Friction stir welding tool including improved pin

Abstract

This disclosure relates to a friction stir welding pin (8), the pin (8) having: - at least one thread (81); - at least one groove (82) transverse to the thread; and - at least one flat (83) entering the thread. Abstract figure: Fig. 3a

Description

Title of the invention: Friction stir welding tool comprising an improved pin Technical field

[0001] This disclosure relates to friction stir welding. STATE OF THE ART

[0002] Friction stir welding (known by the English acronym "FSW" for Friction Stir Welding) has been used for several years to weld mechanical parts. The weld is created by means of a welding tool comprising a pin and a shoulder, rotating or static depending on the welding configurations chosen (in particular depending on the materials, thicknesses and required rate) and the desired weld quality. The pin is rotating and penetrates the parts to be welded. As for the face of the shoulder, it is brought into contact with the parts to be welded. Then, the tool is driven in a forward movement along the joint line to be made between the parts. This process is particularly advantageous for an alloy with a low melting point, for example an aluminum alloy, because it does not cause it to melt.This avoids problems of porosity and hot cracking, inherent in fusion welding of alloys, particularly aluminum alloys.

[0003] However, the mixing implemented by the pin can cause defects in the weld which reduce the bonding area between the parts to a few millimeters, or even a few tenths of a millimeter. The mechanical performance of the weld is then reduced. Another consequence of these defects is the appearance of incipient cracks which weaken the weld to the point of causing it to break prematurely in certain cases. GENERAL STATEMENT

[0004] An aim of the present disclosure is therefore to improve friction stir welding.

[0005] For this purpose, according to a first aspect of the present disclosure, a friction stir welding pin is proposed, the pin having: - at least one thread; - at least one groove transverse to the thread; and - at least one flat part cutting into the thread.

[0006] Thus, this pin geometry makes it possible to significantly reduce the defects caused by mixing, or even eliminate them. The bonding area is therefore increased and the quality of the weld improved. It also makes it possible to produce welds for wide ranges of welding parameters. This is called geometry universal pawn.

[0007] For example, the welding can be carried out at a high rotation speed of the pin, while having a low feed speed of the tool. Indeed, without this particular geometry, these ranges of values ​​for welding were not envisaged because they were conducive to the appearance of these defects.

[0008] It may be provided that the groove and the flat form a periodic pattern repeating around the pin.

[0009] It may be provided that the pin has a portion of generally truncated cone shape, the flat, the thread and the groove extending over the truncated cone portion.

[0010] It may further be provided that a maximum angle between a main axis of the pin and an envelope circumscribed to the pin is between 4° and 20°, preferably equal to 8°.

[0011] It may be provided that the net extends over at least one turn of the pawn.

[0012] It may be provided that the thread has a pitch less than or equal to 1.2 mm.

[0013] It may be provided that the pawn has several threads.

[0014] It may be provided that the groove is inclined relative to the main axis of the pin.

[0015] It may be provided that the groove runs along the pin around the main axis of the pin in a direction opposite to the net.

[0016] It may be provided that the groove extends in a helical manner around the pin.

[0017] It may be provided that a depth of the groove is greater than or equal to a depth of the net.

[0018] It may be provided that the pawn has several grooves distributed around the pawn.

[0019] It may be provided that the pin has three grooves, in particular helical, regular strictly arranged around the main axis of the pawn.

[0020] It may be provided that the pawn has several flats.

[0021] It can be provided that the flats are distributed around the pin.

[0022] It may be provided that at least two of the flats are coplanar.

[0023] It may be provided that a free end of the pin is flat.

[0024] It may be provided that a free end of the pin is convex.

[0025] It may be provided that a free end of the pin forms a punch.

[0026] According to a second aspect of the present disclosure, there is provided a friction stir welding tool, the tool comprising: - a pawn conforming to the first aspect; and - a body with a shoulder surrounding the pawn.

[0027] It may be provided that the pin is mounted to be able to rotate relative to the shoulder.

[0028] According to a third aspect of the present disclosure, there is provided an electrospindle comprising: - a frame; and - a tool according to the second aspect, the tool being mounted on a free end of the frame.

[0029] According to a fourth aspect, a method of welding parts by friction stir is provided, the method being implemented by a pin according to the first aspect.

[0030] It can be provided that the method is applied to parts superimposed on each other.

[0031] It may be provided that the method is applied to two pieces, the two pieces being at the same time superimposed on each other and juxtaposed field against field.

[0032] According to a fifth aspect, there is provided an assembly comprising welded parts, the assembly resulting from the implementation of a method according to the fourth aspect.

