Method and apparatus for manufacturing metallurgical bonding

Abstract

The present invention relates to a method and apparatus for manufacturing a metallurgical joint between two components, comprising the steps of: using an actuator to integrally metallurgically join a first component and a second component to a component to be pressed by applying energy to opposing surface portions of the components (K1, K2) by an energy transfer element. To improve contact between the parts, prior to pressing, at least one structural element tapering toward its free end is formed on at least one of the surface portions of the first and / or second components (K1, K2). During pressing and / or metallurgical joining, the structural element (c) penetrates the opposite surface portion by a contact surface as part of its surface. The shape of the structural element is maintained during penetration.

Description

Technical Field

[0001] The present invention relates to a method and an apparatus for forming a metallurgical bond between a first member made of a first metal and at least one second member made of a second metal. Furthermore, the present invention also relates to a member used in said method and a member used in manufacturing a metallurgical bond.

Background Art

[0002] Conventionally, various welding methods for metallurgically joining two metal members are known. For example, butt welding is a representative example thereof, and butt welding includes press butt welding and flash butt welding. The following is the definition described in Non-Patent Document 1: "Kompendium der Schweisstechnik (Welding Technology Handbook) Volume 1: Methods of Welding Technology".

[0003] Press butt welding: "The members to be welded are welded by heating the butt surfaces and applying force. The current and force are transmitted via clamp jaws. Heating occurs by the transition resistance between the two members to be welded. For this reason, in order for current to flow uniformly and obtain uniform heating, well-processed parallel butt surfaces are required."

[0004] Flash butt welding: "The members to be welded are heated by lightly bringing the butt surfaces into contact, and molten contact points are formed. Molten material is discharged from the butt surfaces by metal vapor pressure (flashing), and thereafter welded by rapid pressurization using force. Prior to flashing, preheating may be performed by repeated contact (reversal by individual current pulses) or external heating. The current and force are transmitted via contact jaws. In flash butt welding, in addition to resistance heating, the energy of the arc generated at protruding contact points and combustion heat are added. Rough butt surfaces promote arc generation and are smoothed by flashing. Liquid materials (slag, metal) remaining in the welding gap in the flashing step are extruded by rapid pressurization in the final stage of the welding process, forming burrs on the surface."

[0005] Furthermore, Figures 10a and 10b show the conventionally known process of projection welding. Figure 10a shows members K1 and K2 in their initial state before projection welding, and Figure 10b shows the state after projection welding. The following are known DIN standards regarding projection welding: DIN 8519 DIN EN 28167 DIN EN ISO 16432 DIN EN ISO 18278-1 DIN EN ISO 14327 Characteristics of projection welding:

[0006] The contours of bumps (projections) or dimples Sl are primarily formed from flat members (sheet metal or flat rails, thickness ≤ 3.2 mm) by deep drawing, embossing, or forming, resulting in cavities within them. The dimensions (height, outer diameter, internal space) of bumps (circular, longitudinal, and ring-shaped bumps) are determined according to DIN standards, based on customer requirements and material thickness. During the joining process, the materials are heated to a temperature exceeding their softening point under warm pressure, and have already transitioned to a paste-like state.

[0007] In the actual joining process, the two members form a fusion weld or brazed joint. The pre-embossed contours (cavities) are flattened again. The bumps collapse during welding, subsequently forming a flat joint in the shape of a nugget SWL. The dimensions of the nugget-shaped joint area are determined by the bump dimensions and customer-specific welding parameters (contact force, current, time). Oxide films and contaminant layers present on the joint surface before joining may remain in the molten material and potentially form a corrosive layer. After joining, the two components fit together tightly with almost no gaps.

[0008] Integral joining of metals in conventional technology:

[0009] Conventionally, methods for integrally joining metals are generally known, including laser welding, electron beam welding of contact parts, resistance welding and brazing, flash butt welding, press butt welding, and protrusion welding. However, as the required cross-sectional area for joining contact materials increases, existing processes are reaching their limits. Electron beam welding requires a vacuum and is complex and expensive. In resistance welding of aluminum and copper, once the current starts flowing to a certain point, the remaining area cannot be heated, making it impossible to achieve a large-area joint. Ultrasonic (US) welding and ultrasonic bonding: Conventional techniques include ultrasonic welding and ultrasonic bonding. Method 1: Al-US Wire Bonding

[0010] The process is performed at room temperature, where an Al wire is pressed against a solid surface consisting of an Al, gold, or copper layer using a bond head, and ultrasonic vibrations generate the frictional heat necessary for localized melting to create the bond. Second method: Thermosonic bonding

[0011] Gold or copper wires are pressed against an Al, gold, or copper surface heated to approximately 300°C and joined under the action of ultrasonic vibrations. Similar to Joule bonding, the joining process involves cold and / or warm deformation, followed by bonding. [Prior art documents] [Non-patent literature]

[0012] [Non-Patent Document 1] Kompendium der Schweisstechnik (Handbook of Welding Technology), Volume 1: Methods of Welding Technology [Disclosure of the Invention] [Problems that the invention aims to solve]

[0013] The object of the present invention is to improve known methods and apparatus for forming metallurgical joints, as well as the components used in such methods, and to improve contact between components.

[0014] The object of the present invention is achieved by the steps described in claim 1. The method is characterized by the following: Before pressurization, at least one structural element (SE) is formed on the surface of at least one of the members (the first member and / or the second member), which tapers toward the free end.

[0015] During pressurized and / or metallurgical joining, the structural element penetrates the opposing surface portion with a contact surface that constitutes part of its surface, along with the actual indentation depth (actual indentation amount) and the actual input energy, and during this penetration process, the structural element maintains its shape at least substantially.

[0016] The application of contact force and / or energy input shall be continued until the target indentation depth is reached or until a predetermined target energy is supplied to the joint between the members. The target indentation depth can be associated with a specific "way mark". A waymark is an indicator that shows the position of a structural element along the path through which it penetrates an opposing member. Waymarks may be intermediate points along the intrusion path, or they may be terminal points, i.e., the final depth in the intrusion path of the structural element. In the latter case, the target penetration depth is also called the "total target penetration depth."

[0017] The target energy input can be associated with a specific "energy mark". The energy mark is an indicator that indicates a predetermined amount of energy to be input to a final joint between members, or a predetermined energy input amount. The energy mark may be an energy input amount at an intermediate stage, or may be a predetermined total energy input amount for the entire pressing path of a structural element. In the latter case, the target energy input is also referred to as "total target energy input". The term "energy" as used herein refers to heat, that is, thermal energy.

[0018] This thermal energy is introduced to members through an energy transfer element by various methods. For example, in fusion welding: an electric current is applied to the member via an energy transfer element such as an electrode. In brazing (particularly brazing): heat is supplied to the member via an electrode or a heating element. In ultrasonic welding: ultrasonic vibration is transmitted to the member via a sonotrode. The concept of thermal energy referred to herein is distinguished from energy imparted by contact force. Examples of the members include the followings: a contact rail; flexible cables such as stranded cables and ribbon cables; and connection elements (terminals).

