Method for cutting components, method for manufacturing recycled components, and method for manufacturing recycled joined components.

Abstract

To provide a method for cutting components that can cut components with low load. [Solution] A method for cutting a member, comprising the step of cutting the member by friction stirring the member. A method for manufacturing a recycled member, comprising the step of cutting the member by friction stirring the member to obtain a recycled member. A method for manufacturing a recycled joined member, comprising the step of obtaining a recycled member by the manufacturing method, and the step of joining the recycled member with a third member other than the recycled member.

Description

Technical Field

[0001] The present invention relates to a member cutting method, a recycled member manufacturing method, and a recycled joined member manufacturing method.

Background Art

[0002] Against the backdrop of the promotion of multi-material components, friction stir welding (FSW), which is one of the joining techniques for dissimilar members, has attracted attention. Friction stir welding enables solid-state joining and can achieve strong joints, so its application in various fields is under consideration.

[0003] For example, from the perspective of improving vehicle fuel efficiency and the like, the use of joined steel members and aluminum members is under consideration. When a steel member and an aluminum member are joined by friction stir welding, the formation of brittle Fe-Al based intermetallic compound layers can be minimized, and strong joints can be realized.

[0004] Meanwhile, from the perspective of realizing a recycling-oriented society, easy disassembly is required when discarding joined members. Therefore, if a technology (easy separation technology) is established that allows members to be firmly joined to each other during use of the joined member and enables easy disassembly when the joined member is discarded, member recycling can be facilitated, and energy consumption throughout the entire life cycle can be significantly reduced.

[0005] According to studies by the inventors of the present invention, when joining members (for example, joining a steel member and an aluminum member), a foaming agent such as TiH₂ is added to the joining surfaces of the members, then friction stir welding is performed to disperse the foaming agent in the aluminum member. This enables strong joining between the members, and when the joined member is to be discarded, the joint between the members is heated to decompose the foaming agent and generate gas, causing the joint to foam, which makes it possible to cut (separate) the joined member with a low load (see, for example, Non-Patent Document 1).

Prior Art Documents

Non-Patent Documents

[0006] [Non-Patent Document 1] "Study on easy separation of A1050 aluminum / SS400 steel joints using porosification by applying a foaming agent to the joint interface," Light Metals, Vol. 73, No. 4, 164-166, 2023. [Overview of the Initiative] [Problems that the invention aims to solve]

[0007] Cutting (separating) jointed components using a foaming agent allows for cutting with low load, but it is time-consuming and costly because it requires the addition, heating, and foaming of the foaming agent. Furthermore, when cutting a single component rather than a jointed component, a foaming agent cannot be added because the components are not joined together as in the case of jointed components. Therefore, it is desirable to be able to cut components with low load without using a foaming agent.

[0008] Therefore, one aspect of the present invention aims to provide a method for cutting a member that can cut the member with a low load. Another aspect of the present invention aims to provide a method for manufacturing a recycled member by cutting the member with a low load, and a method for manufacturing a recycled jointed member using the recycled member obtained by the method for manufacturing a recycled member. [Means for solving the problem]

[0009] One aspect of the present invention includes, for example, the following: [1] A method for cutting a component, A method comprising the step of cutting the member by performing frictional stirring on the member. [2] The member is a joint member in which a first member and a second member having a different composition from the first member are joined at a joint, The method according to [1], wherein friction stirring is performed along the joint. [3] The method according to [2], wherein the first member comprises aluminum and the second member comprises iron. [4] The method according to [2], wherein the first member comprises aluminum and the second member comprises aluminum. [5] The second member is harder than the first member, The method according to any one of [2] to [4], wherein the friction stirring is performed such that the first member side becomes the advancing side. [6] The second member is harder than the first member, The method according to any one of [2] to [4], wherein the friction stirring is performed such that the second member side becomes the advancing side. [7] A method for manufacturing recycled materials, A manufacturing method comprising the step of cutting a component by friction stirring the component to obtain a recycled component. [8] The member is a joint member in which a first member and a second member having a different composition from the first member are joined at a joint, The manufacturing method according to [7], wherein friction stirring is performed along the joint. [9] The manufacturing method according to [8], wherein the first member contains aluminum and the second member contains iron.

[10] The manufacturing method according to [8], wherein the first member contains aluminum and the second member contains aluminum.