[0033] According to a sixth aspect, there is provided a battery tray comprising at least one skin and at least one hollow profile, a weld of the skin to the profile resulting from an implementation of a method according to the fourth aspect. DESCRIPTION OF FIGURES

[0034] Other characteristics, aims and advantages will emerge from the following description, which is purely illustrative and non-limiting, and which must be read in conjunction with the appended drawings in which:

[0035] [Fig.l] schematically illustrates a friction stir welding electrospindle mounted on a robot;

[0036] [Fig.2] is an elevational view of a friction stir tool mounted on a friction stir welding electrospindle;

[0037] [Fig.3a] illustrates in perspective a pawn having an improved geometry;

[0038] [Fig.3b] is a radial sectional view of the pin of [Fig.3a];

[0039] [Fig.3c] is a schematic view in longitudinal section of the pin of [Fig.3a];

[0040] Figures 4a and 4b are schematic perspective views of friction tools- mixing with a static shoulder;

[0041] Figures 5a and 5b schematically illustrate friction-mixing tools;

[0042] [Fig.6] is a flowchart illustrating a method of implementing a friction stir welding process for parts;

[0043] [Fig.7a], [Fig.7b], [Fig.7c], [Fig.7d], [Fig.7e] and [Fig.7f] schematically illustrate several embodiments of friction stir welding;

[0044] [Fig.8] schematically illustrates a part of an aircraft;

[0045] [Fig.9a], [Fig.9b] and [Fig.9c] schematically illustrate several modes of production of friction stir welding of aircraft parts;

[0046] [Fig. 10] schematically illustrates a welding configuration of an aluminum skin on a hollow aluminum profile typical of an electric vehicle battery tray; and

[0047] [Fig.11a] and [Fig.11b] are photographs of a weld of a battery tray obtained by friction stir;

[0048] [Fig. 12] and [Fig. 13] are metallographs of friction stir welded parts without geometric improvement of the pin;

[0049] [Fig. 14] is a photograph of a weld obtained by a friction stir tool with a movable shoulder;

[0050] [Fig.15], [Fig.16], [Fig.17a], [Fig.17b], [Fig.17c] and [Fig.18a] are metallographs of friction stir welded parts with geometric improvement of the pin;

[0051] [Fig. 18b] and [Fig. 18c] are close-up views of [Fig. 18a];

[0052] [Fig. 19] and [Fig.20] are respectively a photograph and a metallography of a weld obtained by a friction stir tool with fixed shoulder and geometrically improved pin; and

[0053] [Fig.21a] and [Fig.21b] are metallographs of a weld obtained by a friction stir tool with geometric improvement of the pin, fixed shoulder and selection of a maximum cone angle. DETAILED DESCRIPTION

[0054] Illustrated by way of example in [Fig.l] is an industrial robot 100 intended to move in a workspace to weld parts 21, 22 of an assembly 20. The assembly 20 is further illustrated by way of example in [Fig.7a]. The robot comprises at least one arm mounted on at least one axis. In the present application, each axis corresponds to a degree of freedom of the robot. In the exemplary embodiment illustrated in [Fig.l], the robot 100 comprises six axes. The robot further comprises a free end 101 configured to receive a spindle, preferably an electrospindle 10 to carry out the welding operation. Of course, the electrospindle 10 can be mounted on another device, for example a machine tool, to carry out the welding.

[0055] The parts 21, 22 are mounted in a tool 200 fixed to a table 300. According to an exemplary embodiment, notably illustrated in [Fig.l], the tool 200 is placed and held in position on the table 300, typically by screws making it integral with the table 300. The tool 200 further comprises means for clamping the parts 21, 22. According to an exemplary embodiment, the tool 200 comprises clamping flanges configured to keep the parts 21, 22 immobile during the friction stir welding operation.

[0056] Welding is carried out by friction stir. To do this, the electrospindle 10 comprises a friction stir tool 1, illustrated in particular in [Fig.2], mounted on a free end 4 of the electrospindle 10. The electrospindle 10 is known to a person skilled in the art and will therefore not be detailed further. Reference may be made to document FR-3 122 110 which describes an example of an electrospindle 10.

[0057] The friction-mixing tool 1 comprises a rotating pin 8, i.e. mounted to move in rotation around a longitudinal axis Z of the electrospindle.

[0058] It is agreed here that an axial plane is a plane parallel to the longitudinal axis Z and passing through the latter and a radial plane is a plane orthogonal to the longitudinal axis Z. A circumference is understood as a circle belonging to a radial plane and whose center belongs to the longitudinal axis Z. A circumferential plane is a plane tangent to a circumference.

[0059] An example of pawn 8 has been illustrated in detail in [Fig.3a].

[0060] In this example, the pin 8 is of generally truncated cone shape, that is to say that an envelope circumscribed to the pin 8 has a diameter along the longitudinal axis Z, measured perpendicular to the longitudinal axis Z, which is not constant and which, in this case, decreases as one moves towards a free end 80 of the pin 8. In order to facilitate the penetration of the pin 8 into the parts, a maximum cone angle measured between the axis Z and a generatrix of the envelope may furthermore be between 4° and 20°. This range of value is also chosen so that the tool 1 does not collide with the parts during welding for the configuration illustrated in [Fig.7e] which will be detailed later in the description. Furthermore, to maximize the connection area of ​​the parts, the cone angle may preferably be equal to 8°. Alternatively, the pin 8 may be of generally cylindrical shape.That is to say that an envelope circumscribed to the pin 8 has a constant diameter along the longitudinal axis Z, measured perpendicular to the longitudinal axis Z. The pin 8 may also have a generally cylindrical shape on an axial portion and a frustoconical shape on another axial portion. In this case, the free end 80 is flat, and extends in a plane radial to the pin 8. The free end 80 may have another shape, in particular convex, in particular curved, in order to reduce the welding forces and facilitate its insertion into the material. To further facilitate its insertion, the convexity of the free end 80 may be accentuated to the point that the free end 80 forms a punch on the pin 8.