[0019] The structural element of the present invention is formed at an end portion or a surface portion on the connection side or terminal side of these members. A surface portion including the structural element can be formed and arranged at any position on the surface of the member, for example, an end face. In the case of a stranded cable or a ribbon-shaped stranded wire, the stranded wire can be partially compressed to be made compact, and a structural element can be formed in the compressed portion in the form described below. All these examples apply to all members, particularly a first member, a second member, and / or a third member.

[0020] The method of the present invention not only achieves a mechanical joint excellent in durability and elasticity, but also can obtain very good electrical conductivity at a contact surface particularly even when dissimilar metals are used. A structural element is not a mere surface roughness, but a specific physical component of a member.

[0021] Structural elements are formed on the surface of the member before pressurization by processes such as: cutting, sawing, punching, embossing (including die forming), casting, laser processing, and machining (especially milling). The (overall) height of the structural elements is, for example, in the range of a few millimeters to a few centimeters.

[0022] The (overall) height of a structural element is the distance from the free end (tip or highest point) to the base (forming position) on the member. The penetration depth is the height portion to which the structural element penetrates the opposing member, leading from the free end. The contact surface is the surface portion of the structural element involved in this penetration process. The actual penetration depth can be measured directly using the method of the present invention, if possible. Alternatively, it can be calculated indirectly from the difference between the known (overall) height of the structural element and the distance between the first and second members, which decreases with penetration.

[0023] Unless the components, or more precisely, their opposing surfaces, come into full contact after pressing, a repository (retention area) for containing the slag generated during the metallurgical joining process is formed between them. In other words, the repository is a cavity formed by the gap between the components that remains separated from each other after joining according to the present invention.

[0024] The volume of the repository is preferably equal to or greater than the volume of the slag. The repository is used to contain as much of the slag generated and extruded in the contact surface area as possible. When the repository is full, the slag is extruded from the sides of the cavity. In this case, the spread and distribution of the slag can be limited or defined by a mechanical barrier. This allows the slag to solidify into a controlled structure that does not require further processing. Alternatively, the extruded slag can be post-processed as needed.

[0025] The term "slag" encompasses all residues produced during metallurgical joining processes. This includes: residues resulting from the melting of two components, oxides of the component metals, contaminants on the component surfaces, and, if necessary, molten brazing material. The terms "immersion distance" and "immersion depth" are used synonymously.

[0026] In another embodiment, the two members can be moved relative to each other to such an extent that no gap or cavity remains between them. This increases the contact surface accordingly, that is, the contact surface includes not only the entire surface of the structural element but also the portion of the member surface where the opposing members come into contact with each other. This eliminates the need for a repository, and the generated slag flows out from the outside or from the side of the actual joint, as described at the end of the previous paragraph. In known press butt welding processes, large parallel planes are typically joined to each other. In contrast, in the method of the present invention, a structural element that tapers towards its free end, for example, a conical or pyramidal structural element that initially has a small contact surface, penetrates the surface of the opposing members, and in the process the contact surface expands or increases.

[0027] In known flash butt welding processes, surface roughness or molten contact points present on the surfaces of the involved members are utilized under low contact force, resulting in a flashing process and abrupt upset. In contrast, the method according to the present invention provides a local and / or clearly defined initial surface in the form of the free end of the structural element, preferably with a sufficiently constant contact force. A common feature of flash butt welding and the method of the present invention is that the molten material is pushed out of the contact area, thereby freeing the molten core from oxides and contaminants. Characteristic features of the structural element-based member joining method according to the present invention:

[0028] The contour of the structural element is characterized by tapering toward its free end, and is generated in the flat portions of the first, second, and / or third members by punching, embossing, laser cutting, machining, or casting processes, and does not form a cavity that later faces toward the opposing member, as in the case of protruding welds. Elsewhere, the external shape of the structural element may resemble a bump or dimple. During cold forming, which is performed at the start of the joining process, the tapered ends of the structural elements break the oxide layer, pushing them out from the joining area.

[0029] In the warm pressing stage, which may be performed after cold forming if necessary, the structural element is softened only to the extent that a desired initial surface is formed between its tapered end and the opposing member.

[0030] During metallurgical integral joining, the contour of the structural element, particularly its tapered free end, is preserved at least substantially. At most, its surface melts and merges with the opposing member. Because the structural element tapers towards its free end, the contact surface increases during the pressing process.

[0031] In the metallurgical joining stage, at least two members are joined by fusion welding, brazing, or ultrasonic welding, during which the structural element melts into the opposing member. In all cases, a zone of slag is formed on the side flank of the structural element, which is collected in any reservoir between the zone and the opposing member.

[0032] The newly designed contours of the structural elements taper rather than widen towards the free end, resulting in a different heating process than before. The small cross-section of the tapered end of the structural element creates a concentration of energy or current at the start of the metallurgical joining process, resulting in strong heating crucial for initiating welding or brazing, ideally accompanied by localized melting. An advantage is that the shape or contour of the structural element allows for good control of the heat flow during welding or brazing. As the joining process progresses, the two members move closer to each other, and the contact area widens due to the unique shape of the structural element. The varying energy input, such as current, required for optimal heat generation is adjusted continuously or segmentally. The energy input or indentation distance, i.e., indentation depth, can be used as a reference for the control and adjustment process. The joining process ends when a predetermined indentation distance is reached and / or when a predetermined amount of energy is input.

[0033] After the joining process, a gap preferably remains between the two members, here referred to as the repository, where the molten material solidifies, provided that it is not extruded laterally from the two members joined according to the present invention. By melting into the opposing members, only member materials free of oxides and contaminants are joined to each other in the joining region. After joining according to the present invention, the internal contact area between the members is enlarged by the structural elements provided by the present invention, in contrast to butt joints or planar joints of members. The enlarged contact area advantageously and significantly improves the mechanical contact and electrical conductivity between the members. The difference between known bump welding and the joining of metal members via structural elements according to the present invention (using fusion welding as an example):

[0034] [Table 1]

[0035] Pressurization and metallurgical joining can be performed sequentially. Alternatively, metallurgical joining can be performed while the members are being pressed by contact force.

[0036] According to one embodiment of the method of the present invention, the first and second members can also be joined to each other via a third member by metallurgical joining. The third member has at least two surface portions for this purpose and is used or positioned as a connecting member, i.e., a bridge member, for joining the first and second members. During pressurization and the generation of the metallurgical joining, one surface portion of the third member is positioned opposite the surface portion of the first member, and the other surface portion of the third member is positioned opposite the surface portion of the second member. The bridge member can be designed rigidly, for example, as a contact rail, or flexibly, for example, as a cable piece, in particular a cable strand or a stranded ribbon, as with the other members. Alternatively, the cable piece or cable strand can be designed rigidly.