[11] The second member is harder than the first member, The manufacturing method according to any one of [8] to

[10] , wherein the friction stirring is performed such that the first member side becomes the advancing side.

[12] The second member is harder than the first member, The manufacturing method according to any one of [8] to

[10] , wherein the friction stirring is performed such that the second member side becomes the advancing side.

[13] A method for manufacturing recycled joint members, A step of obtaining recycled material by a manufacturing method described in any one of [7] to

[12] , A manufacturing method, comprising a step of joining the recycled member and a third member other than the recycled member.

[14] The manufacturing method according to

[13] , wherein the third member is a recycled member obtained from a member other than the aforementioned member.

Effects of the Invention

[0010] According to one aspect of the present invention, a member cutting method capable of cutting a member with a low load can be provided. According to another aspect of the present invention, a method for manufacturing a recycled member that obtains a recycled member by cutting a member with a low load, and a method for manufacturing a recycled joining member using the recycled member obtained by the method for manufacturing the recycled member can be provided.

Brief Description of the Drawings

[0011] [Figure 1] Figure 1 is a schematic diagram for explaining a member cutting method. [Figure 2] Figure 2 is a schematic cross-sectional view for explaining a cutting method of the joining member of Example 1. [Figure 3] Figure 3(a) is an observation image of Sample A obtained in Comparative Example 1, and Figure 3(b) is an observation image of Sample B obtained in Example 1. [Figure 4] Figure 4 is a load-displacement curve of Sample A and Sample B. [Figure 5] Figure 5 is a graph showing the breaking stress of Sample A and Sample B.

Modes for Carrying Out the Invention

[0012] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In the following description, the same or corresponding parts are denoted by the same reference numerals, and redundant descriptions are omitted.

[0013] <Member Cutting Method> A method for cutting a member according to an embodiment of the present invention includes a step of cutting the member by performing friction stirring on the member. By performing friction stirring on the member, the load required for cutting the member can be reduced compared to the case where friction stirring is not performed.

[0014] Examples of the material constituting the member include aluminum, copper, iron, magnesium, titanium, nickel, zinc, alloys of these metals, and resins. Examples of the aluminum alloy include A6061 which is an Al-Mg-Si based alloy, and ADC12 which is an Al-Si-Cu based alloy. The material of the member is preferably a material containing aluminum such as aluminum or an aluminum alloy, from the viewpoint of having a relatively low melting point and allowing the member to be easily cut by friction stirring.

[0015] The shape of the member is not particularly limited as long as the effects of the invention are not impaired. The member may be, for example, plate-shaped.

[0016] The member may be a joined member in which a first member and a second member having a composition different from that of the first member are joined at a joint portion, or may be a joined member in which a first member and a second member having the same composition as the first member are joined at a joint portion. In such a joined member, by performing friction stirring along the joint portion of the joined member, the load required for cutting can be reduced compared to the case where friction stirring is not performed.

[0017] Figure 1 is a schematic plan view for explaining a method for cutting a joined member. As shown in Figure 1, in the joined member 10, the first member 1 and the second member 2 are joined at the joint portion 5. The joined member 10 is cut into the first member 1 and the second member 2 by performing friction stirring at the joint portion 5. The friction stirring is performed by scanning along the joint portion 5 while rotating the tool 4.

[0018] The joining member may be one that is scheduled to be discarded due to damage to the first and second members constituting the joining member. The shape of the joining member is not particularly limited as long as it does not impair the effect of the invention. The joining member is formed by joining the first member and the second member at a joint, and the joining of the first member and the second member may be done by, for example, friction stir welding, welding, brazing, ultrasonic bonding, etc.

[0019] The materials constituting the first and second members can be, independently, aluminum, copper, iron, magnesium, titanium, nickel, zinc, alloys of these metals, or resins. Examples of aluminum alloys include A6061, an Al-Mg-Si alloy, and ADC12, an Al-Si-Cu alloy. The materials of the first and / or second members are preferably aluminum-containing materials such as aluminum or aluminum alloys, from the viewpoint of having a relatively low melting point and allowing the joined members to be easily cut by friction stir.

[0020] The second member may have a different composition from the first member, or it may have the same composition as the first member. In this specification, "having a different composition" means that the types of materials (elements) constituting the members, the content of those materials (elements), etc., are different. For example, the first member may contain aluminum, and the second member may contain iron. Alternatively, for example, the first member may contain aluminum, and the second member may also contain aluminum. In this case, both the first and second members contain aluminum, but the content of aluminum, the types of materials (elements) other than aluminum, etc., may differ between the first and second members. The second member may be harder than the first member.