[0061] The pin 8 further has a thread 81 extending along the longitudinal axis around the pin 8, in this case over several turns, entirely or partially. Thus, the thread 81 allows the pin to mix the kneaded material up to the free end 80. In the present application, the thread 81 is defined as a pattern having an edge 801, more commonly called a top of the thread 81, and a hollow 802, more commonly called a bottom of the thread 81, extending in a helicoid around the pin. Thus, in any axial plane passing through the pin 8, the thread 81 has a periodic variation of vertex portions and hollow portions. Of course, the thread is not limited to a particular typology and can have any known shape, for example metric, trapezoidal (the edge and the hollow are generally trapezoidal), round (the edge and the hollow are generally rounded), gas, or even sawtooth.

[0062] The pin 8 may further have several threads following one another along the pin 8. In other words, the edges of each thread may follow one another so as to form a continuous or discontinuous helix by offsetting each thread along the Z axis. The number of turns of the thread may vary from one pin to another. In other words, the thread 81 may have one or more turns. A value of the pitch of the thread 81, that is to say a maximum distance taken between two flanks 803a, 803b of the edge 801 facing each other, is preferably less than or equal to 1.2 mm. Alternatively, the pin 8 may have several threads following one another around the pin 8, each of the threads extending over less than one turn of the pin 8.

[0063] The pin 8 also has three grooves 82 regularly arranged around the Z axis. In other words, the grooves 82 are distributed around the pin 8 by isometry. That is to say that the grooves 82 are mutually spaced by a constant angle around the pin 8. In this case the angle 120° because there are three grooves. But it can take other values, for example 180° for two grooves or 90° for four grooves. We also speak of circular repetition of the grooves 82 around the pin 8. We also say that the grooves 82 are distributed around the pin 8 by isometry in a radial plane passing through the pin 8. Each groove 81 runs through the pin 8 around the Z axis in a direction opposite to the thread 81 in the present example. Thus, the grooves allow additional mixing which opposes that of the net during mixing by pin 8. The mixing is then further improved.The pin 8 may have fewer than three grooves 82 or more than three grooves 82, or even a single groove 82. Each groove 82 is transverse to the thread and is inclined. The grooves are all rectilinear but may alternatively all be helical, or each groove may be selectively rectilinear or helical. They may also have other shapes. The grooves 82 further have a depth Pr greater than or equal to a depth of the thread Pf (see [Fig.3b]).

[0064] The pin 8 also has flats 83. Each flat 83 extends partially over the thread 81, here in a circumferential plane crossing the thread 81. The flats 83 cut into the thread 81 because a height Hm, taken in an axial plane between a base of the hollow 802 and the flat 83, is less than a nominal height Hn taken in the same axial plane between the base of the hollow 802 and a top of the edge 801 ([Fig.3c]). The flats 83 have the effect of accentuating the mixing effect by the grooves 82 and the thread 81. The flats 83 are regularly arranged around the pin 8 between the grooves 82. That is to say that the flats 83 are mutually spaced in the radial plane by a constant angle. In this case the angle 120° because there are three flats. But it can take other values, for example 180° for two flats or 90° for four flats. We also speak of circular repetition of the flats 83 around the pin 8. In addition, since they are between the grooves 82 which are themselves regularly arranged around the pin 8, the flats 83 are angularly offset relative to the grooves 82. The grooves 82 and the flats 83 are therefore periodically repeated around the pin 8.

[0065] In the present example, the flats 83 are arranged along three lines 820, 821, 822 included in non-coplanar circumferential planes. Of course, the flats 83 can be arranged on more than three lines, less than three lines, or even on a single line. On each line, the pin 8 has four flats 83.It may also have more than four flats, or fewer than four flats. The flats 83 are regularly spaced on each line. In other words, they are images of each other by homothety of the same ratio. The homothety ratio may also vary from one line to another, for example to arrange the flats 83 in a staggered pattern around the pin 8. Alternatively, the flats 83 may be regularly arranged around the pin 8 on a circumference. In other words, the flats 83 are distributed around the pin 8 by isometry in a radial plane passing through the pin 8.

[0066] The friction-stirring tool 1 further comprises a body 5 distinct from the pin 8. The body 5 can be mounted fixed relative to the pin 8. The body 5 comprises a base 6 and a shoulder 3. The base 6 is mounted on the electrospindle 10 and the shoulder 3 is configured to be in contact with the parts 21, 22 during welding. The body 5 is delimited axially from the base 6 to the shoulder 3 and radially by a lateral face 7 extending around the longitudinal axis Z. The shoulder 3 surrounds the pin 8 and has a diameter D2 greater than a diameter DI of the pin 8. Thus, the shoulder forms a variation in cross-section between the body 5 and the pin 8.

