Method for improving the mechanical properties of beam-welded or gas metal arc-welded metal connections using powder- or wire-based application material

Abstract

The invention relates to a method for joining two joint partners using a metal welding process, involving: providing two joint partners, each joint partner having at least one contact surface via which the joint partners are to be joined; providing an application material to be applied, the application material comprising a layer material which contains at least one metal or semimetal and / or at least one oxide of a metal or semimetal; applying the application material in order to form an adhesive layer on at least one of the contact surfaces using a specified amount of layer material per unit area, the layer being formed either by applying the application material, which is present as a dispersion, or using a thermal spraying method for applying the application material; and joining the joint partners via the at least one contact surface coated with the adhesive layer using a beam-welding method or a gas metal arc-welding method, preferably laser or electron welding, or using a plasma keyhole welding process.

Description

[0001] - 1 - Method for improving the mechanical properties of beam-welded or gas-shielded metallic joints using powder- or wire-based coating material

[0002] TECHNICAL AREA

[0003]

[0001] The present disclosure relates to a method for joining two, in particular thick-walled, joining partners by means of metal welding.

[0004] TECHNICAL BACKGROUND

[0005]

[0002] The joints formed during welding or joining are metallurgical, i.e., they can only be broken by destruction. Therefore, the requirements placed on the resulting welds or joints are correspondingly high. The properties, in particular the mechanical properties of the resulting welds, depend, among other things, on the material composition and the position of the weld to be formed.

[0006]

[0003] It is known that when combining beam- and arc-based welding processes, filler materials can be used to improve the properties of the resulting welds. However, the material transport of these filler materials over the entire weld depth is often insufficient, resulting in a non-homogeneous distribution across the entire weld depth. This can lead to variations in mechanical properties along the weld and potentially to deterioration in the root area. Therefore, for welding or joining thick-walled components, such as thick-walled steels, a process is needed that achieves a homogeneous distribution of the filler material over the entire weld.

[0007]

[0004] Another problem that can occur when welding or joining metal-based components using beam or arc welding is the deterioration of the mechanical properties in the weld seam due to different cooling rates. This, along with the inhomogeneity of the filler material distribution, makes it difficult to use beam or arc welding processes for joining in constrained positions, and especially for joining or welding sheet metal and / or thick-walled steels. Es-2-

[0008] Therefore, a method is needed that exhibits a certain degree of position independence and is thus more universal, i.e., also applicable to constrained situations.

[0009]

[0005] Currently, the aforementioned problems are overcome by inserting (metal) foils between the joining partners before joining or welding them, or by coating the joining partners using a direct energy deposition (DED) process. A DED process is disclosed, for example, in A. Straße, A. Gumenyuk, M. Rethmeier, Adv. Eng. Mater. 2022, 24, 2101327, doi: 10.1002 / adem.202101327.

[0010]

[0006] However, the use of films or the DED process is costly and time-consuming, so there is still a need for more cost-effective and time-saving alternatives.

[0011]

[0007] One object of the present disclosure is to provide a cost-effective and time-efficient method, particularly for joining thick-walled components, with which the mechanical properties of beam-welded metallic joints can be improved. This object is achieved by a method according to claim 1.

[0012] SUMMARY OF THE INVENTION

[0013]

[0008] According to one aspect of the present disclosure, a method for joining two joining partners, in particular two thick-walled joining partners, by means of metal welding according to claim 1 and a beam welding device according to claim 10 is provided.

[0014]

[0009] According to the present disclosure, the method comprises: providing two,

[0015] especially thick-walled joining partners, each having at least one contact surface over which the joining partners are to be joined; providing a coating material to be applied, wherein the coating material comprises a layer material containing at least one metal or semimetal and / or at least one oxide of a metal or semimetal; applying the coating material to form an adhesive layer on at least one of the contact surfaces with a predetermined amount of layer material per surface, wherein the layer is formed either by applying the coating material, which is in the form of a dispersion, or by a thermal spraying process for applying the coating material; joining the joining partners over the at least one contact surface coated with the adhesive layer using a beam welding process or a gas metal arc welding process, preferably by laser or electron beam welding, or by plasma keyhole welding.- 3-

[0016]

[0010] The method of the present disclosure comprises the fact that the application material can be applied to only one of the contact surfaces, to several of the contact surfaces, or to all of the contact surfaces. For example, if two joining partners are to be joined via a contact surface each, this means that, within the framework of the method of the present disclosure, the application material can be applied to only one of the two contact surfaces as well as to both of the contact surfaces.

[0017] [Advantages of the procedure]

[0018]

[0011] An advantage of the method of the present disclosure is that, prior to joining, materials such as fine-grain formers or fine-grain-forming elements are applied to the at least one contact surface of the joining partners in the form of a coating agent. This allows for a homogeneous distribution of the fine-grain formers or fine-grain-forming elements contained in the coating agent over the entire weld seam (depth) during joining of the joining partners via the at least one contact surface thus coated. A homogeneous distribution of the fine-grain formers, in turn, leads to an improvement in the mechanical properties, such as toughness, in particular impact toughness, especially compared to uncoated welded joints.

[0019]

[0012] A particular advantage of the method according to the present disclosure is that, due to the coating prior to joining the joining partners, the homogeneous distribution of the fine composite formers or fine composite-forming elements contained in the coating material can be achieved even in constrained positions and / or with thick-walled joining partners. Thus, even in constrained positions and / or with thick-walled joining partners, such as thick-walled steels, the mechanical properties can be improved over the entire weld depth by the method of the present disclosure.

[0020]

[0013] Furthermore, the joining partners can be coated with the same or different coating materials independently of each other in terms of time and location before being joined. For example, the method of the present disclosure can make it possible to prepare two joining partners at different locations, e.g., by coating them, and then join them at one location. The method of the present disclosure has the advantage that the joining of the joining partners does not have to take place immediately after coating them. This makes the method particularly advantageous for joining in constrained positions and / or when the joining partners have to be transported before joining. Furthermore, the method of the present disclosure can offer the advantage that the dosage of the materials contained in the coating material can be controlled simply and precisely by measuring the amount of an-4- applied to at least one of the contact surfaces.

[0021] The layer material per area can be controlled. This makes the method of the present disclosure particularly advantageous for automation.

[0022]

[0014] Furthermore, it may be advantageous that no additional materials or metallic foils are required for the method of the present disclosure, which may make the method more cost-effective and / or more efficient compared to, for example, the use of foils or the use of a DED process.

[0023]

[0015] According to one aspect of the present disclosure, a beam welding device is provided for use in a method as described above, wherein the beam welding device preferably comprises: an application device, which preferably includes: a reservoir in which the application agent is provided; a nozzle with which the application agent can be applied to form an adhesive layer on at least one of the contact surfaces prior to joining the joining partners; and a control element that is connected to the nozzle and the reservoir and that is preferably configured such that the application agent can be applied once or several times to form the adhesive layer, so that the layer applied to the at least one of the contact surfaces has a predetermined amount of layer material per area; and an energy source for joining the joining partners via the at least one contact surface coated with the adhesive layer.

[0024]

[0016] Further advantages, features, aspects and details that can be combined with the embodiments described herein are evident from the pending claims, the description and the drawings.

[0025] BRIEF DESCRIPTION OF THE IMAGES

[0026]

[0017] The details are described below, including with reference to the following illustrations:

[0027]

[0018] Fig. 1 is a flow diagram for a method for joining two joining partners by metal welding according to embodiments of the present disclosure.

[0028]

[0019] Figures 2a-b show possible embodiments for applying an application means in accordance with the present disclosure.

[0029]

[0020] Fig. 2c outlines the joining of two joining partners via the coatings applied by the application material.

[0030] Contact surfaces.- 5-

[0031]

[0021] Fig. 2d shows two joining partners that were joined by metal welding in accordance with the present disclosure.

[0032] DETAILED DESCRIPTION OF THE IMAGES AND EXECUTIONS

[0033]

[0022] In the following, the various embodiments will be discussed in detail, one or more examples of which are shown in each figure. Each example serves for illustration and is not to be understood as a limitation. For example, features shown or described as part of one embodiment or aspect can be used in or in conjunction with another embodiment or aspect to obtain a further embodiment or aspect. It is intended that the present disclosure includes such modifications and variations.

[0034]

[0023] More generally, the method according to the present disclosure provides a way to join two or more, in particular thick-walled, joining partners, wherein, prior to joining the joining partners, a layer material containing the materials relevant for the properties of the joint formed between the joining partners is applied to at least one of the surfaces of the joining partners between which the joint is to be formed. The joining of the joining partners then takes place via the at least one of the surfaces on which the layer material has been applied. In the method according to the present disclosure, the joining partners to be joined are joined, i.e., the joint formed between the joining partners constitutes a weld.

[0035]

[0024] According to the present disclosure, the method for joining two,

[0036] The joining of thick-walled partners by metal welding is described in four steps (SI - S4, see Fig. 1). For the sake of clarity, these steps are described as four individual steps. However, depending on the implementation of the process in accordance with this disclosure, the steps can also be combined, e.g., summarized into fewer steps, and / or further subdivided, without thereby deviating from the process of this disclosure.

[0037]

[0025] The process begins by providing two joining partners, each of which has at least one contact surface (SI, see Fig. 1). For the purposes of this disclosure, “contact surface” refers to those surfaces or areas of surfaces of the joining partners-6-

[0038] The contact surfaces are defined as those areas where the joining partners are intended to come into contact via welds. Areas where no weld is formed are not considered contact surfaces.