[0021] The shapes of the first and second members are not particularly limited, as long as they do not impair the effects of the invention. The first and second members may each be plate-shaped. The shapes of the first and second members may be the same or different.

[0022] Friction stirring can be performed, for example, using a FSW (Fiber Stir Welding) device. This involves pressing the FSW tool against the material and rotating and scanning the tool. Friction stirring generates frictional heat, softening the material and creating defects such as tunnel-shaped defects. Conventional friction stir welding optimizes the tool's rotation speed, movement speed, joining load, and tool shape to suppress the occurrence of such defects. In contrast, the present invention optimizes the friction stirring conditions to induce defects, making it a completely different technology from friction stir welding. The optimal conditions for friction stirring when cutting a material vary depending on the type of material, size, and shape of the material. However, by, for example, reducing the tool's rotation speed, increasing the tool's scanning speed, or adopting a tool design that reduces the joining load and friction stirring force, defects can be formed in the stirred area, enabling cutting.

[0023] Friction stirring may be performed, for example, at any position on the surface of the member, and in any direction on the surface of the member. The direction in which friction stirring is performed (i.e., the direction in which the tool is scanned) can be appropriately determined according to the position where the member is to be cut. The direction in which friction stirring is performed may be, for example, from one end of the member to the other. The trajectory of the tool when performing friction stirring is not particularly limited and may be straight or curved.

[0024] If the member to be cut is a jointed member, friction stirring may be performed by scanning the tool along the joint of the jointed member. In this specification, "scanning the tool along the joint" means scanning the tool in the joint and the area near the joint. The area near the joint means within a range from the outer edge of the joint to an area approximately the size of the probe at the tip of the tool. By performing friction stirring along the joint between the first member and the second member in a jointed member, the jointed member can be cut and separated into the first member and the second member.

[0025] When friction stirring is performed, the side where the scanning direction of the tool and the rotation direction of the tool coincide is called the advancing side (AS), and the side where the scanning direction of the tool and the rotation direction of the tool do not coincide is called the retreating side (RS). For example, in Figure 1, the first member 1 side is the AS because the scanning direction of tool 4 and the rotation direction of tool 4 coincide, while the second member 2 side is the RS because the scanning direction of tool 4 and the rotation direction of tool 4 do not coincide.

[0026] When the components are joined components, and the first and second components each contain different types of metal elements (i.e., the joined components are composed of dissimilar metal components), the components tend to be easier to cut by friction stirring along the joint compared to when the first and second components contain the same type of metal element. Even when the first and second components contain the same type of metal element, by changing the friction stirring conditions (tool scanning speed, tool rotation speed, advance angle, tool shape, etc.), it becomes easier to create defects such as tunnel-shaped defects, thus allowing the joined components to be cut by friction stirring.

[0027] In a method for cutting a member according to one embodiment, the first member is made of AS, the second member is made of RS, and the second member is harder than the first member. That is, the RS member is harder than the AS member. When the RS member is harder than the AS member, friction stir defects are more likely to occur compared to when the AS member is harder than the RS member, and it tends to be easier to cut the member by performing friction stir along the joint. Even when the AS member is harder than the RS member, the member can be cut by performing friction stir along the joint by changing the friction stir conditions (tool scanning speed, tool rotation speed, advance angle, tool shape, etc.).

[0028] The scanning speed of the tool may be, for example, 100 mm / min or more, 200 mm / min or more, 300 mm / min or more, or 400 mm / min or more, or it may be 1500 mm / min or less, 1200 mm / min or less, 1000 mm / min or less, or 800 mm / min or less. The scanning speed of the tool can be determined by considering the material constituting the member (if the member to be cut is a joined member, the material constituting each member of the joined member), the rotation speed of the tool, the forward angle, etc.

[0029] The tool's rotational speed may be 500 rpm or more, 1000 rpm or more, 1500 rpm or more, or 2000 rpm or more, or it may be 5000 rpm or less, 4000 rpm or less, or 3000 rpm or less. The tool's rotational speed can be determined by considering the material constituting the member (if the member to be cut is a joined member, the material constituting each member of the joined member), the tool's scanning speed, the forward angle, etc.