[0037] Alternatively, if the third member faces only the second member (or the first member), the metallurgical bond can also join the third member to only the second member (or the first member). In this case, the third member is joined indirectly to the first member (or the second member) via the second member (or the first member). The first member becomes an intermediate member in that it can be positioned between the third and second members. Alternatively, the second member can become an intermediate member and be positioned between the third and first members. In either case, the third member has at least one surface portion for this purpose. In addition to the first surface portion, the second member (or the first member) has a surface portion facing the first member (or the second member), and furthermore, the second member (or the first member) has at least one second surface portion formed facing the surface portion of the third member during pressurization and the generation of the metallurgical bond.

[0038] In both alternatives relating to the third member, at least one structural element can be formed on at least one surface of the third member before pressurization. During pressurization and / or metallurgical joining, the structural element, along with the contact surfaces that constitute part of its surface, penetrates the opposing surfaces of the first and / or second member with an actual indentation depth and actual energy, continuing until a predetermined target indentation depth or a predetermined target energy input is reached. In this case as well, the tapered contour of the structural element is maintained at least substantially during penetration. In addition to, or instead of, the alternative of forming the structural element on the surface of the third member, the structural element can also be formed on the first and / or second member and penetrated into the third member.

[0039] In yet another embodiment, before pressurization, between pressurization and metallurgical bonding, or during metallurgical bonding, at least one layer of auxiliary material, such as a brazing material, coating, and / or film in the case of brazing, can be applied to the surface of at least one surface portion of the first, second, and / or third member and / or the surface of a structural element, or introduced between the structural element and the surface facing it.

[0040] The application of brazing material is particularly advantageous for brazing joints, where a eutectic molten material is formed between the brazing layer and the opposing member, having a melting point significantly lower than the lowest melting points of the two metals involved. The intermetallic compound phase should be ductile. The objective is for the opposing member to melt only in the molten region. The remaining metal portion of the member with structural elements remains solid and thus maintains dimensional stability. Pressurization can be performed by cold pressurization only, cold pressurization followed by warm pressurization, or warm pressurization of the component only.

[0041] During cold and / or warm pressurization, the static component of the contact force can be superimposed, at least temporarily, on the dynamic component of the contact force, such as periodic oscillations of the contact force. This offers the advantage that the dynamic component loosens and removes contaminants from the contact surface.

[0042] According to the present invention, cold pressurization is terminated when any of the following cold pressurization termination criteria are met: when the actual indentation depth reaches a predetermined target indentation depth, and / or when the actual cold pressurization time exceeds a predetermined target cold pressurization time.

[0043] During any warm pressurization, heat is applied to the member via energy transfer elements, and the energy input realized during warm pressurization constitutes the first part of the total energy input if warm pressurization is performed, while the second part of the total energy input occurs during the subsequent metallurgical bonding process. If warm pressurization is not performed, the total energy input occurs only during the metallurgical bonding process.

[0044] The input of (thermal) energy to a joint during warm pressurization has at least a static component, which can be superimposed on or modulated by a periodic component of energy as needed. For example, modulating the energy input by electricity causes alternating heating and cooling of the contact surface between the structural elements of one member and the opposing surface of the other member into which the structural elements penetrate. For example, because the thermal expansion coefficients of pure metals and their oxides differ greatly (Al: 22 ppm and 8 ppm), temperature changes induce shear motion, leading to the desirable delamination of the oxide layer at the contact surface. Additional modulation of the contact force enhances this mechanism.

[0045] The penetration of structural elements into opposing surfaces can begin during warm pressurization if warm pressurization is performed. The penetration of structural elements does not need to begin during the formation of the metallurgical joint.

[0046] Warm pressurization usually ends when any of the following warm pressurization termination criteria are met: when the actual indentation depth reaches a predetermined target indentation depth, and / or when the actual warm pressurization time reaches a predetermined target warm pressurization time, and / or when the actual energy applied to the joint during warm pressurization reaches a predetermined target warm pressurization energy value.

[0047] During pressurization and metallurgical joining, the members can be positioned so that their end faces face each other or at least partially overlap each other, via at least one structural element.

[0048] During warm pressing and / or metallurgical bonding, electrodes can not only generate and transmit electric current but also function as actuators that provide contact force. This has the advantage of preventing the electrodes from becoming unloaded during the bonding process.

[0049] During warm pressing and / or metallurgical bonding, the contact force of the actuator, preferably an electrode also used to apply contact force, is always greater than zero. The contact force is set or varied in accordance with the changing contact surface. Since the bonding process takes place for a very short time, specifically within tens of milliseconds, and during this time the contact force must be maintained within a specified force range, the dynamic characteristics of commonly used actuators or force control devices are generally insufficient. Force fluctuations cause changes in surface resistance, resulting in overheating or insufficient heating. Therefore, according to the present invention, a spring device is provided in addition to the actuator to compensate for force fluctuations with the necessary dynamic characteristics.

[0050] Furthermore, certain metals, such as aluminum, exhibit a very strong tendency to oxidize. After cold and / or warm pressurization, the oxidized surface layer is destroyed or removed, forming initial energy channels, such as current channels between members. If the energy transfer elements are temporarily unloaded or lifted during pulse-to-pulse transitions or during the penetration of structural elements, re-oxidation occurs immediately, causing surface roughness to reappear with even slight displacement and increasing surface resistance. This is highly unfavorable for the good electrical conductivity clearly desired between members joined according to the present invention, especially at their contact surfaces.

[0051] In yet another embodiment, upon reaching the target indentation depth, it is confirmed whether the energy input up to that point is within a predetermined range, or after a predetermined amount of energy has been input, it is confirmed whether the indentation depth is within a predetermined range relative to the target indentation depth. Both confirmation methods are optional and are used for quality control purposes. Ideally, the joint produced according to the method of the present invention satisfies both criteria, namely that the target indentation depth is reached and the energy input to the joint is appropriate without excess or deficiency. If either condition is not yet met, corrections can be made. This means readjusting the indentation depth or the input energy to meet the relevant specifications. This is advantageous for achieving the desired good electrical conductivity between metallurgically joined members.

[0052] Applying a protective gas to the joining area during pressurized and / or metallurgical joining has the advantage of protecting the joint formed between the two members from oxygen or harmful substances. This is also advantageous for achieving the desired good electrical conductivity between metallurgically joined members. 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 metals, the same metal, or a metal alloy.

[0053] The first metal that constitutes the first component is preferably copper or a copper alloy, and the second metal that constitutes the second component is aluminum or an aluminum alloy. Both metals have very good electrical conductivity.

[0054] The shape of the structural element according to the present invention is particularly useful for ultrasonic (US) pressurization and / or metallurgical bonding according to the present invention. Instead of an electric current being introduced into the member by an electrode, ultrasonic waves are introduced into the member by a sonotrode, heating the member at the contact surface. Specifically, structural elements enable a level of joint quality that cannot be achieved in planar contact areas on members without structural elements. This is known from prior art.