[0039]

[0026] In principle, the two joining partners can have multiple contact surfaces. The joining partners can also differ in the number of their contact surfaces. Preferably, the two joining partners have the same number of contact surfaces. In one embodiment, each joining partner has exactly one contact surface.

[0040]

[0027] Furthermore, the contact surfaces can have any geometry. Preferably, the contact surfaces of the joining partners are congruent to each other. For example, if both joining partners each have only one contact surface, these contact surfaces can be rectangular and have the same area. In one embodiment, the contact surfaces of both joining partners are congruent to each other. In another embodiment, the contact surfaces of both joining partners are different in the sense that they differ in shape, for example rectangular, square, circular, etc., in area, or in both.

[0041]

[0028] As a second step (S2, see Fig. 1) of the method according to the present disclosure, a coating agent is provided for application to at least one of the contact surfaces, wherein the coating agent contains a coating material that includes at least one metal or semimetal and / or at least one oxide of a metal or semimetal. This means that the coating material can contain at least one metal or semimetal and at least one oxide of a metal or semimetal. It also means that the coating material can contain at least one metal or semimetal, or at least one oxide of a metal or semimetal. Alternatively, the coating material can also contain only one metal, one semimetal, one oxide of a metal, or one oxide of a semimetal. Preferably, the metal or semimetal contained in the coating material is a fine-composition element such as aluminum (Al) or titanium (Ti).

[0042]

[0029] According to one aspect, the layered material contains at least one metal or semimetal, wherein the metal or semimetal is a pure element selected from the list comprising aluminum (Al), nickel (Ni), and titanium (Ti), or a mixture thereof. For the purposes of this disclosure, a “pure element” is understood to be a metal or semimetal consisting of only one element and having an impurity level of less than 1% (wt%), preferably less than 0.1 wt%. The wt% refers here only to the metal or semimetal itself that is to be considered as the pure element.-7-

[0043]

[0030] The layered material according to the present disclosure can contain exactly one metal or semimetal, wherein this metal or semimetal is a pure element. Alternatively, the layered material according to the present disclosure can also contain several metals or semimetals, for example, an unalloyed mixture of several metals or semimetals, wherein each of the contained metals or semimetals is a pure element or wherein at least one of the contained metals or semimetals is a pure element.

[0044]

[0031] According to one embodiment, the layer material contains aluminum and nickel, each as pure elements. According to one embodiment, the layer material consists of aluminum and nickel, each as pure elements.

[0045]

[0032] According to one embodiment, the layer material contains aluminum and titanium, each as pure elements. According to one embodiment, the layer material consists of aluminum and titanium, each as pure elements.

[0046]

[0033] According to one aspect, the layered material contains at least one metal or semimetal, wherein the metal or semimetal is an alloy of at least one element selected from aluminum (Al), nickel (Ni), and / or titanium (Ti). The layered material according to the present disclosure can contain exactly one metal or semimetal, wherein this metal or semimetal is an alloy, preferably an alloy of at least one element selected from aluminum (Al), nickel (Ni), and / or titanium (Ti). This alloy can either consist of exactly these elements, i.e., Al, Ni, and Ti. Alternatively, this alloy can contain all or only some of these elements. In addition, the layered material according to the present disclosure can contain several metals or semimetals, wherein each of the contained metals or semimetals is an alloy, or wherein at least one of the contained metals or semimetals is an alloy.

[0047]

[0034] According to one embodiment, the layer material contains an alloy of aluminum (Al) and titanium (Ti). According to one embodiment, the layer material consists of an alloy of Al and Ti. According to one embodiment, the layer material contains an alloy of Al, Ti, and nickel (Ni). According to one embodiment, the layer material consists of an alloy of Al, Ti, and Ni.

[0048]

[0035] Preferred alloys that can be used in a method according to the present disclosure are Alloy INCONEL 625, EN-AW6082 and TC4 (Ti6Al4V).

[0049]

[0036] According to one aspect, the layer material contains at least one oxide of a metal or semimetal, wherein the oxide is an oxide selected from the list comprising aluminum(III)-- 8-

[0050] The coating material as defined in this disclosure may contain exactly one oxide, wherein this oxide is an oxide selected from the list comprising aluminum(III) oxide (A12O3), titanium(II) oxide (TiO), titanium(III) oxide (Ti2O3), and titanium(IV) oxide (TiO2), or a mixture thereof. Additionally, the layer material as defined in the present disclosure may contain several oxides, wherein each of the contained oxides is an oxide selected from the list comprising aluminium(III) oxide (A12O3), titanium(II) oxide (TiO), titanium(III) oxide (Ti2O3) and titanium(IV) oxide (TiO2), or a mixture thereof, or wherein at least one of the contained oxides is an oxide selected from the list comprising aluminium(III) oxide (A12O3), titanium(II) oxide (TiO), titanium(III) oxide (Ti2O3) and titanium(IV) oxide (TiO2), or a mixture thereof.

[0051]

[0037] According to one embodiment, the layer material contains aluminum(III) oxide (A12O3) and titanium(II) oxide (TiO). According to one embodiment, the layer material consists of aluminum(III) oxide (A12O3) and titanium(II) oxide (TiO).

[0052]

[0038] In general, the layered material as defined in this disclosure can therefore contain at least one metal or semimetal as a pure element, at least one metal or semimetal as an alloy, and / or at least one oxide of a metal or semimetal. Further aspects of the layered material will be discussed later.

[0053]

[0039] As a third step (S3, see Fig. 1) of the method according to the present disclosure, the coating agent is applied to form an adhesive layer on at least one of the contact surfaces with a predetermined amount of coating material per surface, wherein the layer is formed either by applying the coating agent, which is in the form of a dispersion, or by a thermal spraying process for applying the coating agent.

[0054]

[0040] As already mentioned, the application agent can be applied to just one contact surface, to several contact surfaces, or to all contact surfaces. When joining two joining partners in constrained positions, for example, it may be necessary for the application agent to be applied to only at least one of the contact surfaces of one joining partner. In the following, it is predominantly described that the joining partners each have one contact surface and that the application agent is applied to both contact surfaces. This is not to be understood as a limitation to this case, but serves to facilitate the understanding of the present disclosure. It is to be understood in the same way if the joining partners each have at least one contact surface and / or if the application agent is applied to only at least one of the contact surfaces.-9-

[0055]

[0041] If the joining partners have multiple contact surfaces, preferably all contact surfaces of at least one joining partner should be coated with the coating material. In one embodiment, the joining partners have multiple contact surfaces and the coating material is applied to all contact surfaces of only one of the joining partners. In another embodiment, the joining partners have multiple contact surfaces and the coating material is applied to all contact surfaces of both joining partners.

[0056]

[0042] According to one aspect, the application agent is provided as a dispersion of a particulate layer material in a dispersion medium and is applied to at least one of the contact surfaces by spraying, painting or brushing.

[0057]

[0043] According to one aspect, the coating agent is provided as a powder, rod, wire, or a combination thereof and applied to at least one of the contact surfaces by means of a thermal spraying process. Within the scope of the present disclosure, suitable thermal spraying processes include flame spraying, high-velocity flame spraying, detonation spraying, plasma spraying, arc spraying, melt bath spraying, and / or laser beam spraying. According to one embodiment, plasma spraying is used as a thermal spraying process for applying the coating agent. According to another embodiment, high-velocity flame spraying is used as a thermal spraying process for applying the coating agent.

[0058]

[0044] According to one aspect, the application material applied to the at least one contact surface of one joining partner can differ from the application material applied to the at least one contact surface of the other joining partner. For example, the application material applied to the at least one contact surface of one joining partner can differ from the application material applied to the at least one contact surface of the other joining partner in the type of application material, e.g., dispersion, stick, powder, etc. Alternatively or additionally, the application material applied to the at least one contact surface of one joining partner can differ from the application material applied to the at least one contact surface of the other joining partner in the method of application, e.g., spraying, painting, brushing, thermal spraying.The aspect of application will be discussed again later.

[0059]

[0045] According to one aspect, applying the application agent forms an adhesive layer on at least one of the contact surfaces with a predetermined amount of layer material per surface. The amount of layer material per surface can be adjusted. For example, the amount of layer material per surface can be adjusted by the frequency of the- 10-

[0060] The amount of coating material per area on at least one of the contact surfaces of the joining partners is adjusted by applying the coating material once or several times.

[0061]

[0046] Various quantities can be used to describe the amount of layer material per area. For example, the amount of layer material can be described by the thickness of the layer formed by applying the coating agent to at least one of the contact surfaces of the joining partners. Alternatively, the amount of layer material can also be described by, for example, its density and / or volume. The quantity used to describe the amount of layer material can depend on the application method and / or the type of coating agent. For example, the thickness of the resulting layer can be used to describe the amount of layer material if the coating agent contains only the layer material.In contrast to describing the amount of layer material by the volume or density of the layer, describing it by the layer thickness may suffice to understand the effects and advantages described in this disclosure. Therefore, for the sake of clarity, layer thickness will generally be used in the following text, particularly in the examples, to describe the amount of layer material in a formed layer.

[0062]

[0047] As a fourth step (S4, see Fig. 1) of the method according to the present disclosure, the joining partners are joined via the at least one contact surface coated with the adhesive layer using a beam welding process or a gas metal arc welding process. Joining the joining partners via the at least one contact surface coated with the adhesive layer can also be referred to as joining the joining partners via the at least one contact surface coated with the coating material.