[0067] According to an exemplary embodiment of the body 5, notably illustrated in figures 4a and 4b, the base 6 of the body 5 has a first cylindrical section 60 and a second cylindrical section 61 having a diameter greater than the diameter of the first cylindrical section 60. The first cylindrical section 60 comprises flats 63 configured to lock the body 5 in rotation in the electrospindle 10. Thus, when mounting the body 5 on the electrospindle 10, the body 5 is put in position with the electrospindle 10 by centering on the first section 60 and a flat support on the second section 61. The body 5 is held in position by a clamping means making it possible to make the body 5 integral with the electrospindle 10.

[0068] According to an exemplary embodiment of the lateral face 7, notably illustrated in [Fig.5a], the lateral face 7 is cylindrical. It has a constant diameter D2 along the longitudinal axis Z, measured perpendicular to the longitudinal axis Z. As a variant, the face lateral face 7 may be non-cylindrical. It is for example frustoconical as illustrated by way of example in [Fig.5b]. It has a diameter D2 measured perpendicular to the axis which is not constant and which, in this case, decreases as one moves towards the pin. The lateral face 7 may also be non-cylindrical on a first portion 70 and cylindrical on a second portion 71. It is for example frustoconical on the first portion 70 as illustrated by way of example in [Fig.4a] and in [Fig.4b].

[0069] The pin 8 can be mounted so as to be movable relative to the shoulder 3, which is then said to be fixed, for example by assembling the shoulder 3 to a base of the electrospindle 10. Thus, the tool 1 is more robust thanks to the fixed shoulder 3. In addition, the weld 23 has a better surface quality. It is therefore more resistant. In addition, the tool 1 welds more quickly. A rate of the tool 1 is therefore improved. Alternatively, the pin 8 can be mounted by being rigidly fixed to the shoulder 3, for example by assembling the pin 8 and the shoulder 3 to the same axis of rotation of the electrospindle 10.

[0070] Thus, the pin 8 extends projecting from the shoulder 3. The thread 81 and the grooves 82 then extend as far as the shoulder 3. As for the flats 83, they can be arranged between the shoulder 3 and the free end 80.

[0071] The shoulder 3 has at least one axial end face 30 of generally planar shape and configured to be in contact with the surface of the parts 21, 22 to be welded.

[0072] The axial end face 30 may have another shape. For example, a junction between the axial end face 30 and the side face may be rounded or chamfered. The face 30 may have a concave shape.

[0073] Thanks to the fixed shoulder, the shape of the shoulder can be particularly well adapted to the shape and configuration of the parts to be welded. This shoulder then constitutes a "counterform" of the joint plane and contains the material being welded (see for example on this subject the embodiment of figures 7e and 7f described later.) For each particular welding configuration, it is possible to adapt the shape of the shoulder to that of the joint to be produced.

[0074] The device carrying the tool 1, for example the aforementioned robot, is configured to move the tool in vertical translation, in order to bring the axial end face 30, typically planar, into contact with a portion of the parts 21, 22, and in horizontal translation, in order to advance the tool along the parts to be welded. Thus, during welding, in particular when the shoulder is fixed, the face 30 slides on the portion of the parts 21, 22 and at the same time, the pin 8 driven by a rotational movement around the longitudinal axis heats and kneads the joint plane, to create a weld 23 of the parts 21, 22. The face 30 then makes it possible to contain the material during the welding operation.

[0075] The shoulder 3 may further comprise several axial end faces, in particular flat, non-coplanar 30, 31, 32. Thus, it is possible to produce the weld 23 between parts extending angularly, for example perpendicularly or presenting an angle less than 90°, such as 70°, relative to each other.

[0076] According to an exemplary embodiment, notably illustrated in [Fig.4b], the face 3 is decomposed into a first axial end face 30 which extends in a radial end plane and two other flat faces 31, 32 which extend symmetrically from one another with respect to the axial plane giving rise to two distinct oblique planes from the face 30. As a variant, the two other flat faces 31, 32 extend asymmetrically from one another with respect to the axial plane in order to weld parts which do not extend perpendicularly but which have an angle of less than 90°, for example 70°.

[0077] A mode of implementing a method of welding a first part 21 and a second part 22 of an assembly 20 is described with reference to [Fig.6].

[0078] The welding process is implemented by tool 1 of the present disclosure.

[0079] In the case of a removable tool 200, the tool 200 is fixed on a table 300 at during a step E20. According to an exemplary implementation of step E20, the tool 200 is placed and held in position on the table 300, typically by screws. Alternatively, the tool is part of the table 300. The tool 200 is then already mounted on the table 300.

[0080] During a step E21, the parts 21, 22 to be welded are placed in position in the tool 200 and then held in position by fixing means, for example clamping flanges placed in the tool 200. The parts 21, 22 can be placed in position according to different configurations: - in juxtaposition field against field ([Fig.7a]), the parts 21, 22 then having coplanar main faces 210, 220; - superimposed on each other in parallel ([Fig.7b]), one of the parts 21 then extending above the other part 22. The lower main face 211 of the upper part 21 is in surface contact with the upper main face 220 of the lower part 22; or - superimposed on each other angularly, for example perpendicularly or at an angle less than 90° such as 70°, or face against field (figures 7c, 7e and 7f), one of the parts 21 extending above the other part 22, the lower main face 211 of the upper part 21 being in surface contact with a field 222 of the lower part 22 ([Fig.7c]) or a field 212 of the upper part 21 being in contact with the upper main face 220 of the lower part 22 ([Fig.7e] and 7f). The main faces 220, 221 of the latter are perpendicular to those of the upper part 21.