[0055] When there is a perfectly flat contact surface between two members, the oxide and contamination layers present on both surfaces are not extruded except in the edge regions, and remain in the joint region in an undefined state, hindering and blocking the formation of the joint (prior art). These contaminated areas can reduce joint strength, increase contact resistance, and become a "breeding ground" for subsequent corrosion damage during operation (conventional technology).

[0056] The shape of the structural element according to the present invention allows for velocity conversion of the sonotrode-side contact surface of the member. This means that the ultrasonic motion of the sonotrode is converted into greater lateral and / or axial motion of the "tip" of the structural element, which heats the tip. The shape and dimensions of the structural elements are preferably adapted to the selected US frequency and coupling method. The number, shape, and dimensions of structural elements determine joint strength and contact resistance.

[0057] The above-mentioned objectives of the present invention can also be achieved by the apparatus according to claim 29 and the component according to claim 33. The advantages of these solutions correspond to the advantages described above with respect to the method of the present invention.

[0058] The apparatus preferably comprises cutting, sawing, machining, laser cutting, punching, or embossing units, particularly dies, for forming structural elements on the surfaces of the first, second, and / or third members. Implementing at least one of these units within the apparatus for generating the metallurgical bond offers the advantage that the structural element formation process can be carried out within the apparatus. This implementation is optional and is expressed by being described in a dependent claim. Alternatively, the unit for forming the structural elements may be located outside the apparatus for generating the metallurgical bond. From a temporal standpoint, the formation of structural elements is always carried out independently of and prior to the pressurization of the members, as a separate process. Further advantageous embodiments of the method and apparatus of the present invention are subject to the dependent claims. [Brief explanation of the drawing]

[0059] This specification includes ten figures. [Figure 1] This illustrates or shows various embodiments of the free end of the tapered structural element. [Figure 1a] This illustrates or demonstrates various embodiments for forming holes within structural elements and / or within members on which structural elements are formed. [Figure 2] This illustrates or shows various embodiments of the arrangement of structural elements between the first member and the second member. [Figure 3] This illustrates or demonstrates an integral metallurgical joining between first and second metal members carried out according to the method of the present invention. [Figure 4a] , 4b and 4c show or illustrate a third member as a connecting member between the first member and the second member, the third member having at least two surface portions on which structural elements are formed to penetrate, for example, the first and second members. [Figure 5a] and 5b illustrate or show an example of the temporal relationships between different process steps of the method of the present invention. [Figure 6] This shows or illustrates the arrangement of members and electrodes at the start of the joining process by fusion welding according to the present invention. [Figure 7] This shows or illustrates the arrangement of electrodes and members after the method of the present invention has been carried out by generating a fused weld joint. [Figure 8] This shows or illustrates the arrangement of electrodes and members at the start of the brazing joining process according to the present invention. [Figure 9] This shows or illustrates the joining of members according to the present invention after the brazing process has been carried out. [Figure 10a] Figure 10b shows or illustrates a projection welding method known from the prior art. The present invention will be described in detail below in the form of embodiments with reference to the figures. In all figures, the same technical elements are indicated by the same reference numerals. [Best Mode for Carrying Out the Invention]

[0060] The present invention aims to join at least two metal members K1, K2, and K3 to each other. To achieve this joining as well as possible, a structural element c, in the sense of the present invention, is formed on at least one surface of the members to be joined. The structural element c is intended to penetrate the opposing members within the scope of the method of the present invention and improve the joining.

[0061] Structural elements are three-dimensional geometric objects that taper towards a free end. For example, they can exist in the form of teeth (see Figure 11), cones (see Figure 1 VI), frustums of cones (see Figure 1 V), pyramids (see Figure 1 VII), pyramidal bases (see Figure 1 VII), spheres or spherical segments (see Figure 1 II), horizontal cylinders, horizontal cylinder segments, especially semicylinders (see Figure 1 III), columns (see Figure 1 IV), or any combination of these objects, which may also be arbitrarily positioned vertically.

[0062] It is particularly preferable that the free end of the structural element c has an inclined side surface. This applies, for example, to the cone or pyramidal and trapezoidal shapes. In the joining method of the present invention, the tapered shape or inclined side surface generates a very high surface pressure under a predetermined force due to the small initial area, which is useful for reliably pushing out slag components such as molten material, oxides, and contaminants from the molten area. Therefore, it is preferable that the free end of the structural element c tapers to a tip shape or a generally rounded shape. Structural element c can be manufactured using the units described in the general section, regardless of its contour. The structural element c and the end regions of members K1, K2, and K3 on which the structural element is formed are preferably made of a solid material.

[0063] However, as shown in Figure 1a, holes 40 (including blind holes) and other types of artificial deformations such as indentations can also be formed within structural element c or in the end regions of members K1, K2, and K3. The holes 40 or corresponding blind holes can be designed in the form of elongated holes, one or more circular holes, or triangular holes, as shown in Figure 1a I), II), III). Current must flow around the holes 40, which alters the current flow, increasing the current density at the edges of the holes and therefore increasing heat generation. Compared to the design of structural elements without holes, holes cause additional localized heating. In this regard, by appropriately selecting the placement and configuration of holes or deformations, a desired heat distribution in the end regions of structural elements or members can be achieved, which differs from the case without holes or deformations.

[0064] This is particularly clearly shown in Figure 1a IV, which illustrates an example in which multiple structural elements c are formed on member K1. Small holes 40 in member K1 near structural elements c force the current to detour into current paths between the small holes 40, which are symbolized by thick arrows in these intermediate regions. This significantly increases the current density and, consequently, the heat accumulation in these intermediate regions. At the same time, heat conduction from the region where the structural elements penetrate the opposing member, which later becomes the junction, to member K1 is reduced. The large holes 40' in the rear region of the member are bores for fixing the member.

[0065] Another advantage is the provision of optional channels 45, which connect the surface portion of the structural element intended to penetrate the opposing member to the holes 40 or blind holes. This allows the holes or blind holes to function as additional repositories, enabling slag generated during the joining process to flow through the channels.

[0066] Figure 2I) shows linearly arranged structural elements c, some of which are designed as circumferentially closed ring shapes. Figure 2II) shows linearly arranged structural elements c in a star shape. Figure 2III) shows individual structural elements c arranged in a row. Figure 2IV) shows different individual structural elements arranged in a row between a first member K1 and a second member K2 that overlaps it.

[0067] In Figure 2, the first member K1 and the second member K2 are superimposed as an example. The ring-shaped arrangement shown in Figure 2I) is preferably closed in the circumferential direction, but does not necessarily have to be circular, and its circumferential structure has the advantage of preventing the outflow of slag or molten material in the form of a seal collar. Free molten material, oxides, and contaminants accumulate as slag in the repository. If there is no ring-shaped arrangement of structural elements, slag may solidify in areas outside the joint area and may have to be removed in an additional process.