[0063]

[0048] In the following, the formulation is usually used that the joining of the joining partners takes place via the contact surfaces coated with the adhesive layer. As already mentioned above regarding the application of the coating material, this is not to be understood as a limitation to the case in which the coating material is applied to all contact surfaces and thus an adhesive layer is present on all contact surfaces at the time of joining. Rather, these formulations are intended to facilitate the understanding of the present disclosure. Thus, it is to be understood in the same way if the joining partners each have at least one contact surface, the coating material is applied only to at least one of the contact surfaces, and the joining takes place via the at least one contact surface coated with the adhesive layer.- 11 -

[0064]

[0049] As already mentioned, within the meaning of this disclosure, the joining partners are joined using a beam welding process or a gas metal arc welding process. For example, the joining partners can be joined using laser or electron welding, or using plasma keyhole welding. According to one embodiment, the joining partners are joined by laser beam welding over the at least one contact surface coated with the adhesive layer. It should be noted again that the joining of the joining partners can also take place if the coating material applied to the at least one contact surface of one joining partner differs from the coating material applied to the at least one contact surface of the other joining partner.According to one embodiment, a different coating material is applied to the at least one contact surface of one joining partner than to the at least one contact surface of the other joining partner before the joining partners are joined via the contact surfaces thus coated. According to another embodiment, the same coating material is applied to the at least one contact surface of both joining partners.

[0065]

[0050] By joining the joining partners via the at least one contact surface coated with the adhesive layer, a weld seam consisting of molten material is formed. As will be explained in more detail later, the molten material contains both the coating material and the material of the joining partners. It is known that the characteristics of the weld seam, e.g., the amount of molten material or the thickness of the weld seam, depend, among other things, on the characteristics of the joining partners. It is also known that the thickness of a weld seam can be adjusted by selecting welding process parameters, which can be obtained, for example, from welding procedure specifications such as ISO 15609-3 or ISO 15609-4. The thickness of a weld seam can be determined by test welds, for example, within the framework of a welding procedure qualification test according to ISO 15614-11, on a metallographic section of the welded specimen.

[0066]

[0051] For the purposes of considering the amount of molten material, it shall be assumed that it represents the amount of molten material that is produced when carrying out the joining techniques mentioned in this disclosure, i.e.

[0067] Beam welding process or gas metal arc welding process, is created.

[0068]

[0052] According to one aspect, the formation of the layer, and thus the application of the application agent to at least one of the contact surfaces, can be adjusted such that a predetermined ratio, in particular a predetermined and material-specific- 12 -

[0069] A ratio is set between the amount of layer material per area and the amount of molten material per area. Preferably, this ratio is set between the total amount of layer material per area and the amount of molten material per area. The total amount of layer material per area can include the total amount of a specific layer material, taking into account all contact surfaces on which a layer of this layer material has been formed. Alternatively, the total amount of layer material can also include the total amount of layer material per area, taking into account all contact surfaces. Unless otherwise specified, the term "total amount" refers to the total amount of layer material per area.

[0070]

[0053] The ratio between the amount of layered material per area and the amount of melted material per area can be determined via the quantities by which the amounts are described, e.g. volume, density or thickness.

[0071]

[0054] For illustrative purposes, it is assumed here that two joining partners, each with a contact surface, have been coated with the same coating material. The contact surfaces of both joining partners, onto which the coating material has been applied, thus each have a layer of the same coating material. The amount of coating material per surface can be determined and described for each individual contact surface. For the sake of simplicity, in this example, the amounts of coating material per surface on the contact surfaces of the joining partners are described in terms of the thicknesses of the adhering layers. Thus, here, the bd2 the thicknesses of the layers on the contact surface of one joining partner (t / 7) and on the contact surface of the other joining partner (GZ?). The total amount of layer material per area can then be expressed in this example as the total thickness (t / ges ) described and e.g. by adding d } and d2 are determined (tZ ges = d + t / 2). As described above, joining the components creates a weld seam of molten material between them. The amount of molten material can also be described as thickness (y). The ratio between the total amount of layered material per area and the amount of molten material can then be determined using the ratio of the thicknesses t / ges and y can be described, e.g. t / ges: y. According to one aspect of the process as defined in the present disclosure, the application of the application agent, and thus the amount of layer material per area, can be adjusted to achieve such a ratio. Further reference will be made to this aspect later.- 13 -

[0072] [General Aspects]

[0073]

[0055] Next, general aspects of the invention will be described. Each aspect can be combined with any other aspect or embodiment, unless otherwise described.

[0074] [Ordering the order resource]

[0075]

[0056] Figures 2a-b show possible views of an embodiment for applying an application agent as described in the present disclosure. According to this embodiment, an application agent 200 containing a coating material is applied to the contact surface 102 of a joining partner 100 by means of an application device 300, whereby a layer 104 with a layer thickness 106 is formed on the contact surface 102. The layer 104 adheres to the contact surface 102 and preferably completely covers it after application of the application agent.

[0076] [ Joining partner]

[0077]

[0057] The method according to the present disclosure is suitable for joining thick-walled components, for example, thick-walled steels. According to DEM EN 10079, "thick-walled" components can be understood as having a thickness of at least 3 mm. The components that can be joined using the method according to the present disclosure can thus be classified as "heavy plates". According to one aspect, the method according to the present disclosure can be used to join components with a thickness of at least 10 mm, preferably at least 15 mm, and in particular at least 20 mm. In particular, the method according to the present disclosure can be used to join components with a thickness of 15 mm to 150 mm, for example, with a thickness of 20 mm to 150 mm. This makes the method according to the present disclosure particularly advantageous for joining steel plates in heavy-duty applications.

[0078]

[0058] In general terms, the weldability of components for joining is primarily influenced by the chemical composition, the metallurgical properties, and the physical properties of the components. For example, the chemical composition can influence aging tendency or hardening, while the metallurgical properties, such as melting mode or hot / cold forming, can be decisive for inclusions or segregation. Physical properties, such as thermal conductivity or expansion behavior, can also play a role.- 14 -

[0079]

[0059] It is advantageous in the context of the method of the present disclosure if the two joining partners have the same weldability. According to one embodiment, the two joining partners have the same weldability. As mentioned, the method in the context of the present disclosure is particularly suitable for joining thick-walled steels. According to one embodiment, both joining partners are thick-walled steels with similar weldability, preferably with the same weldability.

[0080]

[0060] With regard to chemical composition, it is particularly advantageous for weldability if both joining partners have the same or at least a similar chemical composition. According to one embodiment, both joining partners have the same chemical composition. As mentioned, the method according to the present disclosure is suitable for joining thick-walled steels. According to one embodiment, both joining partners are steels of type S355 with a thickness of at least 15 mm.

[0081] [The term: “adherent layer”]

[0082]

[0061] By applying the coating material to a contact surface, an adhesive layer is formed, without being bound to any specific theory, through mechanical interlocking with the material of the respective joining partner (substrate material). Mechanical interlocking is understood to mean a form-fit connection through positive-locking adhesion and not through chemical bonding. Depending on the type of coating material, the layer formed on at least one of the contact surfaces may consist solely of the coating material or of the coating material plus components of a dispersion medium.

[0083]

[0062] A layer formed by applying the application material to a contact surface within the framework of the method of the present disclosure shall always be understood as an “adherent layer”, even if the layer has not been explicitly characterized as “adherent” in the individual case.

[0084]

[0063] By applying the coating agent, a uniform, adhesive layer can be formed on at least one of the contact surfaces of the joining partners within the framework of the method of the present disclosure. According to one embodiment, the coating agent is applied to the at least one of the contact surfaces of the joining partners in such a way that a uniform, adhesive layer is formed. The term "uniform" in this context is to be understood as meaning that the layer has a constant amount of coating material per area along the directions of extension of the at least one contact surface on which it was formed. The joining of the joining partners via the contact surfaces with an adhesive,- 15 -

[0085] A uniformly coated contact surface can be of particular interest for joining partners whose contact surfaces are parallel to each other and / or when an I-shaped weld, i.e., an I-joint, is to be achieved when joining these partners. For example, Figure 2c shows, in a highly simplified manner, two joining partners 100, 500, each with a layer 104, 504 on its contact surfaces. It is assumed here that the contact surfaces are parallel to each other. Figure 2c can be understood to mean that the two joining partners 100, 500 are joined end-to-end. The method according to the present disclosure makes it possible for the two layers 104, 504 to be formed in such a way that they are uniform, i.e., each has a constant amount of coating material per area. If the amount of coating material is described in terms of the thickness of the layers, then Figure 2c can be interpreted as...Figure 2c is understood to mean that the layers 104, 504 have a constant thickness along the expansion directions of the contact surfaces, i.e., here along the expansion directions of the coated sides of the cuboid joining partners 100, 500 shown in Figure 2c. As illustrated in Figure 2c, the method according to the present disclosure also allows the layers 104, 504 of such joining partners to each have the same amount of layer material per area.