[0030] After friction stirring is performed on the member (or along the joint of the joined member), the member may be cut by applying a load to it. In this case, the member can be cut with a lower load compared to when friction stirring is not performed on the member.

[0031] In the method of cutting the member described above, the joining member is composed of two members joined together, but the joining member may be composed of three or more members.

[0032] <Method for manufacturing recycled materials> Recycled material can be obtained by the method of cutting the material described above. Another embodiment of the present invention provides a method for manufacturing recycled material, which includes the step of cutting the material by friction stirring the material to obtain recycled material. For a method of manufacturing recycled material, refer to the description of the method of cutting the material described above.

[0033] In a method for manufacturing recycled materials, if the material is a jointed material in which a first material and a second material having a different composition from the first material are joined at a joint, the method for manufacturing recycled materials involves cutting the material by friction stirring along the joint to obtain the recycled material.

[0034] If the member is not a joined member, the recycled member obtained by cutting the member has substantially the same composition as the member being cut. If the member is a joined member, the recycled member obtained by cutting the member has substantially the same composition as the first member or the second member. The recycled member may be either the first member or the second member, or both members may be used as recycled members.

[0035] Recycled materials obtained by cutting other materials may be processed as needed. For example, since the shape of the edges of recycled materials (or the joint area in the case of joined materials) may be deformed due to friction stirring, the edges of recycled materials may be processed by compression, polishing, or other means to make them flat before reuse. In addition, surface treatments may be applied to recycled materials depending on their intended use.

[0036] <Method for manufacturing recycled jointing members> A recycled jointed member may be manufactured using the recycled member obtained by the recycled member manufacturing method described above. Another embodiment of the present invention includes a method for manufacturing a recycled jointed member, which includes the steps of obtaining a recycled member by a manufacturing method and joining the recycled member with a third member other than the recycled member. The method for manufacturing a recycled jointed member can be described by referring to the above-described method for cutting the member and the method for manufacturing a recycled member.

[0037] The third component is a component other than the recycled component, for example, a component having a different composition from the recycled component. The third component can be described by referring to the above-mentioned description of the component. The third component may have the same composition as either the first component or the second component. For example, if the recycled component has the composition of the first component, the third component may have a different composition from the first component, for example, it may have the same composition as the second component, or it may have a composition different from either the first or second component. The third component may be a component obtained by cutting a component other than the component used to obtain the recycled component (another recycled component), and the recycled jointed component may be a joint of recycled components.

[0038] The shape of the third component is not particularly limited. The third component may be plate-shaped. The shape of the third component and the shape of the recycled component may be the same or different.

[0039] The recycled material and the third material may be joined by, for example, friction stir welding, welding, brazing, ultrasonic bonding, etc.

[0040] After obtaining a recycled jointed member using recycled materials, if it becomes necessary to cut the recycled jointed member due to damage to the recycled materials and the third material constituting the recycled jointed member, the above-described method for cutting the jointed member can be applied. In this way, by repeatedly recycling the materials, energy consumption throughout the entire lifecycle can be significantly reduced. [Examples]

[0041] The present invention will be described in more detail below with reference to examples. However, the present invention is not limited to the following examples.

[0042] (Comparative Example 1) [Joining material] A general structural rolled steel plate SS400 (105mm x 40mm x 5mm thick) and an industrial pure aluminum A1050 (105mm x 40mm x 6mm thick) were placed side by side, butting them together. As shown in Figure 2, the FSW device tool 34 was positioned on the A1050 side (member 31 side) from the contact surface of each member, and the probe side of the tool 34 was inserted 0.8mm into the SS400 (member 32 side) and scanned by sliding it along the contact surface. The tool was made of tool steel with a shoulder diameter of 17mm, and the probe had an M6 thread and a length of 4.8mm. The tool scanning speed was 300mm / min, the tool rotation speed was 2000rpm, and the tool advance angle was 3°, with the tool rotation direction such that the SS400 side was AS. Sample A was obtained by performing FSW. Figure 3(a) shows the observation image of sample A viewed from the thickness direction (Top) and the observation image viewed from the side (Side).

[0043] (Example 1) Similar to sample A, the tool was scanned along the contact surface of the material to join SS400 and A1050, obtaining a joined material. Next, sample B was prepared by placing the tool in the same location where the tool was scanned to obtain the joined material, reversing the direction of rotation of the tool compared to when sample A was obtained, and scanning the tool at a scanning speed of 1000 mm / min and a rotation speed of 3000 rpm. Figure 3(b) shows the observation image of sample B viewed from the thickness direction (Top) and the observation image viewed from the side (Side).