[0068] As shown in Figure 3, instead of the overlapping arrangement shown in Figure 2, the first member K1 and the second member K2 can also be joined together with their end faces facing each other according to the present invention. For this purpose, at least one structural element c that penetrates the first member K1 within the scope of the method of the present invention is formed on at least the end face of the second member K2.

[0069] The structural element c shown in Figure 3 is formed, for example, in a tooth-like shape on the second member K2. These are pressed onto the first member K1 by an actuator using contact forces F1 and F2. In this example, the electrodes E1 and E2 of members K1 and K2 are formed independently of the actuator and contact members K1 and K2 at different positions.

[0070] Generally, it is advantageous to spatially and temporally separate the two processes of "formation of structural elements" and "pressure." In a single press system for embossing or punching structural elements, separate from the apparatus of the present invention that produces metallurgical joints, first a first member is inserted, preferably a heated die is placed on it, and finally an actuator, such as an upper electrode, presses the die onto the surface of the first member under temperature, force, and / or stroke monitoring, thereby forming a structural element. The die is then removed. If necessary, a second member is inserted into the single press system, and the embossing by the die is repeated, forming a structural element on the surface of the second member. Pressure is then initiated.

[0071] The characteristic that structural elements are retained during warm pressurization and metallurgical bonding, particularly during penetration into the surface of opposing members, does not prevent slight melting of the surface of the structural elements during the penetration process. However, this means that the structural elements retain at least substantially their geometric shape.

[0072] Figure 4a shows, as an example, an embodiment in which a first member K1 and a second member K2 are joined to each other via a third member K3, which takes the form of an intermediate member positioned between them. According to Figure 4I), a circumferentially ring-shaped integrated structural element c is formed on the upper side of the third member K3. On the lower surface of the third member, individual structural elements c distributed circumferentially are formed, for example, according to Figure 4III). Figure 4II) shows a cross-sectional view of the third member K3. Finally, Figure 4IV) shows an arrangement in which the first member K1 and the second member K2 are superimposed via the third member K3. The structural elements c shown in relation to Figures 4I), II), and III) penetrate the first member K1 and the second member K2 in Figure 4IV) according to the method of the present invention, thereby ensuring good integral metallurgical bonding, particularly good electrical conductivity, between all the involved members. The design of the ring-shaped third member K3 shown in Figure 4a is merely illustrative; the third member can also be designed as an object of any other arbitrary geometric shape.

[0073] In contrast to Figure 4a, Figure 4b shows an embodiment in which a first member K1 and a second member K2 are joined to each other via a third member K3 in the form of a parallel bridge member. The lower surface of the third member K3 has a first surface portion and a second surface portion formed thereon, which include structural elements c. In Figure 4b I), the structural elements c of the first surface portion are initially located only on the first member K1, and the structural elements of the second surface portion are initially located only on the second member K2.

[0074] Figure 4b II) shows how structural element c penetrates the first member K1 and the second member K2 according to the method of the present invention, ensuring good integral metallurgical bonding, particularly good electrical conductivity, between all involved members. The structural element of the third member K3 does not penetrate completely into the first and second members K1 and K2, for example, leaving an intermediate space as a repository 10 for slag to escape. The bridge member shown in Figure 4b is an example that enables the joining of two planar members K1 and K2 made of the same or different materials.

[0075] Figure 4c shows a further embodiment of the third member K3, namely a series bridge member. The structural element c is formed here on the end face of the bridge member K3. Figure 4c I) shows a top view of members K1, K3, and K2 before applying the method of the present invention. Figure 4c II) shows, in a horizontal section and a top view, how the structural element c of the third member K3 has penetrated the opposing surfaces of the first and second members K1 and K2 after completion of the method of the present invention. The remaining repository 10 is also clearly shown. In this embodiment, the third (bridge) member K3 is designed as a particularly flexible stranded ribbon, the strands of which are compressed at the free end, and the compressed region at the free end is indicated by reference numeral c10. A preferred material combination is that the first and second members are made of aluminum or an aluminum alloy, and the third (bridge) member is made of copper or a copper alloy. Figure 4c III) shows a longitudinal section of members K1, K3, and K2 joined according to the present invention.

[0076] Figures 5a and 5b show the temporal changes of various physical parameters when the method of the present invention is carried out. These parameters are contact force, current, indentation depth, (thermal) energy input to the joint, and the contact area between the structural element c and the opposing member into which it penetrates. Detailed explanation of the parameters:

[0077] Contact Force: The final control element (actuator), either motor-driven, pneumatic, or hydraulic, generates the contact force necessary to establish good contact between members K1, K2, K3 and the energy transfer element, as well as between the members themselves. Modulation of the contact force, optionally superimposed on the static contact force during the cold and / or warm pressurization phases, is used to break down the oxide and contamination layers and form a reproducible contact surface. Furthermore, the contact force, in combination with additional thermal energy input, such as electrical input, controls the heating of the contact surface between the structural element and the opposing member.

[0078] Current: In the warm pressurization and metallurgical bonding stages, the current generates the heat required for each step. Any modulation in the warm pressurization stage superimposes additional temperature changes, accelerating the delamination of the oxide layer. In the metallurgical bonding stage, the current adapts to the changing conditions. As the contact surface increases during the bonding process, the amount of current required to generate the necessary heat also changes. This adaptation can be continuous or segmental. These changes in force and / or current are carried out depending on the indentation distance or supplied energy.

[0079] Indentation Depth: Starting from the initial contact height between structural element c and the opposing member, the indentation depth, or indentation distance, increases continuously until a predetermined target indentation depth is reached. The indentation distance or indentation depth is divided into multiple segments, or sections, and different or identical energy input levels, such as current and contact force levels, are set for each section. The transitions between individual segments are indicated by planes or waymarks in the figure. Each waymark represents a predetermined indentation depth up to or below a predetermined maximum target indentation depth. Alternatively, a waymark may represent a predetermined energy level to be reached at each stage of the indentation path; in this case, the waymark is also called an energy mark. When a waymark or energy mark is reached, specific quality control methods described later may be implemented. Regardless of whether these control procedures are implemented, when a predetermined (total) target indentation depth or predetermined (total) target energy input is reached, further energy input is stopped, in particular the current is cut off, and the cooling process is initiated. Contact surface: As the bonding process progresses, the contact surface increases.

[0080] The method of the present invention is divided into the following steps in chronological order: cold pressurization, warm pressurization (optional), metallurgical bonding, and cooling, which is equally clear from both Figure 5a and Figure 5b.

[0081] The time curves shown in Figures 5a and 5b are purely schematic and merely illustrative. They apply regardless of whether the metallurgical joining by the present invention is achieved by fusion welding, brazing, or ultrasonic welding. Actual time curves may differ from those shown.