[0086]

[0064] Alternatively, by applying the coating agent in accordance with the method of the present disclosure, local variations in the amount of layer material per area can also be achieved. If a layer has an amount of layer material per area that is not constant along the directions of extension of the at least one contact surface on which this layer was formed, it is referred to as "locally varying" in the context of the present disclosure. According to one embodiment, the coating agent is applied to at least one of the contact surfaces in such a way that a locally varying, adhesive layer is formed. If the amount of layer material per area is described, for example, by the thickness of the layer, a locally varying layer would not have a constant thickness along the directions of extension of the contact surface on which it was formed.A locally varying amount of layer material can be suitable for compensating for irregularities in the surface of the contact area on which the layer is formed and / or for aligning the contact surfaces of the joining partners. For example, supposing that the contact surfaces of the joining partners 100, 500 shown in Fig. 2c were not parallel to each other, a layer could be formed on the contact surfaces using the method of the present disclosure such that the layers 104, 504, as shown in Fig. 2c, would be parallel to each other after formation and could be joined end-to-end. In particular, layers with a locally varying amount of layer material can be of interest when the contact surface to be formed between the joining partners- 16 -.

[0087] The weld seam is not I-shaped, but wedge-shaped, as in a V-joint or a Y-joint.

[0088]

[0065] Regardless of whether the layer formed on at least one of the contact surfaces is uniform or locally varying, it should be emphasized again at this point that by applying the application agent in accordance with the method of the present disclosure, the layer material is homogeneously distributed in this layer. A layer formed by the method of the present disclosure should therefore always be considered “homogeneous” and

[0089] "Liability" is to be understood as such unless otherwise described.

[0090] [Type of procurement instrument]

[0091]

[0066] When describing the components of the coating agent, a distinction is made between the coating material and any dispersion agents.

[0092]

[0067] Depending on the application method, the application agent can consist solely of the coating material or of the coating material and certain dispersion agents. The dispersion agents contained in the application agent together form a dispersion medium.

[0093]

[0068] For example, if the coating material is to be applied to at least one of the contact surfaces of the joining partners by means of a thermal spraying process, the coating material is preferably provided as a powder, rod, wire or a combination thereof. In these cases, the coating material can consist solely of the coating material.

[0094]

[0069] If, for example, the application agent is to be applied to at least one of the contact surfaces of the joining partners by spraying, painting, or brushing, the application agent is preferably provided by dispersing a coating material in a dispersion medium. Consequently, in these cases, the application agent can contain both the coating material and the dispersion agents selected depending on the dispersion medium.

[0095]

[0070] Gases or liquids are suitable dispersion media within the meaning of this disclosure. A dispersion medium can contain several dispersion agents or consist of only one dispersion agent. For example, the application agent can be provided as an aerosol in which the coating material is dispersed in a gas or gas mixture (dispersion medium). Alternatively, the application agent can be provided as a suspension in which the coating material is dispersed in a liquid or liquid mixture (dispersion medium).- 17 -

[0096]

[0071] According to one embodiment, an application agent is provided as a suspension of ethanol and the coating material. In this embodiment, the dispersion medium is a liquid containing only the dispersion agent ethanol. According to another embodiment, an application agent is provided as a suspension of an ethanol-water mixture and the coating material. In this embodiment, the dispersion medium is a liquid mixture containing the dispersion agents ethanol and water.

[0097]

[0072] Within the scope of this disclosure, a distinction is made between the state of matter of the dispersion medium at the time the coating agent is provided and at the time the coating agent is applied to at least one of the contact surfaces. If a coating agent is provided as a suspension, this only means that the coating agent is formed from one or more liquids (dispersion medium) and the coating material at the time of provision. The method of application of the coating material is independent of this. For example, the coating agent can be provided as a suspension of a liquid, such as ethanol (dispersion agent), and the coating material, but the same coating agent can be applied as an aerosol by spraying onto the contact surfaces of the joining partners to be welded together.At the time of spraying, the dispersion medium would therefore be a gas mixture consisting of the dispersion agents ethanol and air.

[0098]

[0073] Impurities may be present in the coating material in all cases without this deviating from the present disclosure. Preferably, the mass fraction of the impurities in the coating material is less than 1 wt%, more preferably less than 0.1 wt%, ideally 0 wt%.

[0099] [Material]

[0100]

[0074] According to the present disclosure, the coating material contains at least one metal or semimetal and / or at least one oxide of a metal or semimetal. For the sake of simplicity, this at least one metal or semimetal and / or at least one oxide of a metal or semimetal is hereinafter referred to as the “material”. The materials are decisive for the chemical, metallurgical, and physical properties of the joint formed between the joining partners. When mass fractions (wt%) are specified for materials, these refer only to the coating material. Preferably, the material is a fine-graining aggregate. Fine-graining elements are, for example, aluminum (Al) or titanium (Ti).-18-

[0101] [Pure element]

[0102]

[0075] According to one aspect, the layer material can contain at least one metal or semi-metal, wherein the metal or semi-metal is a pure element selected from the list comprising aluminium (Al), nickel (Ni) and titanium (Ti), or a mixture thereof.

[0103] Alternatively, the layer material can consist of at least one metal or semimetal, wherein the metal or semimetal is a pure element selected from the list comprising Al, Ni, and Ti, or a mixture thereof. If several metals or semimetals are each present as pure elements in the layer material or together constitute the layer material, these pure elements are present as an unalloyed mixture. For example, if a powdered layer material is to be used and the layer material contains aluminum powder and nickel powder, or consists of aluminum powder and nickel powder, the aluminum powder and the nickel powder form an unalloyed mixture.

[0104]

[0076] By using aluminium or nickel, for example as pure elements, the toughness of the weld seam formed between the joining partners by joining in accordance with the present disclosure can be improved.

[0105]

[0077] According to one embodiment, the layer material contains nickel as a pure element. According to one embodiment, the layer material contains aluminum as a pure element. According to one embodiment, the layer material contains aluminum and titanium, each as pure elements.

[0106]

[0078] According to one embodiment, the layer material consists of nickel. According to one embodiment, the layer material consists of aluminum. According to one embodiment, the layer material consists of aluminum and titanium, each as pure elements.

[0107] [ Alloy]

[0108]

[0079] According to one aspect, the layer material can contain at least one metal or semimetal, wherein the metal or semimetal is an alloy of at least one element selected from aluminum (Al), nickel (Ni), and / or titanium (Ti). Alternatively, the layer material can consist of at least one metal or semimetal, wherein the metal or semimetal is an alloy of at least one element selected from aluminum (Al), nickel (Ni), and / or titanium (Ti). This also means that, within the meaning of the present disclosure, alloys containing the elements Al, Ni, and Ti, preferably mainly, and alloys consisting of the elements Al, Ni, and Ti are also eligible.- 19 -

[0109]

[0080] According to one embodiment, the coating material contains a nickel-based alloy. According to one embodiment, the coating material contains the nickel alloy Alloy INCONEL 718. According to one embodiment, the coating material consists of the nickel alloy Alloy INCONEL 718. According to one embodiment, the coating material contains the nickel alloy Alloy INCONEL 625. According to one embodiment, the coating material consists of the nickel alloy Alloy INCONEL 625. In particular, when the coating material contains these nickel alloys, the coating agent can be provided as a wire or powder.

[0110]

[0081] According to one embodiment, the coating material contains an aluminum-based alloy. Preferred aluminum alloys are EN-AW 4047, EN-AW 5019, and EN-AW 6082. According to one embodiment, the coating material contains at least one of these preferred aluminum alloys, e.g., EN-AW 4047 and EN-AW 5019. According to one embodiment, the coating material contains exactly one of these preferred aluminum alloys, e.g., EN-AW 4047. According to one embodiment, the coating material consists of at least one of these preferred aluminum alloys, e.g., EN-AW 4047 and EN-AW 6082. According to one embodiment, the coating material consists of exactly one of these preferred aluminum alloys, e.g., EN-AW 6082.

[0111]

[0082] According to one embodiment, the layer material contains a titanium-based alloy. According to one embodiment, the layer material contains the titanium alloy TC4 (Ti6Al4V). According to one embodiment, the layer material consists of the titanium alloy TC4 (Ti6Al4V).

[0112]

[0083] According to one embodiment, the layer material contains aluminum and titanium alloys. According to one embodiment, the layer material contains the aluminum alloy (EN-AW6082) and the titanium alloy TC4. According to one embodiment, the layer material consists of the aluminum alloy (EN-AW6082) and the titanium alloy TC4.

[0113] [Oxide]

[0114]

[0084] According to one aspect, the layer material can contain at least one oxide of a metal or semimetal, wherein the oxide is an oxide selected from the list comprising aluminum(III) oxide (A12O3), titanium(II) oxide (TiO), titanium(III) oxide (Ti2O3), and titanium(IV) oxide (TiO2), or a mixture thereof. Alternatively, the layer material can consist of at least one oxide of a metal or semimetal, wherein the oxide is an oxide selected from the list comprising aluminum(III) oxide (A12O3), titanium(II) oxide (TiO), titanium(III) oxide-20-

[0115] (Ti2O3) and titanium(IV) oxide (TiO2), or a mixture thereof. Investigations carried out within the scope of the present invention have shown that, in particular, when aluminum(III) oxide (A12O3) and / or titanium(IV) oxide (TiO2) are included as materials in the coating material, the welding performance is improved.

[0116]

[0085] According to one embodiment, the coating material contains titanium(II) oxide (TiO). According to one embodiment, the coating material contains titanium(IV) oxide (TiO2). According to one embodiment, the coating material contains aluminum(III) oxide (A12O3). According to one embodiment, the coating material contains titanium(II) oxide (TiO) and aluminum(III) oxide (A12O3). According to one embodiment, the coating material contains titanium(IV) oxide (TiO2) and aluminum(III) oxide (A12O3).