[0081] Of course, it is also possible to mix configurations. For example the parts 21, 22 can be at the same time superimposed on each other and juxtaposed field against field ([Fig.7d]). From then on, the upper part 21 is supported against the lower part 22 by making their fields and the lower main face 211 of the upper part 21 coincide simultaneously with one of the upper faces 220 of the lower part 22.

[0082] During a step E22, the tool 1 is moved in vertical translation until the end face 30 comes into contact with at least one of the first and second parts 21, 22.

[0083] In juxtaposition, the end face 30 is in contact with the two parts 21, 22 simultaneously. In superposition, the tool 1 can be in contact with one of the parts 21, 22 or both. According to an exemplary embodiment, notably illustrated in [Fig.7b], the parts are superimposed on each other in parallel and the end face 30 is in contact with the upper main face 210 of the upper part 21.

[0084] According to another exemplary embodiment, notably illustrated in [Fig.7c], one of the parts 21 extends perpendicularly above the other part 22, the lower main face 211 of the upper part 21 being in surface contact with a field 222 of the lower part 22. Thus, the end face 30 is in contact with the upper main face 210 of the upper part 21.

[0085] As a variant, notably illustrated in figures 7e and 7f, the upper part 21 has a main planar portion 213, having main faces extending parallel, and a flared edge 214 in which the main faces move away as one approaches the field. This field 212 of the upper part 21 is in contact with the upper main face 220 of the lower part 22. Thus: - the axial end face 30 and the first oblique face 31 of the shoulder 3 are respectively in contact with the edge 214 and a flat face of the main part 213 of the upper part 21; and - the second oblique face 32 of the shoulder 3 is in contact with the upper main face of the lower part 22.

[0086] The tool 1 is ready to weld. During a step E23, the pin 8 is rotated and the tool 1 is moved in a direction, typically horizontal, to follow a joint line so as to make a pass and form the weld 23 of the first and second parts 21, 22. Several passes can be made to form the weld 23, typically two passes.

[0087] In juxtaposition, an example of which is notably illustrated in [Fig.7a], and when the configurations are mixed, for example when the parts 21, 22 are at the same time superimposed on each other and juxtaposed field against field ([Fig.7d]), the end face 30 passes simultaneously over the coplanar main faces 210, 220 of the parts 21, 22.

[0088] In the case where the parts 21, 22 are superimposed on each other in parallel, a configuration of which an example is notably illustrated in [Fig.7b], the end face 30 passes over the external main face 210 of the upper part 21 and welds the two parts to each other.

[0089] In the case where one of the parts 21 extends angularly above the other part 22, for example perpendicularly in an example illustrated in [Fig.7c] or presenting an angle less than 90° such as 70°, the lower main face 211 of the upper part 21 being in surface contact with a field 222 of the lower part 22, the end face 30 passes over the upper main face 210 of the upper part. As a variant, notably illustrated by way of example in [Fig.7e] and 7f, the field 212 of the upper part 21 can be in contact with the upper main face 220 of the lower part 22, the end face 30 passes over the main face 214 of the upper part 21 and the oblique faces 31, 32 pass respectively over the main face 213 of the upper part 21 and the upper main face 220 of the lower part 22.

[0090] The parts 21, 22 are then welded. Steps E20 to E23 can be repeated until the assembly 20 is entirely welded. Consequently, the assembly 20 then comprises at least two parts.

[0091] In the following, we detail two concrete applications of the welding process.

[0092] [Fig.8] shows an aircraft fuselage. It comprises stringers 51 extending along a longitudinal direction of the fuselage, frames 55 extending in a transverse direction of the fuselage, and a skin 52 covering the stringers 51 and frames 55. The frames 55 and stringers 51 act here as stiffeners of the skin 52 of the fuselage.

[0093] For the sake of brevity, frames 55 and rails 51 will be called stiffeners in the remainder of this description.

[0094] The stiffeners therefore extend over an internal face 520 of the skin 52, an external face 521 of the skin 52 being free and opposite the stiffeners. The skin and each stiffener are welded to each other by the welding method implemented by the tool 1. It is therefore not necessary to fix them to each other by means of an assembly by added fixing members. Thus, the mass of the aircraft 50 is reduced and the efficiency of the aircraft 50 is improved. The aircraft 50 is also assembled more quickly.

[0095] According to a first exemplary embodiment, notably illustrated in [Fig.9a], the stiffener has a profiled wedge shape and comprises a sole 53, the sole 53 being welded superimposed on the fuselage skin 52. The welding takes place with the axial end face 30 in contact with the sole 53, on the side of the stiffener 51, 55 opposite the skin 52.