[0082] Figures 5a and 5b differ in that they correspond to different quality control methods in the rows of the energy curve and indentation depth curve. The energy input time curve in Figure 5a shows the position of the energy corridor relative to a given indentation depth waymark. The indentation depth time curve in Figure 5b shows the position of the height corridor relative to a given energy mark of energy input. Both control methods can be implemented as open-loop or closed-loop control.

[0083] Figure 5a illustrates a depth-of-indentation controlled quality control method, particularly in the parameter rows for "indentation depth" and "energy." This method consists of the following substeps:

[0084] a) Confirm that the structural element c of the first member K1 reaches the first waymark when it penetrates the second or third members K2, K3. b) At the first waymark, confirm whether the actual energy input to the joint generated by the penetration is within the target corridor of the target energy input assigned to the first waymark. c') If yes: Continue the penetration process to the next waymark and repeat step b there. c) For open-loop control, if no: Adjust at least one manipulated variable so that a predetermined target energy input is expected to be achieved for the next waymark when it is reached, and then perform step c') using the adjusted manipulated variable. c) For closed-loop control, if no: Determine the difference between the actual energy input and the target energy input at the first waymark as the energy control deviation, adjust at least one manipulated variable according to this deviation so that the energy control deviation at the next waymark is expected to be zero, and then perform step c') using the adjusted manipulated variable.

[0085] In this depth-of-indentation controlled quality control method, energy is the controlled variable. The manipulated variables include contact force, current level, sonotrode amplitude or frequency (when using ultrasonic welding), or brazing temperature. In open-loop control, the correction values ​​for the manipulated variables are fixed values ​​based on a table.

[0086] The distances between waymarks, and therefore the number of control points and the correction values ​​for manipulated variables, are set during process optimization. The distances may differ for each waymark, but are preferably equally spaced. Steps b) through c') or c") are repeated for subsequent waymarks until the final (total) target indentation depth is reached.

[0087] When the stop waymark corresponding to the final target indentation depth is reached, the current is cut off and it is checked whether the total energy input is within the target corridor. If the total energy is outside this range, the welded parts will not be automatically released.

[0088] Figure 5b illustrates an energy-controlled quality control method, particularly in the parameter rows for "indentation depth" and "energy." This method consists of the following substeps:

[0089] a) When structural element c of the first member K1 penetrates the second or third member K2, K3, confirm that it reaches the first energy mark. This energy mark represents a predetermined amount of energy to be injected into the joint generated by the penetration. b) At the first energy mark, confirm whether the actual indentation distance reached up to that point is within the target corridor of the target indentation distance assigned to the first energy mark. c') If yes: Continue the penetration process to the next energy mark and repeat step b). c) For open-loop control, if no: Adjust at least one manipulated variable so that a predetermined target indentation distance is expected to be achieved for the next energy mark when it is reached, and then perform step c') using the adjusted manipulated variable. c) For closed-loop control, if no: Determine the difference between the actual indentation distance and the target indentation distance at the first energy mark as the indentation distance control deviation, adjust at least one manipulated variable according to this deviation so that the indentation distance control deviation at the next energy mark is expected to be zero, and then perform step c') using the adjusted manipulated variable.

[0090] In this energy-controlled quality control method, the indentation depth is the controlled variable. The manipulated variables include contact force, current level, sonotrode amplitude or frequency (when using ultrasonic welding), or brazing temperature. In open-loop control, the correction values ​​for the manipulated variables are fixed values ​​based on a table.

[0091] The distance between energy marks, and therefore the number of control points and the correction values ​​for manipulated variables, are set during process optimization. The energy distance may differ for each energy mark, but preferably it is always the same in absolute terms. Steps a) through c') or c) are repeated for subsequent energy marks until the total target energy mark is reached.

[0092] When the stopping energy mark, i.e., the predetermined total target energy, is reached, the current is cut off and it is checked whether the achieved indentation distance is within the target corridor. If the total indentation distance is outside this range, the welded parts will not be automatically released.

[0093] Furthermore, multi-channel control can be implemented using indentation distance and energy as controlled variables, and contact force, current, US amplitude, and / or brazing temperature as manipulated variables. In this case, the controlled variables are read continuously at very short, identical time intervals, and the optimal manipulated variable is determined and set by a complex control algorithm. When the total target indentation depth or total target energy stop condition is reached, the corresponding energy transfer element is shut off, and it is checked whether the controlled variable has reached the target corridor. If it has, it is automatically released. The joining method according to the present invention will be described in more detail below with reference to Figures 6 and 7, specifically the process for joining components metallurgically using fusion welding.

[0094] Figure 6 shows the arrangement at the start of the joining process (fusion welding). Electrode E1 is in contact with surface A0 of the first component K1. The two-tiered structural element is provided on the first component K1 / K1, with the following exemplary planar or reference position: A1: Base surface of structural element A2: Intermediate surface corresponding to the repository location A3: The joint surface between the first and second stages of the structural element, preferably located at the shut-off level of the hot pressurizing process. A4: This is an intermediate surface, preferably located at the shut-off level of the cold pressurization process. St: Starting level (zero point for the measured quantity "penetration depth") Electrode E2 is in contact with surface A5 of the second component K2.

[0095] Figure 7 shows the results after performing the metallurgical joining according to the present invention, and the time progression of the process is shown in Figures 5a and 5b. Figure 7 shows the results of molten welding joining according to the present invention when the melting point of the second metal of the second component K2 is lower than the melting point of the first metal of the first component K1. A molten material SM consisting of the second metal and a mixture of the first metal and the second metal is formed between the structural element c and the second component K2. In addition to the molten material of the structural element c and the second component K2, a slag SL consisting of oxides and contaminants on the surface is pushed out of the molten area and moved into the repository 10.

[0096] Because the structural element tapers towards its tip, and the contact area of ​​the plane near the zero point is small, the temperature of the structural element is higher towards the second component K2 than towards the first component K1. Therefore, melting occurs at the tip of the structural element facing the second component.

[0097] Temperature estimation for the combination of copper (K1) and aluminum (K2): Melting point temperature: 548°C, Melting point of copper: 1084°C, Melting point of aluminum: 660°C. The liquid phase exists only in a narrow molten region. For example, the weight ratio of the molten materials is approximately 33% copper and 67% aluminum (eutectic composition). The joining method according to the present invention will be described in more detail below with reference to Figures 8 and 9, specifically the steps involved in metallurgical joining of components in the form of (hard) brazing. Brazing joining process

[0098] Figure 8 shows the arrangement at the start of the joining process (brazing). Electrode E1 is in contact with surface A0 of the first component K1. The two-tiered structural element c is located on the first component K1, with the following exemplary planes or reference positions: A1: Base surface of the structural element A2: Intermediate surface corresponding to the repository position A3: Joint surface between the first and second stages of the structural element, preferably located at the shut-off level of the hot pressing process A4: Intermediate surface, preferably located at the shut-off level of the cold pressing process Starting level: Zero point of the measured quantity "penetration depth" Electrode E2 is in contact with surface A5 of the second component K2. The first component K1 is covered with brazing material LB.