[0117]

[0086] According to one embodiment, the coating material consists of titanium(II) oxide (TiO). According to one embodiment, the coating material consists of titanium(IV) oxide (TiO2). According to one embodiment, the coating material consists of aluminum(III) oxide (A12O3). According to one embodiment, the coating material consists of titanium(II) oxide (TiO) and aluminum(III) oxide (A12O3). According to one embodiment, the coating material consists of titanium(IV) oxide (TiO2) and aluminum(III) oxide (A12O3).

[0118] [Pure element and alloy]

[0119]

[0087] According to one aspect, the layered material according to the present disclosure can comprise at least one metal or semimetal, wherein the metal or semimetal is a pure element selected from the list comprising aluminum (Al), nickel (Ni), and titanium (Ti), or a mixture thereof, and at least one metal or semimetal, wherein the metal or semimetal is an alloy of at least one element selected from Al, Ni, or Ti. Alternatively, the layered material according to the present disclosure can comprise at least one metal or semimetal, wherein the metal or semimetal is a pure element selected from the list comprising Al, Ni, and Ti, or a mixture thereof, and at least one metal or semimetal, wherein the metal or semimetal is an alloy of at least one element selected from Al, Ni, or Ti.

[0120]

[0088] According to one embodiment, the layer material contains aluminum (Al) as a pure element and the titanium alloy Ti64. According to one embodiment, the layer material consists of Al as a pure element and the titanium alloy Ti64.- 21 -

[0121]

[0089] According to one embodiment, the layer material contains titanium (Ti) as a pure element and the aluminum alloy EN-AW6082. According to one embodiment, the layer material consists of titanium (Ti) as a pure element and the aluminum alloy EN-AW6082.

[0122] [ Pure element and oxide]

[0123]

[0090] According to one aspect, the layer material according to the present disclosure can comprise at least one metal or semimetal, wherein the metal or semimetal is a pure element selected from the list comprising aluminum (Al), nickel (Ni), and titanium (Ti), or a mixture thereof, and at least one oxide, wherein the oxide is an oxide selected from the list comprising aluminum(III) oxide (Al₂O₃), titanium(II) oxide (TiO), titanium(III) oxide (Ti₂O₃), and titanium(IV) oxide (TiO₂), or a mixture thereof. Alternatively, the layer material according to the present disclosure can also consist of only at least one metal or semimetal, wherein the metal or semimetal is a pure element selected from the list comprising Al, Ni, and Ti, or a mixture thereof, and at least one oxide, wherein the oxide is an oxide selected from the list comprising Al₂O₃, TiO, Ti₂O₃, and TiO₂, or a mixture thereof.

[0124]

[0091] According to one embodiment, the layer material contains Al as a pure element and TiO2.

[0125] According to one embodiment, the layer material consists of Al as a pure element and TiO2.

[0126]

[0092] According to one embodiment, the layer material contains Ti as a pure element and A12O3.

[0127] According to one embodiment, the layer material consists of Ti as a pure element and A12O3.

[0128] [ Alloy and oxide]

[0129]

[0093] According to one aspect, the layer material according to the present disclosure can comprise a metal or semimetal, wherein the metal or semimetal is an alloy of at least one element selected from aluminum (Al), nickel (Ni), or titanium (Ti), and at least one oxide, wherein the oxide is an oxide selected from the list comprising Al₂O₃, TiO₂, Ti₂O₃, and TiO₂, or a mixture thereof. Alternatively, the layer material according to the present disclosure can also consist of only at least one metal or semimetal, wherein the metal or semimetal is an alloy of at least one element selected from Al, Ni, or Ti, and at least one oxide, wherein the oxide is an oxide selected from the list comprising Al₂O₃, TiO₂, Ti₂O₃, and TiO₂, or a mixture thereof.-22-

[0130]

[0094] According to one embodiment, the coating material contains, in addition to the titanium alloy TC4, aluminum(III) oxide (A12O3). According to one embodiment, the coating material consists of the alloy TC4 and aluminum(III) oxide (A12O3).

[0131]

[0095] According to one embodiment, the coating material comprises an alloy of titanium (Ti), vanadium (V), and aluminum (Al), such as the alloy “Ti64” (containing: 90% Ti, 6% Al, 4% V), and aluminum(III) oxide (A12O3). According to one embodiment, the coating material consists of Ti64 and A12O3.

[0132] [Pure element, alloy and oxide]

[0133]

[0096] According to one aspect, the layer material can contain at least one metal or semimetal, wherein the metal or semimetal is a pure element selected from the list comprising aluminium (Al), nickel (Ni) and titanium (Ti), or a mixture thereof; at least one metal or semimetal, wherein the metal or semimetal is an alloy of at least one element selected from aluminium (Al), nickel (Ni), titanium (Ti); and at least one oxide of a metal or semimetal, wherein the oxide is an oxide selected from the list comprising aluminium(III) oxide (Al₂O₃), titanium(II) oxide (TiO), titanium(III) oxide (Ti₂O₃) and titanium(IV) oxide (TiO₂), or a mixture thereof.This means that a layered material within the meaning of the present disclosure may contain at least one metal or semimetal that is a pure element selected from the list comprising Al, Ni and Ti, or a mixture thereof, at least one metal or semimetal that is an alloy of at least one element selected from Al, Ni and / or Ti, and / or at least one oxide of a metal or semimetal, wherein the oxide is an oxide selected from the list comprising aluminum(III) oxide (A12O3), titanium(II) oxide (TiO), titanium(III) oxide (Ti2O3) and titanium(IV) oxide (TiO2), or a mixture thereof.

[0134]

[0097] According to one embodiment, the layer material contains aluminum (Al) as a pure element, an alloy of titanium (Ti), vanadium (V) and aluminum (Al), such as the alloy “Ti64” (containing: 90% Ti, 6% Al, 4% V), and aluminum(III) oxide (A12O3). According to another embodiment, the layer material consists of aluminum as a pure element, an alloy of titanium (Ti), vanadium (V) and aluminum (Al), such as the alloy “Ti64” (containing: 6% Al, 4% V), and aluminum(III) oxide (A12O3).

[0135]

[0098] In this context, it should be noted again that mass fractions of the materials contained in the layer material are given. When mass fractions for materials are specified within the scope of this disclosure, these refer only to the layer material. For example: A layer material consisting of 50% (wt%) aluminum (Al) as a pure element,-23-

[0136] 25% (wt%) aluminum alloy AW 4047 and 25% (wt%) titanium(II) oxide (TiO) can be described as Al : AW4047 : TiO (2:1:1). 50% (wt%) elemental aluminum (Al) here means that elemental aluminum (Al) constitutes 50% of the mass of the coating material, regardless of whether the coating material is supplied alone or with dispersion media in the coating agent.

[0137] [Particle size]

[0138]

[0099] In principle, the particle sizes familiar to those skilled in the art are suitable for the materials. However, in the case of coating materials in which the coating material contains, in particular, titanium(IV) oxide (TiO2) and aluminum(III) oxide (A12O3), care should be taken to ensure that these materials are used as nanoparticles, since larger particles may not dissolve during remelting and could form metallic inclusions. According to one embodiment, the coating material contains titanium(IV) oxide (TiO2) and aluminum(III) oxide (A12O3), wherein TiO2 and A12O3 are present as nanoparticles. According to one embodiment, the coating material consists of titanium(IV) oxide (TiO2) and aluminum(III) oxide (A12O3), wherein TiO2 and A12O3 are present as nanoparticles.

[0139] [Type of application]

[0140]

[0100] The method of applying the coating material may depend on how the coating material is provided and / or the geometric requirements imposed by the joining partners and the contact surfaces. In particular, the chemical composition of the coating material, the particle size of the materials it contains, or the presence of certain dispersion agents may be important. Furthermore, the ease or difficulty of accessing the contact surfaces may also be a factor in choosing the application method.

[0141] [Application by spraying, painting, brushing]

[0142]

[0101] According to one aspect, the application agent is provided as a dispersion of a particulate coating material in a dispersion medium. If the application agent is provided as a dispersion, spraying, painting, or brushing are particularly suitable for applying the application agent.

[0143]

[0102] According to one embodiment, a coating material containing titanium(IV) oxide (TiO2) is provided in a dispersion medium consisting of polyethylene glycol and ethanol and applied by spraying.-24-

[0144]

[0103] According to one embodiment, a layer material consisting of titanium(IV) oxide (TiO2) in a dispersion medium consisting of polyethylene glycol and ethanol is provided and applied by spraying.

[0145] [Orders using thermal spraying processes]

[0146]

[0104] According to one aspect, the coating material is provided as a powder, rod, wire, or a combination thereof. In these cases, thermal spraying processes are suitable for applying the coating material. For the purposes of this disclosure, surface coating processes, and especially thermal spraying processes according to DIN EN 657, are suitable. An important factor in choosing the thermal spraying process is that, unlike in welding overlays, the thermal spraying process does not create a metallurgical bond with the materials of the joining partners (substrate material). This is something the thermal spraying process has in common with the other application methods described in this disclosure, such as brushing, painting, or spraying.

[0147]

[0105] This means that neither when applying the coating material, which is provided as a dispersion of a particulate coating material in a dispersion medium and applied by spraying, painting or brushing, nor by a thermal spraying process for applying the coating material, which is provided as a powder, rod, wire or a combination thereof, should a metallurgical bond of the coating material with the materials of the joining partners occur: A coating material that is in the form of a dispersion and is applied, for example, by spraying, painting or brushing onto at least one of the contact surfaces forms an adhesive layer on this at least one contact surface without a metallurgical bond to the joining partners being formed.An application agent, provided as a powder, rod, wire or combination thereof and applied to the at least one contact surface by means of a thermal spraying process as defined in the present disclosure, already in liquid form, comes into contact with this at least one contact surface and forms an adhesive layer there, without creating a metallurgical bond to the joining partners.