[0096] According to a second exemplary embodiment, notably illustrated in [Fig.9b], the stiffener 51, 55 is welded superimposed on the fuselage skin 52 and the tool is this time in contact with the fuselage skin 52 during welding, extending over the external face 521 of the skin, opposite the stiffener 51, 55. A field of the stiffener 513 is in contact with the internal face 520 of the skin 52.

[0097] According to a third exemplary embodiment, notably illustrated in [Fig.9c], the stiffener 51, 55 is welded superimposed on the fuselage skin 52 and the tool is in contact with both the fuselage skin 52 and the stiffener 51, 55 during welding. The welding takes place from the internal face 520 and not visible from the skin representing a considerable advantage compared to the configuration of [Fig.9b]. The welding takes place in the configuration of Figures 7e and 7f. The oblique faces 31, 32 of the shoulder 3 come into contact with both the main face of the stiffener 511 and the internal main face 520 of the skin 52 and the end face 30 of the face 3 is in contact with the portion 512 of the stiffener 51, 55. The tool 1 therefore performs the weld by passing simultaneously over the flat portions 511, 512 of the stiffener 51, 55 as well as the internal face 520 of the skin 52, for example on the left in [Fig.9c]. Another pass allows the same to be done on the right.Since the welding is carried out on the internal side of the aircraft, a finishing step, for example by machining or grinding the weld 23, is then eliminated. There is also no longer any need for a sole 53, which reduces the weight of the assembly.

[0098] The welding method implemented by the tool 1 of the present disclosure also makes it possible to obtain an assembly 90 having a hollow welded structure and illustrated in [Fig. 10]. This architecture is typical of aluminum battery boxes used in electric vehicles and consists of welding a skin element 91 onto a hollow aluminum profile 92. The hollow profile 92 makes it possible to save weight in order to improve the weight / power efficiency of the electric vehicle and to consume less energy.

[0099] According to an exemplary embodiment, notably illustrated in figures 11a and 11b, the skin element 91 and the hollow aluminum profile 92 are placed one on top of the other in parallel, the skin element 91 then extending above the profile 92. The weld 23 of the skin 91 with the profile 92 is then obtained by passing the tool over an upper main face 910 of the skin 91 opposite the hollow aluminum profile 92.

[0100] The welding method implemented by the tool 1 of the present disclosure has many advantages. Indeed, the welded assembly 20 is macroscopically different from that obtained by known friction-stirring tools. The weld 23 no longer has defects at the interface between the parts 21, 22. The mixed material of the parts 21, 22 at the weld 23 is then homogeneous. Consequently, the connection zone between the parts 21, 22 is increased. The mechanical performance of the weld also. The incipient cracks are reduced, or even eliminated. The weld is therefore more robust and no longer risks premature rupture.

[0101] In the case of a fixed shoulder, the weld 23 of the assembly 20 also has an improved surface quality. This has the effect of reducing, or even eliminating, surface defects in the weld that may be encountered in the case of a rotating shoulder. Therefore, the mechanical performance of the weld 23 is further improved.

[0102] Thus, the pin 8 with improved geometry and the fixed shoulder 3 make it possible in combination to obtain a weld 23 which does not have defects either on the surface or within it. EXAMPLES

[0103] Concrete, but in no way limiting, examples illustrating the advantages of the geometric improvement of the pin 8 are detailed in the examples which follow. Examples without geometric improvement of the pin

[0104] [Fig. 12] is a metallographic section of a weld of a first plate 21 of 7075 aluminum (7000 series) of 1 mm thickness 7075 on a second plate of 2024 aluminum (2000 series). The plates are superimposed on each other and the section is taken in a plane orthogonal to the direction of advance of the tool 1.

[0105] In this figure, we notice defects on either side of the weld 31 in the form of a wave 25 (better known by the English terminology "cold lap") and a hook 26 (better known by the English terminology "hook"). These defects reduce the connection zone 27. It is small (of the order of a few millimeters, or even a few tenths of a millimeter) and heterogeneous.

[0106] Wave 25 is caused by insufficient shearing of the material of the plates to completely break the initial joint plane 24. A lack of stirring of the pin 8 is the cause of this insufficient shearing. It takes the form of a wave of variable height depending on the lack of stirring.

[0107] The hook 26 takes the form of a hook, or a comma, caused by the shearing of the material. The hook causes a sudden rise of the joint plane 24. In extreme cases, the hook 26 can be completely vertical and rise up to the upper plate.

[0108] These defects are the cause of poor quality welding which is the cause of all the drawbacks mentioned above in this presentation.

[0109] In order to reduce these defects, it is possible to act on the welding parameters as shown in [Fig. 13]. Indeed, the wave 25 is less pronounced and the bonding zone 27 is more extensive and more homogeneous. Nevertheless, the hook 26 remains pronounced.

[0110] In particular, due to a particularly high feed rate per revolution (defined as the ratio between the feed rate of the tool and the rotation rate of the pin) weak, hook 26 tends to rise extremely. Conversely, wave 25 is generally reduced under these conditions (better stirring). This is called "hot parameterization". Acting on the welding parameters in order to limit hook 26 and wave 25 at the same time is therefore very complex.

[0111] However, this method is tedious because it requires a large number of welding tests and has low robustness. In addition, it is necessary to redefine the parameters, and therefore to redo tests, for each new configuration (thicknesses, materials, etc.).