[0099] Figure 9 shows the results after implementing the metallurgical joining method according to the present invention, and the time progression of the process is shown in Figures 5a and 5b. The brazing applied according to the present invention is for introducing thermal energy into the joint to be formed when the melting point of the K2 material is lower than that of the K1 material. Here, structural element c is coated with brazing material LB. Alternatively, the brazing material can be supplied separately as an insert (paste, foil, strip). Hard brazing material is preferred, but soft brazing material can also be used.

[0100] A molten material consisting of brazing material and K2 material is formed between structural element c and the second component K2. In addition to the molten material of the brazing material and the opposing member K2, slag consisting of oxides and contaminants on the surface is extruded into the repository 10 or outside the joint area.

[0101] Because the structural element tapers towards its tip, and the surface area of ​​the plane near the zero point is small, the temperature of structural element c is higher towards the second component K2 than towards the first component K1. Therefore, melting occurs at the tip on the K2 side.

[0102] The brazing material on the structural element c of the first component K1 (a material with a high melting point) forms a eutectic fusion bond with the second metal of the second component K2. In the second bonding region, where the surface area is increased by the structural element, a ductile intermetallic compound phase may be formed. Regardless of the method of introducing thermal energy (fusion welding, ultrasonic welding, or brazing), the following applies:

[0103] Because the structural elements have a tapered shape towards the free end, the contact surface, which was initially small, changes to a larger contact surface as the joining process progresses, i.e., as penetration increases. The number and arrangement of structural elements can be arbitrarily selected. Multiple components can be joined, in which case a structural element is formed on at least one surface portion of each joining partner, i.e., the component.

[0104] In the embodiments shown in Figures 6, 7, 8, and 9, the structural elements and the first components are each made of a metal having a higher melting point than the second (opposing) component.

[0105] The energy transfer elements, particularly electrodes E1 and E2, function, for example, as actuators that simultaneously apply pressure. Alternatively, the actuators can be provided independently of or in addition to the energy transfer elements, resulting in a configuration similar to that shown in Figure 3. [Explanation of symbols]

[0106] A1 Area = Plane = Reference Position = Level A2 Area = Plane = Reference Position = Level A3 Area = Plane = Reference Position = Level A4 Area = Plane = Reference Position = Level A5 Area = Plane = Reference Position = Level c structural element c10 Compression Area E1 Energy transfer element (e.g., first electrode) E2 Energy transfer element (e.g., second electrode) F1 Contact force F2 Contact force K1 First component K2 Second component K3 Third component LB solder coating Sl: Dimple (indentation) SL: Slag SM: Melt St: Starting level SWL: Nugget (weld nucleus) 10 Repository 20 Control device 40 Hole (through hole or blind hole) 40' Fastening borehole 45 Flow channel

Claims

1. A method for forming a metallurgical bond 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 second components (K1, K2) each have at least one surface portion facing each other, and the method comprises the following steps: - A step of applying a contact force greater than zero (F1, F2) to the components using an actuator to press the first and second components (K1, K2) (with additional energy input by an energy transfer element as necessary); and, - A process of integrally joining the components (K1, K2) by applying energy to the opposing surface portions of the components (K1, K2) using an energy transfer element; Equipped with, Prior to pressing, at least one structural element (c) having a tapered shape toward the free end is formed on at least one surface portion of the first and / or second components (K1, K2), and during pressing and / or metallurgical joining, the structural element (c) penetrates into the opposing surface portion with an actual penetration depth and actual energy, with a contact surface which is part of its surface, and maintains its shape at least substantially during penetration, and the application of the contact force and / or energy input is continued until a predetermined target penetration depth is reached or a predetermined target amount of energy is introduced into the joint of the components (K1, K2). A method characterized by the following:

2. The structural element (c) is formed from a solid material, The structural element (c) consists of a three-dimensional geometric shape, such as a toothed body, cone, frustum of a cone, square pyramid, frustum of a square pyramid, sphere or spherical segment, horizontal cylinder, horizontal cylindrical segment, semicylinder, or any combination thereof. The free end of the structural element (c) is formed as at least one of the following contours: a non-planar shape and a tip shape. The structural element (c) is formed integrally with the first (K1), second (K2), and / or third (K3) components on at least one of their surface portions by, for example, blanking, casting, laser processing, machining or milling, or by embossing with a die. A single structural element (c) or a plurality of structural elements (c) are formed or arranged on the surface portion, and these are, for example, linear, star-shaped, curved, or closed annular arrangements, or any combination thereof. The method according to claim 1.

3. The metallurgical joining involves joining a third component (K3) made of a third metal in addition to the first and second components (K1, K2), wherein the third component (K3) has at least two surface portions and is arranged as a connecting member for joining the first and second components (K1, K2), wherein one surface portion of the third component (K3) is positioned opposite the surface portion of the first component (K1) during pressing and formation of the metallurgical joining, and the other surface portion of the third component (K3) is positioned opposite the surface portion of the second component (K2) during pressing and formation of the metallurgical joining. The metallurgical joining involves joining a third component (K3) made of a third metal in addition to the second component (K2), wherein the third component (K3) has at least one surface portion, and the second component (K2) is configured to have at least one second surface portion that faces the surface portion of the third component (K3) in addition to a first surface portion that faces the first component (K1), during pressing and during the formation of the metallurgical joining. The method according to claim 1 or 2.

4. Prior to pressing, at least one structural element (c) having a tapered shape toward the free end is formed on at least a portion of the surface of the third component (K3), During pressing and / or metallurgical joining, the structural element (c) penetrates into the opposing surface portions of the first and / or second components (K1, K2) with an actual penetration depth and actual energy, with a contact surface which is part of its surface, and the penetration continues until a predetermined target penetration depth is reached or a predetermined target amount of energy is introduced into the joint, and the structural element is held in place during penetration. The method according to claim 3.

5. Before pressing, between pressing and metallurgical bonding, or during metallurgical bonding, at least a single layer of auxiliary material, such as brazing material, coating and / or film, is applied to at least one surface portion of the first, second and / or third components (K1, K2, K3) and / or the surface of the structural element (c), or introduced between the structural element and the surface facing it. At least one of the pressing and metallurgical joining of the structural elements is performed under a protective gas atmosphere. The method according to any one of claims 1 to 4.

6. The aforementioned pressing is performed by cold pressing alone, cold pressing followed by hot pressing, or hot pressing alone. During cold pressurization and / or hot pressurization, the static component of the contact force is superimposed at least temporarily by a dynamic component of the contact force in the form of periodic oscillations, Cold pressurization is subject to at least the following cold pressurization shutoff conditions: - When the actual penetration depth reaches the predetermined target penetration depth; and / or, - If the actual cold pressurization time exceeds the predetermined target cold pressurization time; or, - During at least one of hot pressing and metallurgical joining, the contact force applied by the actuator is always greater than zero or constant and is applied at least partially by a spring device. The program terminates when any of the following conditions are met. The method according to any one of claims 1 to 5.