[0148]

[0106] As explained above, the layer or layers resulting from the application of the coating material are intended to adhere only to the joining partners. Thus, the methods of applying the coating material disclosed here, in particular the thermal spraying process and its use in a process as defined in the present disclosure, differ from known processes such as the DED process. In the DED process, a starting material is typically first applied to the contact surface and then liquefied by the input of energy, typically by a laser, whereby a-25-

[0149] A metallurgical bond is formed between the starting material and the substrate material.

[0150]

[0107] One advantage that the method according to the present disclosure can offer compared to the DED method, among others, is that the substrate material is not altered by the way the coating agent is applied. Therefore, the method according to the present disclosure can also be used for joining components where, for example, the application of the DED method is not feasible because a metallurgical bond between the starting material applied by the DED method and the substrate material is not desired. This can be the case, for example, when thin-walled and / or flat components are to be joined together and a metallurgical bond between the substrate material and the starting material would impair the properties of the thin-walled and / or flat components.

[0151]

[0108] More generally, the method of applying the coating agent as described in this disclosure could be understood more as surface finishing, i.e., surface enhancement, in which the substrate material is not altered. In contrast, other application methods, such as those used in the DED process, in which a metallurgical bond is formed between the applied material and the substrate material, could be understood more as surface modification, in which the surface of the substrate material is altered.

[0152]

[0109] Preferred thermal spraying methods for applying the coating agent in a process in accordance with the present disclosure are flame spraying, high-velocity flame spraying, detonation spraying, plasma spraying, arc spraying, melt bath spraying or laser beam spraying.

[0153]

[0110] According to one embodiment, a coating agent comprising a coating material containing nickel as a pure element is applied by means of high-speed flame spraying. According to one embodiment, a coating agent comprising a coating material containing aluminum as a pure element is applied by means of high-speed flame spraying. According to one embodiment, a coating agent comprising a coating material containing Al₂O₃ and / or TiO₂ is applied by means of

[0154] High-speed flame spray applied.

[0155]

[0111] According to one embodiment, a coating agent consisting of a layering material containing nickel as a pure element is applied by means of high-speed flame spraying.-26 -

[0156] According to one embodiment, a coating material consisting of a layer containing pure aluminum is applied by means of high-speed flame spraying. According to another embodiment, a coating material consisting of a layer containing Al₂O₃ and / or TiO₂ is applied by means of

[0157] High-speed flame spray applied.

[0158]

[0112] According to one embodiment, a coating agent comprising a coating material consisting of pure nickel is applied by means of high-speed flame spraying. According to one embodiment, a coating agent comprising a coating material consisting of pure aluminum is applied by means of high-speed flame spraying. According to one embodiment, a coating agent comprising a coating material consisting of Al₂O₃ and / or TiO₂ is applied by means of

[0159] High-speed flame spray applied.

[0160]

[0113] According to one embodiment, a coating agent consisting of a coating material consisting of nickel is applied by high-speed flame spraying. According to one embodiment, a coating agent consisting of a coating material consisting of aluminum is applied by high-speed flame spraying. According to one embodiment, a coating agent consisting of a coating material consisting of Al₂O₃ and / or TiO₂ is applied by high-speed flame spraying.

[0161] [Type of means of commission, type of commissioning]

[0162]

[0114] High-quality welds can be obtained if the same coating material is applied to all contact surfaces of both joining partners in the same way and the joining partners are then joined over these coated contact surfaces.

[0163] Particularly preferred in this sense are embodiments in which the same coating material, for example a powder of a specific composition, is applied to all contact surfaces of both joining partners in the same manner, for example by a thermal spraying process. However, it is possible that both joining partners are coated with different coating materials and the same application method, with the same coating materials and different application methods, or with different coating materials and different application methods.

[0164]

[0115] According to one embodiment, a powdered coating agent is applied to at least one contact surface of the joining partners by means of a thermal spraying process. According to one embodiment, a powdered coating agent is applied to all contact surfaces of one of the two joining partners by means of a thermal spraying process. According to-27 -

[0165] In one embodiment, a powdered application agent is applied to all contact surfaces of both joining partners by means of a thermal spraying process.

[0166]

[0116] According to one embodiment, a suspension-like application agent is applied by spraying to at least one contact surface of the joining partners. According to one embodiment, a suspension-like application agent is applied by spraying to all contact surfaces of one of the joining partners. According to one embodiment, a suspension-like application agent is applied by spraying to all contact surfaces of both joining partners.

[0167]

[0117] According to one embodiment, a suspension-like application agent is applied by spraying to at least one contact surface of one of the two joining partners, while a powder-like application agent is applied by thermal spraying to at least one contact surface of the other joining partner. According to another embodiment, a suspension-like application agent is applied by spraying to all contact surfaces of one of the two joining partners, while a powder-like application agent is applied by thermal spraying to all contact surfaces of the other joining partner.

[0168] [Applicator]

[0169]

[0118] For the method according to the present disclosure, an application device 300 can be used in particular, which includes a reservoir, one or more nozzles, and a control element. The application agent can be provided in the reservoir and applied to at least one of the contact surfaces via the one or more nozzles. By means of the control element, which is preferably connected to the reservoir and the one or more nozzles, it can be set how often, i.e., once or several times, the application agent is applied to form the layer. Thus, such a control element can enable the layer applied to the at least one of the contact surfaces to have a predetermined amount of layer material per area.

[0170]

[0119] A steel welding device for use in a method of the present disclosure preferably comprises, in addition to the application device, an energy source which can be used to join the joining partners via the at least one contact surface coated with the adhesive layer.-28-

[0171] [ Quantity of the application material]

[0172]

[0120] According to one aspect of the method as defined in the present disclosure, an adhesive layer with a predetermined amount of layer material per surface is formed on at least one of the contact surfaces. For forming the layers, the use of machines for applying the coating material and computers for controlling the machines can be advantageous.

[0173]

[0121] According to one embodiment, an application agent is applied to at least one contact surface of each joining partner in such a way that the layers formed there have the same amount of layer material per surface.

[0174]

[0122] If layers are formed on several contact surfaces, these layers can have the same amount of layer material per surface. Alternatively, these layers can also have different amounts of layer material per surface. In both cases, the layers can be uniform or locally varying.

[0175]

[0123] According to one aspect of the method as defined in the present disclosure, the amount of coating material per area of ​​the layer or layers adhering to at least one of the contact surfaces of the joining partners can be adjusted. Adjusting the amount of coating material can be achieved by varying the frequency of application of the coating agent, e.g., single or multiple applications. The application method can be taken into account. For example, to achieve a specific amount of coating material, it may be necessary to apply a coating agent provided as a dispersion with a high proportion of dispersion medium more frequently than a coating agent that is also a dispersion but has a lower proportion of dispersion medium.

[0176]

[0124] As already mentioned, the amount of layer material per area can be described using various parameters. For example, the thickness of the layer formed on at least one of the contact surfaces can be used to describe the amount of layer material in that layer. At the very least, adjusting a specific amount of layer material per area can be clearly illustrated by the thickness of the resulting layer.

[0177]

[0125] The following describes how the amount of coating material per area can be adjusted, for example, in addition to the frequency of application, whereby the application of the coating agent by spraying is considered here with reference to Fig. 2 and the thickness of the resulting layer is used to illustrate the amount: If the-29-

[0178] If the application agent is provided as a dispersion and applied by spraying, the distance between an application device, such as application device 300 (see Fig. 2), and at least one contact surface, such as contact surface 102 (Fig. 2), can be varied. The distance between the application device 300 and a contact surface 102 can be changed manually. Preferably, the distance between the application device 300 and a contact surface 102 is changed mechanically and / or by computer control.

[0179]

[0126] Alternatively or additionally, if the application agent is provided as a dispersion and applied by spraying, the configuration of one or more nozzles can be varied. Various parameters are suitable for configuring the one or more nozzles. For example, the spray volume, spray radius, spray direction, or spray duration can be changed to form an adhesive layer with a predetermined amount of layer material per area on at least one of the contact surfaces of the joining partners. The configuration of the one or more nozzles can be performed manually. Preferably, the configuration of the one or more nozzles is carried out and implemented using computers.

[0180]

[0127] Alternatively or additionally, the coating agent itself can be varied, for example by varying the proportion of the coating material in the coating agent. If a coating agent comprises, for example, a coating material and a dispersion medium consisting of one or more dispersion agents, the coating agent can, for example, be diluted by increasing the proportion of dispersion medium, i.e., in this case, by adding one or more dispersion agents. Changing the proportion of dispersion medium, such as dilution, can be carried out simultaneously with the application of the coating agent and / or at a later time.

[0181] [ Joining the joining partners]

[0182]

[0128] Fig. 2c illustrates the joining of two joining partners 100, 500 via the contact surfaces coated by one or more coating agents 200, showing in particular the layers 104, 504 adhering to the contact surfaces. Fig. 2c thus illustrates the case in which both joining partners each have a contact surface and a coating agent has been applied to both contact surfaces, forming a layer with a predetermined amount of coating material per surface. As already explained above, the present disclosure is not limited to this case. Rather, the joining of the joining partners can also take place if a coating agent has been applied to at least one of the contact surfaces, so that a uniform or localized coating is formed only there.