[0044] [Evaluation of breaking load] For each obtained sample, the surface of A1050 was milled by 1 mm so that the thickness was 5 mm (the same thickness as SS400). Next, two strips of material with a width of 20 mm were cut from each sample using an electrical discharge machine. Tensile tests were performed on the obtained strips of material using a universal testing machine at a speed of 1 mm / min. The maximum load in the load-displacement curve obtained from the tensile test was defined as the breaking load. Figure 4 shows the load-displacement curve.

[0045] In sample A, the breaking load required to cut the joint member was large, and the displacement was also large. On the other hand, in sample B, the breaking load required to cut the joint member was small, and the displacement was also small.

[0046] Figure 5 shows the fracture stress of each sample. The fracture stress is calculated by dividing the fracture load by the cross-sectional area perpendicular to the tensile direction of each sample (the area of ​​the interface at the joint). The fracture stress of sample B was approximately one-tenth of the fracture stress of sample A.

[0047] (Comparative Example 2) A long side of an Al-Cu-Mg 2017 plate (105 mm × 40 mm × 5 mm thick) and a long side of an Al-Mg-Si A6061 plate (105 mm × 40 mm × 6 mm thick) were placed facing each other. As shown in Figure 2, the tool 34 of the FSW device was positioned on the A6061 side (part 31 side) from the contact surface of each member, and the probe side of the tool 34 was inserted 0.8 mm into the A2017 side (part 32 side) to scan the contact surface. The tool scanning speed was set to 400 mm / min, the tool rotation speed to 1200 rpm, and the tool advance angle to 3°, with the rotation direction of the tool so that the A2017 side was AS. Sample C was obtained by performing FSW.

[0048] (Example 2) Similar to sample C, the tool was scanned along the contact surface of the members to join A2017 and A6061, obtaining a joined member. Next, the tool was positioned 4.4 mm further towards A2017 from the point where the tool was scanned to obtain the joined member. The rotation direction of the tool was reversed compared to when obtaining sample C, and sample D was fabricated by scanning the tool at a scanning speed of 400 mm / min and a rotation speed of 3000 rpm.

[0049] In sample C, the fracture stress required to cut the joint member was high. On the other hand, in sample D, the fracture stress required to cut the joint member was low, and it was possible to break it with about 1 / 10 the stress of sample C. [Explanation of Symbols]

[0050] 1...First member, 2...Second member, 4, 34...Tool, 5...Joint, 10...Jointing member, 31, 32...Members.

Claims

1. A method for cutting a component, A method comprising the step of cutting the member by performing frictional stirring on the member.

2. The member is a joint member in which a first member and a second member having a different composition from the first member are joined at a joint. The method according to claim 1, wherein friction stirring is performed along the joint.

3. The method according to claim 2, wherein the first member contains aluminum and the second member contains iron.

4. The method according to claim 2, wherein the first member contains aluminum and the second member contains aluminum.

5. The second member is harder than the first member. The method according to claim 2, wherein the friction stirring is performed such that the first member side becomes the advancing side.

6. The second member is harder than the first member. The method according to claim 2, wherein the friction stirring is performed such that the second member side becomes the advancing side.

7. A method for manufacturing recycled materials, A manufacturing method comprising the step of cutting a component by friction stirring the component to obtain a recycled component.

8. The member is a joint member in which a first member and a second member having a different composition from the first member are joined at a joint. The manufacturing method according to claim 7, wherein friction stirring is performed along the joint.

9. The manufacturing method according to claim 8, wherein the first member contains aluminum and the second member contains iron.

10. The manufacturing method according to claim 8, wherein the first member contains aluminum and the second member contains aluminum.

11. The second member is harder than the first member. The manufacturing method according to claim 8, wherein the friction stirring is performed such that the first member side becomes the advancing side.

12. The second member is harder than the first member. The manufacturing method according to claim 8, wherein the friction stirring is performed such that the second member side becomes the advancing side.

13. A method for manufacturing recycled jointing members, A step of obtaining a recycled member by a manufacturing method described in any one of claims 7 to 12, A manufacturing method comprising the step of joining the recycled material with a third material other than the recycled material.

14. The manufacturing method according to claim 13, wherein the third member is a recycled member obtained from a member other than the aforementioned member.

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