[0112] It is possible to reduce the hook 26 by using a greater forging force (force along the Z axis when driving the pin 8 into the parts 21, 22). Indeed, it makes it possible to reduce the rise of the interface. However, using a greater plating force will generate burrs 28 (visible in particular in [Fig. 14]), also called weld “flash” due to the relief formed by the projected pieces of material which agglomerate at the periphery of the weld during the rotation of the shoulder 3, due to an increased penetration of the tool 1 into the parts 21, 22. In addition, a greater forging force generates an increase in the stresses in the parts 21, 22, and therefore greater deformations reducing the quality of the welded assembly 20. Finally, this range of force may prove incompatible with the use of the tool 1 on the industrial robot 100 which is generally limited in load capacity.

[0113] It is also possible to reduce the wave 25 by increasing the rotation speed of the pin 8. In return, this leads to significant weld flashes 28, or even weld collapse, as well as cavities 29 (visible in particular in [Fig. 14]) due to excessive energy at the surface. Increasing the rotation speed of the pin 8 also locally raises the joint plane 24 and therefore generates a larger hook 26.

[0114] Obtaining a compromise to reduce these defects can prove tedious. Indeed, the defects on the surface and within the weld 30 reduce its mechanical properties. The flashes 28 also form corrosion initiation points for the parts 21, 22. In addition, the weld 23 is irregular. Indeed, as illustrated in the example in [Fig. 14], the weld 23 has numerous reliefs in its center, because of the cavities 29 and on its periphery because of the weld flashes 28. Examples with geometric improvement of the pawn

[0115] Various tests were carried out in order to highlight the advantages linked to the geometric improvement of the pin. In these tests, different sets of thickness and types of materials of the parts are tested. The parts are also welded for several ranges of rotation speed of the pin 8 and feed rates of the tool 1. Thus, a significant range of feed values ​​per revolution, defined as the ratio between the feed rate of tool 1 and the rotation speed of pin 8, is tested. Other parameters such as the forging force vary between tests.

[0116] [Fig. 15] is a metallographic section of a weld of a cover 21 of 6061 T6 aluminum (6000 series) 2 mm thick on a support 22 of 6061 T6 aluminum (6000 series) of approximately 10 mm. The cover 21 and the support 22 are welded in the configuration of [Fig.7d] and the section is taken in a plane orthogonal to the direction of advance of the tool 1. The rotation speed of the pin 8 is 3500 rpm and the advance speed of the tool 1 is 100 cm / min.

[0117] [Fig. 16] is a metallographic section of a weld of a 1 mm thick 6061 T6 (6000 series) aluminum sheet 21 to a 2 mm thick 6061 T6 (6000 series) aluminum plate 22. The sheet 21 and the plate 22 are welded in the configuration of [Fig.7b] and the section is taken in a plane orthogonal to the direction of feed of the tool 1. The rotational speed of the pin 8 is 3000 rpm and the feed speed of the tool 1 is 48 cm / min.

[0118] Figures 17a, 17b and 17c are metallographic sections of several welds of a plate 21 of 6061 T6 aluminum (6000 series) 3 mm thick on a support 22 of 6061 T6 aluminum (6000 series) 15 mm thick. These welds require significant forging forces. The plate 21 and the support 22 are welded in the configuration of [Fig. 7b] and the section is taken in a plane orthogonal to the direction of advance of the tool 1. The rotation speed of the pin 8 is 3000 rpm and the advance speed of the tool 1 is 78 cm / min. [Fig. 17a] illustrates a weld 23 obtained with a forging force of 350 kg, [Fig. 17b] 400 Kg and [Fig. 17c] 450 kg (25% variation).

[0119] To differentiate from the previous application tests which are on 6000 series aluminums, Figure 18a is a metallographic section of a weld of two pieces 21, 22 of 2000 series aluminum. The pieces 21, 22 are welded in the configuration of [Fig.7b] and the section is taken in a plane orthogonal to the direction of advance of the tool 1. The weld 23 is obtained by a double welding pass (one back and forth). The material is therefore considerably heated, which promotes the appearance of a significant hook. Figures 18b and 18c are close-up views of the same metallographic section on either side of the weld 23 at the joint plane 24.

[0120] In all these configurations, there is an absence of hook and wave type defects and a contrast ranging from light to dark in the weld 23 along the joint plane 24 which indicates a homogeneous mixture of the material of the two parts 21, 22. Thus, the connection zone 27 is extensive and homogeneous. The improved geometry of the pin 8 makes it possible to eliminate defects within the weld 23 for a wide range of welding parameters (rotation speed of the pin 8, feed speed of the tool 1, forging force), for different welding configurations and for different part thicknesses.

[0121] Examples with geometric improvement of the pawn and fixed shoulder

[0122] A weld 23 was also made with a geometric improvement of the pin, to avoid hook and wave type defects, as well as with a fixed shoulder 3.

[0123] [Fig. 19] illustrates the weld 23 obtained under conditions similar to those of the case illustrated in [Fig. 17b]. Here, in particular, the forging force is 400 kg. The weld 23 has neither flash nor cavities.