[0183] A varying layer is formed with a predetermined amount of layer material per area.

[0184]

[0129] Figure 2c illustrates that two joining partners 100, 500 are joined end-to-end, i.e., across their respective end faces, whereby an I-shaped weld can be produced. The method according to the present disclosure is particularly suitable for I-joints.

[0185]

[0130] In the context of this disclosure, the term “joining” is understood to mean the connecting or joining of several workpieces with formless material, whereby cohesion is created locally and increased overall (DIN 1910). The terms “welding” and “joining” are used synonymously in this disclosure. By joining the joining partners, a weld seam is formed between the joining partners, as illustrated in Fig. 2d. The material of which the weld seam consists is referred to in this disclosure as “molten material,” unless explicitly stated otherwise. According to this disclosure, the joining partners are joined via the at least one contact surface of the joining partners coated with the adhesive layer. It follows that the molten material, i.e., the material of the weld seam, contains the material of the layer or layers formed on at least one of the contact surfaces.Furthermore, the molten material also contains material from the joining partners (substrate material). It is assumed that the weld seam created by the joining process contains the coating material, whereby the layers applied to the contact surfaces of the joining partners no longer exist as distinct layers. In other words, the adhesive layers are dissolved by the joining process and thus no longer exist as separate layers after joining. Instead, the joining partners are metallurgically bonded via the weld seam, whereby the weld material can be understood as a mixture, e.g., an alloy, comprising proportions of the substrate material and the coating material. The joining process can also be understood as "alloying," for example, when both joining partners are thick-walled steels, whereby an alloy of the steel material and the coating material is formed in the weld seam, and the two steels are joined directly via the weld seam.

[0186]

[0131] For illustration, reference is again made to Fig. 2d: After joining and thus after the formation of the weld 400, the two joining partners 100, 500 are materially bonded via this weld. A composite structure is thus formed, which comprises the two joining partners and the weld. This composite structure can be described as follows- 31 -

[0187] that it represents a three-component system (100, 400, 500), whereby the two formerly separate joining partners are connected by a mixing area, e.g. alloy area, which is represented by the weld seam 400.

[0188]

[0132] In addition to the method of weld formation described here, the materials contained in the coating material can influence the properties of the weld. The use of aluminum (Al) or titanium (Ti) as a fine-grain former is advantageous for toughness, particularly impact toughness.

[0189]

[0133] For the purposes of this disclosure, the joining of the components is carried out using an arc welding process or a gas metal arc welding process. Laser welding and / or electron beam welding are particularly suitable as arc welding processes. Plasma keyhole welding is particularly suitable as a gas metal arc welding process.

[0190]

[0134] According to one embodiment, the joining partners are joined by laser welding, wherein the coating material applied to at least one of the contact surfaces of the joining partners contains a coating material containing Al as a pure element and aluminum(III) oxide (Al₂O₃). According to one embodiment, the joining partners are joined by laser welding, wherein the coating material applied to at least one of the contact surfaces of the joining partners contains a coating material containing Al₂O₃ and TiO₂.

[0191]

[0135] According to one embodiment, the joining partners are joined by plasma keyhole welding, wherein the coating material applied to at least one of the contact surfaces of the joining partners contains a coating material comprising the titanium alloy TC4. According to one embodiment, the joining partners are joined by plasma keyhole welding, wherein the coating material applied to at least one of the contact surfaces of the joining partners comprises a coating material comprising the alloy TC4 and A12O3.

[0192]

[0136] It should be noted again at this point that it is assumed here that a weld obtained in the course of a process in accordance with the present disclosure has the amount of molten material that is produced when the joining techniques mentioned in this disclosure are carried out.

[0193]

[0137] According to one aspect, the application of the layer or layers to the contact surfaces of the joining partners is adjusted so that a predetermined ratio, in particular a predetermined and material-specific ratio, is set between the amount of layer material and the amount of molten material of the weld seam- 32 -

[0194] Preferably, the application of the layer or layers on at least one of the contact surfaces is adjusted such that a predetermined ratio, in particular a predetermined and material-specific ratio, is established between the total amount of layer material per area and the amount of melted material per area.

[0195]

[0138] As already described, the amount of layer material and the amount of molten material can be described using various quantities. For example, the amount of layer material per area can be described using the volume, density, or thickness of the respective layer. The same applies to the amount of molten material per area. This can also be described using, for example, the volume, density, or thickness of the respective layer. However, the amount of layer material and the amount of molten material can also be described using other quantities without deviating from the present disclosure.

[0196]

[0139] With reference to Figures 2c and 2d, the following example assumes that two joining partners 100, 500 are joined via a contact surface, wherein an application agent has been applied to both contact surfaces such that a layer 104, 504 with a predetermined amount of layer material per surface is formed on both contact surfaces. For the sake of simplicity, it is further assumed that the amount of layer material is the same on both contact surfaces and that both layers are uniform. As already mentioned, the amount of layer material can be described by the thickness of the layers. Thus, tZi04 is the thickness of the layer 104 that was formed on the contact surface of the joining partner 100. Similarly, d 504 The thickness of layer 504 formed on the contact surface of the joining partner 500. Together, tZi04 and d yield 504 the total thickness tZ ges, which thus illustrates the total amount of layered material. After joining the components as shown in Fig. 2, the components are connected via the weld seam 400. The amount of molten material, i.e., the amount of material in the weld seam, can now also be described by a thickness, in this case the thickness of the weld seam t / 400. In this example, from d ges and t / 4O a ratio can be determined, e.g.: t / gcs : tZ 4O This ratio, in turn, can be taken into account when adjusting the amount of layer material per area on at least one of the contact surfaces. For example, a variation of the above example could be that only the contact surface of one of the two joining partners is coated, but the resulting layer, e.g., 104, already has a thickness d. ges exhibits, i.e., tZ 10 4 = d ges, so that the desired ratio can be achieved after joining the components.- 33 -

[0197]

[0140] The ratio described above between the amount of coating material and the amount of melted material can be material-specific. According to one embodiment in which a coating material comprising a coating material containing more than 70% (wt) Ni is applied to at least one contact surface of the joining partners, this ratio can be 1:10. According to another embodiment in which a coating material comprising a coating material containing more than 70% (wt) titanium(IV) oxide (TiO2) and / or aluminum(III) oxide (AlO3) is applied to at least one contact surface of the joining partners, this ratio can be 1:500.If the amount of coating material and the amount of molten material are visualized as the thickness of the layer formed on at least one of the contact surfaces and the thickness of the weld, this means that the weld has a thickness 500 times greater than the layer formed on at least one of the contact surfaces. If the coating material contains aluminum and titanium, either alternatively or additionally, this ratio can even reach 1:1000. In this case, again visualizing the amounts of coating material and the amounts of molten material as the thicknesses of the respective layer and the weld, this means that the weld can have a thickness up to 1000 times greater than the layer formed on at least one of the contact surfaces.

[0198] [Advantages of the invention]

[0199]

[0141] The advantages possible by the method of the present disclosure will be explained in more detail below:

[0200]

[0142] A particularly advantageous aspect of the method according to the present disclosure is that a homogeneous weld seam can be achieved, with which the joining partners are material-bonded, wherein the weld seam material contains a mixture of the coating material as well as a proportion of the material of both joining partners. Furthermore, the method according to the present disclosure does not require filler materials or metallic foils.

[0201]

[0143] According to one aspect, applying the coating agent can form an adhesive layer on at least one of the contact surfaces. In this layer, regardless of whether the layer itself is uniform or locally varying, a homogeneous distribution of the coating material and thus of the materials contained therein can be achieved. In other words, with the method according to the present disclosure, a homogeneous distribution of the coating material and thus of the materials contained therein along the expansion directions of the at least one contact surface can be achieved as soon as the coating agent is applied. This means that no material transport within the formed layer or layers is required during the joining process itself.- 34 -

[0202] The method of applying the coating material as described in this disclosure offers an advantage over, among others, the DED process, in that no metallurgical bond is formed between the coating material and the substrate material.

[0203]

[0144] According to one aspect, during the joining of the joining partners, the material in the layer(s) applied to at least one of the contact surfaces is homogenized. This allows both differences within the layer, e.g., in a locally varying layer, and differences between the layers on the contact surfaces of the joining partners to be compensated. In particular, a method according to the present disclosure can make it possible to produce homogeneous welds that are not I-shaped, for example, wedge-shaped.

[0204]

[0145] By homogenizing the material of the layer(s) applied to at least one of the contact surfaces during the joining of the joining partners, further effects can also be achieved. If, for example, an application agent is provided as a dispersion and applied to at least one contact surface, it is possible that some of the dispersion medium remains in the formed layer after application. Depending on the dispersion medium, these components may escape on their own. However, these components can also be removed by the temperatures used during the joining process. Since a homogeneous distribution of the application agent can already be achieved during application, the removal of the dispersion medium components during joining can occur in such a way that a homogeneous weld seam is still obtained.This can be of particular interest if different application materials are applied to the joining partners.

[0205]

[0146] Between the application of the coating agent and the joining process, any time interval can elapse, within which any components of a dispersion medium, if present, can escape independently, partially or completely. Homogenizing during joining offers the advantage that a process according to the present disclosure can be independent of such time intervals. This can be of particular interest if, for example, the joining partners are coated at different locations or stored after coating before being joined.