7. The actual energy input during hot pressurization is smaller than the total energy input realized during the formation of the metallurgical joint. The energy input during hot pressurization has at least one static component, which is superimposed or modulated by a periodic component. The method according to claim 6.

8. Hot pressurization is subject to the following hot pressurization shut-off conditions: - When the actual penetration depth reaches the predetermined target penetration depth; - When the actual hot pressurization time reaches the predetermined target hot pressurization time; or, - When the actual amount of energy input to the joint during hot pressurization reaches the predetermined target amount of hot pressurization energy; It terminates when at least one of the following conditions is met. The method according to claim 6 or 7.

9. Is the metallurgical joining performed while subjected to pressure from contact forces (F1, F2)? During pressing and metallurgical joining, the components are arranged so that their end faces face each other, or at least partially overlap. The method according to any one of claims 1 to 8.

10. The energy input during hot pressurization and / or the formation of an integral metallurgical joint is one of the following: • Fusion welding: This is performed by applying an electric current to components through an energy transfer element in the form of an electrode; - Brazing or hard brazing: This is done by applying heat to components via energy transfer elements in the form of electrodes or heating elements; • Ultrasonic welding: This is performed by transmitting ultrasonic vibrations to components via an energy transfer element in the form of a sonotrode. Optionally, the electrode, heating element, or sonotrode functions as an actuator that provides energy input and contact force. The method according to any one of claims 1 to 9.

11. The quality control method is characterized by penetration depth control in the form of open-loop or closed-loop control, and the quality control method is described in the following substeps: a) A step of confirming and confirming that the structural element (c) of the first component (K1) has reached the first predetermined reference position (waymark) when it penetrates the second or third component (K2, K3); b) A step of determining whether the actual energy input to the joint formed by the intrusion at the first reference position or a subsequent reference position is within the target corridor of the target energy input assigned to that reference position; c') If yes: The entry process is continued to the subsequent reference position, and process b) is repeated at that subsequent reference position; c) No in the case of open-loop control: The process involves adjusting at least one manipulated variable so that a specified target energy input is achieved for a subsequent reference position when that subsequent reference position is reached, and then performing step c') using the adjusted manipulated variable; c"') No in the case of closed-loop control: The difference between the actual energy input and the target energy input at the initial reference position is determined as the energy control deviation, at least one manipulated variable is adjusted according to the energy control deviation so that the energy control deviation becomes zero at the subsequent reference position, and then step c') is performed using the adjusted manipulated variable. Includes, Repeat steps b) through c') or c) for the subsequent reference position until the final total target penetration depth is reached, Or, The quality control method is characterized by an energy-controlled type of control method in the form of open-loop control or closed-loop control, and the quality control method is characterized by the following substeps: a) A step of confirming that the structural element (c) of the first component (K1) has reached the first energy mark when it penetrates the second or third component (K2, K3), and determining that the energy mark represents a predetermined amount of energy to be input to the joint formed by the penetration; b) A step of checking whether the actual penetration distance reached up to the first or subsequent energy mark is within the target corridor of the target penetration distance assigned to that energy mark; c') If yes: The intrusion process is continued to the next energy mark, and process b) is repeated at that next energy mark; c) No in the case of open-loop control: Adjust at least one manipulated variable so that a specified target penetration distance is achieved to the subsequent energy mark when the subsequent energy mark is reached, and then perform step c') using the adjusted manipulated variable; c') No in the case of closed-loop control: The difference between the actual penetration distance and the target penetration distance at the first energy mark is determined as the penetration distance control deviation, at least one manipulated variable is adjusted according to this deviation so that the penetration distance control deviation becomes zero at subsequent energy marks, and then step c') is performed using the adjusted manipulated variable. Includes, Repeat steps b) through c') or c) for subsequent energy marks until the final total target energy mark is reached. The method according to any one of claims 1 to 10.

12. At least one of the first metal, the second metal, or the third metal is the same or different metal or metal alloy in the area where they are in contact with each other. The aforementioned different metals are either copper and aluminum, or a copper alloy and an aluminum alloy. The method according to any one of claims 1 to 11.

13. An apparatus for forming a metallurgical bond 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 second components each have at least one surface portion facing each other, - At least one actuator that applies a contact force greater than zero to press the first and at least second components (K1, K2); - At least two energy transfer elements that input energy to the components and their surface portions in order to form an integral metallurgical bond between the pressed components (K1, K2); - A control device (20) for operating the at least one actuator and the energy transfer element; Equipped with, The control device is configured to operate the at least one actuator for applying the contact force and the energy transfer element to perform the method according to claim 1. A device characterized by the following features.

14. comprising at least one of the following devices for forming a structural element on the surface portion of at least one of the first, second, and third components: cutting, machining, laser cutting, blanking, or embossing, - A displacement sensor that directly or indirectly detects the actual penetration depth when a structural element of the first component penetrates the opposing surface portion of the second component (K2) or the third component (K3); or, - A comparison device that compares the actual penetration depth with a predetermined target penetration depth and determines the deviation as necessary; Equipped with, The control device (20) is configured to operate the energy transfer elements (E1, E2) in accordance with the method described in claim 1, or - An energy measuring device that directly or indirectly detects the actual energy input to the joint when the structural element (c) of the first component penetrates the opposing surface portion of the second component (K2) or the third component (K3); or, - A comparison device that compares the actual energy input with a predetermined target energy input and determines the deviation as necessary; Equipped with, The control device (20) is configured to operate the energy transfer elements (E1, E2) in accordance with the method described in claim 1. The apparatus according to claim 13.

15. A component (K1, K2, K3) made of metal, used in the method according to any one of claims 1 to 12, comprising at least one structural element (c) having a tapered shape toward a free end, At least one of the structural elements (c) is formed from a solid material, The structural element (c) consists of a three-dimensional geometric shape, namely a toothed body, cone, frustum of a cone, square pyramid, frustum of a square pyramid, sphere or spherical segment, horizontal cylinder, horizontal cylindrical segment, semicylinder, or any combination thereof. The free end of the structural element (c) is formed as a non-planar or tip-shaped contour, A single structural element (c) or a plurality of structural elements (c) are formed or arranged on the surface portion, and these are, for example, linear, star-shaped, curved, or closed annular arrangements, or any combination thereof. The structural element (c) is formed integrally with the component being formed and is made of the same metal as the component. The structural element (c) is formed integrally with the component on which it is formed, and is made of the same metal as the component. The aforementioned metal is copper, a copper alloy, aluminum, or an aluminum alloy. Holes or artificial deformations are formed in the end region of the structural element or the component on which the structural element is formed, in order to obtain a desired current distribution and heat distribution. A component according to any one of claims 1 to 12.

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