[0124] Thus, thanks to the fixed shoulder, the surface quality of the weld 23 is greatly improved. The weld 23 obtained therefore no longer has any defects on the surface or within it.

[0125] [Fig.20] is a metallographic section of a weld 23 made in two passes and in a configuration similar to that illustrated in [Fig.7e] and the section is taken in a plane orthogonal to the direction of advance of the tool 1. This figure shows an overlap zone 40 of the two passes of the weld. This overlap zone makes it possible in particular to improve the robustness of the weld.

[0126] Examples with geometric improvement of the pin, fixed shoulder and selection of the maximum cone angle

[0127] A weld 23 was also produced with, as for the previous configuration, a geometric improvement of the pin and a fixed shoulder 3. In addition, the maximum cone angle is chosen so that the weld 23 extends over a fraction of a thickness of the lower part 22.

[0128] Figures 21a and 21b are metallographic sections under conditions similar to those in the case of [Fig.20]. In the case of [Fig.21a], the maximum angle is any and the lower part is 5 mm thick. In the case of [Fig.21b], the maximum angle is selected and the lower part 22 is 2 mm thick. It can be seen in [Fig.21a] that the weld 23 extends further into the thickness of the part 22 compared to the weld 23 in [Fig.21b]. Furthermore, if the lower part illustrated in [Fig.21a] were 2 mm, the pin 8 would penetrate almost the entire thickness of the lower part. In extreme cases, the pin 8 can even pass through the lower part when the maximum angle is any.

[0129] Thus, the choice of the maximum cone angle makes it possible to reduce the penetration of the pin 8 into the lower part 22 in order to maintain a sufficient margin to avoid passing through the lower part 22. Here, the margin is defined as a minimum difference between the thickness of the part 22, measured perpendicularly between the upper main face 220 and the lower main face 221 or given by the manufacturer, and the penetration of the weld 23 measured perpendicularly between a point PI taken on the upper main face 220 and a point P2 taken on the weld 23. Typically, the margin is between four and five tenths of a millimeter. The margin can for example be measured on metallography by known geometric constructions.

Claims

Claims

1. Friction stir welding pin (8), the pin (8) having: - at least one thread (81); - at least one groove (82) transverse to the thread; and - at least one flat (83) cutting into the thread.

2. A pin (8) according to claim 1, wherein the groove (82) and the flat (83) form a periodic pattern repeating around the pin.

3. Pawn (8) according to one of claims 1 or 2, in which the pawn is of generally truncated cone shape, the flat (83), the thread (81) and the groove (82) extending over the truncated cone portion.

4. Pawn (8) according to one of claims 1 to 3, in which the thread (81) extends over at least one turn of the pawn.

5. Pawn (8) according to one of claims 1 to 4, in which the thread (81) has a pitch less than or equal to 1.2 mm.

6. Pawn (8) according to one of claims 1 to 5, in which the pawn has several threads (81).

7. Pawn (8) according to one of claims 1 to 6, in which the groove (82) is inclined relative to a main axis (Z) of the pawn.

8. Pawn (8) according to one of claims 1 to 7, in which the groove (82) runs through the pawn around the main axis (Z) of the pawn in a direction opposite to the thread (81).

9. Pawn (8) according to one of claims 1 to 8, in which the groove (82) extends in a helical manner around the pawn.

10. Pawn (8) according to one of claims 1 to 9, in which a depth of the groove (Pr) is greater than or equal to a depth of the thread (Pf).

11. Pawn (8) according to one of claims 1 to 10, in which the pawn has several grooves (82) distributed around the pawn.

12. Pawn according to one of claims 1 to 11, in which the pawn has several flats (83).

13. Pawn (8) according to claim 12, in which the flats (83) are distributed around the pawn.

14. Pawn (8) according to one of claims 12 or 13, in which at least two of the flats (83) are coplanar.

15. Pawn (8) according to one of claims 1 to 14, in which a free end (80) of the pawn is flat.

16. Pawn (8) according to one of claims 1 to 14, in which a free end (80) of the pawn is convex.

17. Friction stir welding tool (1), the tool comprising: - a pin (8) according to one of claims 1 to 16; and - a body (5) having a shoulder (5) surrounding the pin.

18. Tool (1) according to claim 17, in which the pin (8) is mounted to be movable in rotation relative to the shoulder (3).

19. Electrospindle (10) comprising: - a frame; and - a tool (1) according to one of claims 17 or 18, the tool being mounted on a free end (4) of the frame.

20. Method of welding parts (21, 22) by friction stir, the method being implemented by a pin (8) according to one of claims 1 to 16.

21. Method according to claim 20, applied to parts (21, 22) superimposed on each other.

22. Method according to claim 20, applied to two pieces (21, 22), the two pieces being at the same time superimposed on each other and juxtaposed field against field.

23. Assembly (20) comprising welded parts (21, 22), the assembly resulting from the implementation of a method according to one of claims 20 to 22.

24. Battery tray (90) comprising at least one skin (91) and at least one hollow profile (92), a weld of the skin (91) to the profile (92) resulting from an implementation of a method according to one of claims 20 to 22.

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