[0206]

[0147] The method according to the present disclosure can also provide that the application material is applied only to at least one contact surface of one of the joining partners, and the joining takes place via the contact surfaces of both joining partners. Thus, the method of the present disclosure is also particularly suitable for joining when one of the- 35 -

[0207] One joining partner is more difficult to access and therefore more difficult to coat than the other. Those skilled in the art will appreciate that even in cases where the coating material is applied to only at least one of the contact surfaces of the joining partners, and the joining partners are subsequently joined via the contact surfaces as described here, the desired mechanical properties, such as toughness, can be achieved.

[0208]

[0148] A further advantage that can result from the method of applying the coating material and / or from the possibility of controlling the amount of coating material as described in this disclosure is that the joining process itself is independent of the wall thickness of the joining partners and / or the spatial requirements of the joining partners. Thus, the method of this disclosure allows the joining partners to be coated independently of one another in terms of time and / or location by applying the coating material. This has the advantage that the joining partners only need to be brought into contact at the time of joining, which particularly facilitates the joining of thick-walled steels and / or joining in constrained positions. The homogeneity of the adhering layer orLayers offer the advantage that beam or gas metal arc welding techniques can be used when joining the components, techniques which, under other circumstances, would not achieve the required material properties of the weld, particularly with thick-walled components. However, joining the components by beam or gas metal arc welding as described in this disclosure allows the desired properties in the weld, such as a homogeneous distribution of materials within the weld, to be achieved despite the thickness of the steels and / or the constrained position during joining. In other words, a method as described in this disclosure offers the advantage that the desired mechanical properties can also be achieved in the root region of the weld formed when joining, for example, thick-walled steels.Facilitating joining in constrained situations makes a method according to the present disclosure advantageous, among other things, compared to the use of foils.

[0209]

[0149] As already explained above, the method of applying the coating material prevents any metallurgical bonding between the coating material and the substrate material. Therefore, the method according to the present disclosure is also suitable for sensitive and / or very thin joining partners. In particular, the method according to the present disclosure can be used for joining partners with a thickness of 10 mm or more, preferably 15 mm or more, and especially 20 mm or more. In particular, the method according to the present disclosure can be used to join joining partners- 36 -

[0210] with a thickness of 15 mm to 150 mm, for example 20 mm to 150 mm. Therefore, the method, as described in this disclosure, is suitable for applications in the "heavy plate" sector (cf. DIN EN 10079), in particular for joining steel sheets in heavy-duty applications.

[0211]

[0150] The advantages mentioned above can be reflected in particular in time savings and / or cost reductions. Thus, a method according to the present disclosure can be more time-efficient and cost-effective than existing methods.

[0212]

[0151] Further disclosed herein is the subject matter of the following clauses:

[0213] (1) Method for joining two components by metal welding, comprising:

[0214] Providing two joining partners, each having at least one contact surface, via which the joining partners are to be joined;

[0215] Providing a coating material to be applied, wherein the coating material includes a coating material containing at least one metal or semimetal and / or at least one oxide of a metal or semimetal;

[0216] Applying the coating material to form an adhesive layer on at least one of the contact surfaces with a predetermined amount of coating material per surface, wherein the layer is formed either by applying the coating material, which is in the form of a dispersion, or by a thermal spraying process for applying the coating material;

[0217] Joining of the joining partners via the at least one contact surface coated with the adhesive layer using a beam welding process or a gas metal arc welding process, preferably by means of laser or electron welding, or by means of plasma keyhole welding.

[0218] (2) Method according to clause 1, wherein the coating material is provided as a dispersion of a particulate coating material in a dispersion medium and is applied to at least one of the contact surfaces by spraying, painting, or brushing.- 37 -

[0219] (3) Method according to clause 1, wherein the coating material is provided as a powder, rod, wire or a combination thereof and is applied to at least one of the contact surfaces by means of the thermal spraying method.

[0220] (4) Methods according to clauses 1 or 3, wherein the thermal spraying method used is flame spraying, high-velocity flame spraying, detonation spraying, plasma spraying, arc spraying, melt bath spraying or laser beam spraying.

[0221] (5) Procedure according to one of the preceding clauses, the procedure further comprising:

[0222] Adjusting the amount of layer material per area on at least one of the contact surfaces of the joining partners by applying the application agent once or several times.

[0223] (6) Method according to one of the preceding clauses, wherein, when joining the partners, a weld seam of molten material is formed over the coated at least one contact surface; and wherein the application of the coating agent is adjusted so that a predetermined ratio, in particular a predetermined and material-specific ratio, is established between the amount of coating material per area and the amount of molten material per area.

[0224] (7) Method according to any of the preceding clauses, wherein the metal or semi-metal is a pure element selected from the list comprising aluminium (Al), nickel (Ni) and titanium (Ti), or a mixture thereof.

[0225] (8) Method according to any of the preceding clauses, wherein the metal or semimetal is an alloy of at least one element selected from aluminium (Al), nickel (Ni), titanium (Ti).- 38 -

[0226] (9) Method according to any of the preceding clauses, wherein the oxide is an oxide selected from the list comprising aluminium(III) oxide (A12O3), titanium(II) oxide (TiO), titanium(III) oxide (Ti2O3) and titanium(IV) oxide (TiO2), or a mixture thereof.

[0227] (10) Beam welding apparatus for use in a process according to any of the preceding clauses, comprising

[0228] a coating device comprising

[0229] a reservoir in which the contract funds are provided;

[0230] a nozzle with which the application agent is applied to at least one of the contact surfaces prior to joining the joining partners in order to form the adhesive layer; and

[0231] a control element that communicates with the nozzle and reservoir and is configured to apply the application agent once or several times to form the adhesive layer, such that the layer applied to at least one of the contact surfaces has a predetermined amount of layer material per area; and

[0232] an energy source for joining the joining partners via the at least one contact surface coated with the adhesive layer.

[0233] REFERENCE MARK LIST

[0234]

[0152] 100, 500 joining partners

[0235] 102,502 contact area

[0236] 104, 504 layer created by ordering the order means

[0237] 106, 506 Thickness of the layer created by applying the coating material 200 Coating material

[0238] 300 application device

[0239] 400 weld seam

Claims

- 39 - REQUIREMENTS 1. Method for joining two thick-walled components by metal welding, comprising: Providing two joining partners, each having at least one contact surface, via which the joining partners are to be joined; Providing a coating material to be applied, wherein the coating material includes a coating material containing at least one metal or semimetal and / or at least one oxide of a metal or semimetal; Applying the coating material to form an adhesive layer on at least one of the contact surfaces with a predetermined amount of coating material per surface, wherein the layer is formed either by applying the coating material, which is in the form of a dispersion, or by a thermal spraying process for applying the coating material; Joining of the joining partners via the at least one contact surface coated with the adhesive layer using a beam welding process or a gas metal arc welding process, preferably by means of laser or electron welding, or by means of plasma keyhole welding.

2. Method according to claim 1, wherein the application agent is provided as a dispersion of a particulate layer material in a dispersion medium and is applied to at least one of the contact surfaces by spraying, painting, or brushing.

3. The method of claim 1, wherein the application agent is provided as a powder, rod, wire or a combination thereof and is applied to at least one of the contact surfaces by means of the thermal spraying process.

4. Method according to 1 or 3, wherein flame spraying, high-velocity flame spraying, detonation spraying, plasma spraying, arc spraying, melt bath spraying or laser beam spraying is used as the thermal spraying method.-40- 5. Method according to one of the preceding claims, wherein the joining partners have a thickness of at least 10 mm, preferably at least 15 mm, in particular at least 20 mm.

6. Method according to one of the preceding claims, wherein the joining partners have a thickness of 10 mm - 150 mm.

7. Method according to one of the preceding claims, wherein the joining partners are thick-walled steels.

8. Method according to one of the preceding claims, wherein the joining partners have the same weldability.

9. Method according to one of the preceding claims, wherein the joining partners are joined end-to-end, resulting in an I-shaped weld.

10. A method according to any of the preceding claims, wherein the method further comprises: Adjusting the amount of layer material per area on at least one of the contact surfaces of the joining partners by applying the application agent once or several times.

11. A method according to any of the preceding claims, wherein, when joining the joining partners, a weld seam of molten material is formed via the coated at least one contact surface; and wherein the application of the coating agent is adjusted such that a predetermined ratio, in particular a predetermined and material-specific ratio, is established between the amount of coating material per area and the amount of molten material per area. - 41 - 12. Method according to any of the preceding claims, wherein the metal or semimetal is a pure element selected from the list comprising aluminium (Al), nickel (Ni) and titanium (Ti), or a mixture thereof.

13. Method according to any of the preceding claims, wherein the metal or semi-metal is an alloy of at least one element selected from aluminium (Al), nickel (Ni), titanium (Ti).

14. Method according to any of the preceding claims, wherein the oxide is an oxide selected from the list comprising aluminium(III) oxide (A12O3), titanium(II) oxide (TiO), titanium(III) oxide (Ti2O3) and titanium(IV) oxide (TiO2), or a mixture thereof.

15. Beam welding device for use in a method according to one of the preceding claims, comprising a coating device comprising a reservoir in which the contract funds are provided; a nozzle with which the application agent is applied to at least one of the contact surfaces prior to joining the joining partners in order to form the adhesive layer; and a control element that communicates with the nozzle and reservoir and is configured to apply the application agent once or several times to form the adhesive layer, such that the layer applied to at least one of the contact surfaces has a predetermined amount of layer material per area; and an energy source for joining the joining partners via the at least one contact surface coated with the adhesive layer.

Images