one of the preceding claims, characterized in that by means of the metallurgical connection, a third component made of a third metal is also connected to the first and the second components (K1, K2); that the third component (K3) has at least two surface sections and is arranged as a connecting member for connecting the first and the second component (K2) in such a way that one of the surface sections of the third component (K3) faces the surface section of the first component (K1) during pressing and during the production of the metallurgical connection, and that the other the surface sections of the third component (K3) face the surface section of the second component (K2) during pressing and during the production of the metallurgical connection.

7. Method according to one of claims 1 to 5, characterized in that a third component (K3) made of a third metal is also connected to the second component (K2) by the metallurgical connection; that the third component (K3) has at least one surface section; that on the second component (K2), in addition to a first surface section with which the second component (K2) faces the first component (K1), at least one second surface section is formed, with which the second component (K2) faces the surface section of the third component (K3) during pressing and during production of the metallurgical connection.

8. Method according to one of claims 6 or 7, characterized in that before pressing, at least one structural element (c) tapering towards its free end is formed on at least one of the surface sections of the third component (K3); and in that the structural element, during pressing and / or during metallurgical joining, penetrates into the opposite surface section of the first and / or second component (K1, K2) with a contact surface as part of its surface and with an actual immersion depth and an actual energy until a predetermined target immersion depth is reached or until a predetermined target energy input has been introduced into the connection; and in that the structural element is retained during penetration.

9. Method according to one of the preceding claims, characterized in that the structural element (c) is integrally formed with the first, second and / or third component (K1, K2, K3) at at least one of the surface section is formed, for example by punching, casting, lasering, machining, in particular milling, or by embossing with the aid of a die.

10. Method according to one of the preceding claims, characterized in that before the pressing, between the pressing and the metallurgical joining or during the metallurgical joining, an at least single-layer auxiliary material, for example in the form of a solder, a coating and / or a foil, is applied to at least one of the surface sections of the first, the second and / or the third component (K1, K2, K3) and / or to the surface of the structural element (c) or is introduced between the structural element and the opposite surface.

11. Method according to one of the preceding claims, characterized in that the pressing is a sole cold pressing, a cold pressing followed by hot pressing or a sole hot pressing of the components (K1, K2, K3) with one another.

12. The method according to claim 11, characterized in that during the cold and / or hot pressing, a static component of the contact pressure is at least temporarily superimposed with a dynamic component of the contact pressure, for example in the form of a periodic oscillation of the contact pressure.

13. Method according to claim 11 or 12, characterized in that the cold pressing is terminated when one of the following cold pressing shutdown criteria is met: - The actual immersion depth has reached the predetermined target immersion depth; and / or - the actual cold pressing time exceeds a specified target cold pressing time.

14. Method according to one of claims 11 to 13, characterized in that the realized energy input during hot pressing is smaller than the realized total energy input during the production of the metallurgical connection.

15. The method according to claim 14; characterized in that the energy input during hot pressing has at least a static component, which is optionally additionally superimposed or modulated with a periodic component.

16. Method according to one of claims 11 to 15, characterized in that the hot pressing is terminated when one of the following Hot press shutdown criteria are met: - The actual immersion depth has reached the predetermined target immersion depth; and / or - An actual hot pressing time has reached a specified target hot pressing time; and / or - The actual energy introduced into the joint during hot pressing has reached a specified hot pressing target energy input.

17. Method according to one of the preceding claims, characterized in that the metallurgical joining takes place with simultaneous continuous pressing of the components with the contact pressure (F1, F2).

18. Method according to one of the preceding claims, characterized in that the components during pressing and metallurgical joining are arranged so as to face each other or at least partially overlapping relative arranged relative to each other.

19. Method according to one of the preceding claims, characterized in that the energy input during hot pressing and / or during the production of the integral metallurgical connection is realized by fusion welding, wherein an electric current is applied to the components with the aid of the energy transfer elements in the form of electrodes; by soldering, in particular brazing, wherein heat is applied to the components with the aid of the energy transfer elements in the form of electrodes or heating elements; or by ultrasonic welding, wherein ultrasonic vibrations are transmitted to the components with the aid of the energy transfer elements in the form of sonotrodes.

20. Method according to claim 19, characterized in that the electrodes, the heating elements or the sonotrodes function not only for the introduction of energy, but also as the actuators for applying the contact force. 21 . Method according to one of the preceding claims, characterized in that during the hot pressing and / or during the metallurgical joining, the contact pressure applied by the actuators is always greater than zero, preferably constant, further preferably at least partially applied by means of a spring device.

22. Method according to one of the preceding claims; characterized by an immersion depth-controlled quality control method in the form of a control or regulation with the following sub-steps: a) Checking and determining that the structural element (c) of the first Component (K1) has reached a first predetermined path marker when it penetrates into the second or third component (K2, K3); b) checking at the first or following path marker whether the actual energy introduced into the connection created by the penetration up to that point is in a target corridor for a target energy input assigned to the first path marker; c') if yes: continuing the penetration process up to a subsequent path marker and repeating step b) there for the subsequent path marker; and c") In the case of a control system, if no: adjusting at least one manipulated variable such that when the subsequent path marker is reached, a target energy input predetermined for the subsequent path marker is expected to be reached, and then carrying out step c') with the adjusted manipulated variable;or c") In the case of closed-loop control, if no: determining the difference between the actual energy input and the target energy input at the first milestone as the energy control deviation, adjusting at least one manipulated variable in accordance with the energy control deviation so that the energy control deviation is expected to be zero at the subsequent milestone, and then: carrying out step c') with the adjusted manipulated variable.; 23. Method according to claim 22, characterized in that the method steps b) to c') or c") are repeated for the subsequent waypoints until a final total target penetration depth has been reached.

24. Method according to one of the preceding claims; characterized by an energy-controlled quality control method as a control or regulation with the following sub-steps: a) Checking and determining that the structural element (c) of the first component (K1) has reached a first energy mark upon penetrating the second or third component (K2, K3), which represents a predetermined amount of energy that is to be entered at the first energy mark into the connection created by the penetration; b) checking at the first or following energy mark whether the actual immersion path covered up to that point is within a target corridor for a target immersion path assigned to the first energy mark; c') if yes: continuing the penetration process up to a subsequent energy mark and repeating step b) there for the subsequent energy mark; and c") In the case of a control system, if no: adjusting at least one manipulated variable such that upon reaching the subsequent energy mark, a target immersion path predetermined for the subsequent energy mark is expected to be reached, and then: carrying out step c') with the adjusted manipulated variables;or c") In the case of closed-loop control, if no: determining the difference between the actual immersion path and the target immersion path at the first energy mark as the immersion path control deviation, adjusting at least one manipulated variable in accordance with the immersion path control deviation so that the immersion path control deviation is expected to be zero at the subsequent energy mark; and then: carrying out step c') with the adjusted manipulated variable.; 25. Method according to claim 24, characterized in that the method steps b) to c') or c") are repeated for the subsequent energy marks until a final total target energy mark has been reached.

26. Method according to one of the preceding claims, characterized in that the pressing and / or metallurgical joining of the components under protective gas.

27. Method according to one of the preceding claims, characterized in that the first metal, the second metal and / or the third metal, insofar as they touch each other, are each the same or different metals or metal alloys.

28. A method according to claim 27, characterized in that the different metals are copper and aluminum; or that the different metal alloys are a copper alloy and an aluminum alloy.

29. Device for producing a metallurgical connection between a first component (K1) made of a first metal and at least one second component (K2) made of a second metal, wherein the first and the second component each have at least one surface section with which they face each other, comprising: at least one actuator which exerts a contact force greater than zero on the components (K1, K2) for pressing the first and the at least second component together; and - at least two energy transmission elements for introducing energy into the components and their surface sections to produce a cohesive metallurgical connection between the pressed components (K1, K2); and a control device (20) for controlling the at least one actuator and the energy transmission elements; characterized in that the control device is designed to control the at least one actuator for applying the contact force and the energy transmission elements for carrying out the method according to a the preceding claims.

30. Device according to claim 29, characterized by a cutting, machining, laser, punching or embossing device, in particular a die for forming the structural element on the surface portion of the first, the second and / or the third component. 31 . Device according to claim 29 or 30, characterized by: - a displacement sensor for directly or indirectly detecting the actual penetration depth with which the structural element of the first component penetrates into the opposite surface section of the second component (K2) or the third component (K3); - a comparison device for comparing the actual penetration depth with a predetermined target penetration depth and, if necessary, determining any deviation; and wherein the control device (20) is designed to control the energy transmission elements (E1, E2) according to the method according to one of claims 22 to 25.

32. Device according to one of claims 29 to 31, characterized by: - an energy measuring device for directly or indirectly detecting the actual energy introduced into the connection when the structural element (c) of the first component penetrates into the opposite surface section of the second component (K2) or the third component (K3); - a comparison device for comparing the entered actual energy with a predetermined target energy input and, if necessary, determining any deviation; and wherein the control device (20) is designed to control the energy transmission elements (E1, E2) according to the method according to one of claims 22 to 25.

33. Component (K1, K2, K3) made of a metal for use in the method according to one of claims 1 to 28, comprising: at least one structural element (c) tapering towards its free end.

34. Component (K1, K2, K3) according to claim 33, characterized in that the structural element is formed from solid material.

35. Component (K1, K2, K3) according to one of claims 33 or 34, characterized in that the structural element (c) is a 3-dimensional geometric object, for example in the form of a tooth, a cone, a truncated cone, a pyramid, a truncated pyramid, a sphere or a sphere segment, a horizontal cylinder, a horizontal cylinder segment, in particular a half cylinder or any desired combination of these objects, optionally also arranged one above the other.

36. Component (K1, K2, K3) according to one of claims 33 to 35, characterized in that the free end of the structural element (c) is designed in the form of a non-planar, preferably pointed contour.

37. Component (K1, K2, K3) according to one of claims 33 to 36, characterized in that a single structural element (c) or a plurality of the structural elements (c) are formed or arranged on the surface section, for example in the form of a straight, star-shaped, curvilinear or closed annular arrangement or in any desired combination of these arrangements.

38. Component (K1, K2, K3) according to one of claims 33 to 37, characterized in that that the structural element (c) is formed integrally with the component on which it is formed and from the same metal as the component.

39. Component (K1, K2, K3) according to one of claims 33 to 38, characterized in that the metal is copper, a copper alloy, aluminum or an aluminum alloy.

40. Component (K1, K2, K3) according to one of claims 33 to 39, characterized in that holes or artificial deformations are formed in or on the structural element or the end region of the component on which the structural element is formed in order to achieve a desired current and heat distribution within the structural element or the component.

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