• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    The invention relates to a friction stir welding tool comprising a rotationally symmetrical shaft (1) having a proximal end (1a) and a distal end (1b) for contact with joining partners and a pin (2) of smaller diameter than concentric about the axis of rotation the shaft has at its proximal end (1a) and thus protrudes with respect to a shoulder region (3) of the shaft defined thereby, the shaft consisting at least in the shoulder region (3) and the pin (2) each of a high temperature resistant metal or an alloy thereof, characterized in that the pin (2) and / or the shaft in the shoulder region (3) consist of a composite material or is / are coated, which consists essentially of molybdenum, tungsten, niobium or tantalum or one of at least one of these Consists of metals based alloy; and a reinforcing phase embedded therein of at least one hard material having a Mohs hardness; ::: 6, a particle size in the micrometer range and a free energy of formation at 1300 K of less than -350 kJ / mol O 2.
    公开号:AT517894A1
    申请号:T702/2015
    申请日:2015-10-30
    公开日:2017-05-15
    发明作者:Christian Gierl-Mayer Dr；Herbert Danninger Dr；Thomas Weinberger Dr；Ing Gunter Figner Dipl
    申请人:Technische Universität Wien；Stirtec Gmbh；
    IPC主号:
    专利说明:

    The present invention relates to friction stir welding tools made of high temperature resistant metals or alloys and a manufacturing method thereof.
    BACKGROUND OF THE INVENTION Friction stir welding is a welding process known for about two decades in which a tool consisting of a rotationally symmetric, usually cylindrical, shank having a protruding pin of lesser diameter at one end from a shoulder portion of the shank contacts the pin side End is made to be connected to workpieces and rotated. The rotation of the pin and the adjacent shoulder area and the resulting frictional heat, the materials of the workpieces to be joined are heated and doughy. As soon as the materials of the workpieces to be joined are sufficiently doughy, the pin ensures thorough mixing of the materials of the workpieces to be joined in the connection area. Then, when the workpieces cool down in the area of the engagement zone of the pin, an improved welding point, which in particular can be free from pores and / or undesired microstructures, is produced in comparison with conventional welding methods.
    This method eliminates several disadvantages of fusion welding because it is a solid phase process and avoids the known problems of coarse grain formation in the weld, melt shrinkage shrinkage effects, and unfavorable microstructures in the heat affected zone.
    Although still a recent technological development, friction stir welding is already used in many applications, especially for welding workpieces made of low-melting materials, such as aluminum alloys. For light metals, especially sheet metal, the process was also introduced in the aerospace industry, which is known to set high standards in terms of quality and reliability.
    More recently, attempts have also been made to achieve the advantages achieved by friction stir welding in welding higher melting materials, such as steel. However, a problem so far is that the friction stir welding tools used often deform at the high welding temperatures or wear out quickly. Furthermore, in the welding process, detachment or breaking off of the pin or pins from the shaft can occur or the shaft itself can break.
    The required by the tools combination of high hot hardness, heat resistance and toughness, especially in Umlaufbiegebelastungen, and hot wear resistance are currently not reached by commercially affordable materials, which is why the life and tool life of the tools are intolerably short. In contrast to tools for welding aluminum, these tools often only reach a life span of a few meters.
    The hot working steels used for friction stir welding of aluminum fail at the much higher temperatures encountered in friction stir welding of ferrous and steel materials. Even tungsten carbide-cobalt carbides fail due to softening of the cobalt binder. Tungsten-rhenium alloys show interesting potential; Due to the very high price for rhenium, this solution is not commercially feasible. Although other refractory metals such as molybdenum show the required heat resistance, but have a high wear, which has a negative impact on the process safety. In principle, however, refractory metals have the advantage, in comparison with ceramics or hard metal, that the contour is reworked after appropriate wear and the tool can thus be reused several times.
    In addition to the classical failure mechanisms such as abrasive wear or fatigue fracture, the chemical interaction between the tool and the workpieces to be joined is an important factor, which, however, is hardly considered in the literature. The high relative velocity of the components involved, in combination with the high temperatures and applied pressures, leads to tribo-chemical reactions, primarily chemical interactions between the partners, which can damage both the tool and the workpiece.
    The most common tribochemical reaction, tribo-oxidation by reaction of the components involved with the surrounding atmospheric oxygen, can be prevented by conducting the FSW process under inert gas. But can not prevent interdiffusion of the components of the tool and workpieces or reactions with each other. This leads to adhesion and welding of workpiece material to the tool. When these adhesions are torn off in the course of the further process, tool material is also torn loose and the tool surface progressively shattered with it. Such effects occur e.g. Already in the friction stir welding of aluminum with tools made of hot-work steel after a certain period of use and lead to rapid failure of the tool.
    Also classical chemical reactions of tool components with the workpieces have to be considered. For example, the cubic boron nitride (see US 2002/011509 A1) referred to in the patent literature as "superabrasive" and recommended for friction stir welding tools because of its high hardness and wear resistance frequently breaks down very rapidly in contact with metal surfaces under friction stir welding conditions. This is e.g. friction stir welding of Ti materials with tools containing cBN [Y. Zhang, Y.S. Sato, H. Kokawa, S.H.C. Park and S. Hirano, "Stir zone microstructure of commercial purity titanium friction stir-welded using pcBN tool", Materials Science and Engineering A, 488, 25-30 (2008)].
    Another aspect is the contamination of the friction stir welds with material removed from the tool. Since this removal can not be completely avoided due to the system, those tool materials are desirable which do not cause any negative effects on mechanical or chemical properties in the workpieces to be joined (such as, for example, embrittling impurities)
    Base grid be solved as mixed crystal. When using pcBN tools for welding steel, σ-phases and Cr-rich borides could be found in the area of the stirring zone of the material. Especially with austenitic steels, this reduces the corrosion resistance in the weld seam, but this must be avoided at all costs [Y. Sato, M. Muraguchi, H. Kokawa, "Tool Wear and Reactions in 304 Stainless Steel during Friction Stir Welding", Materials Science Forum, Vol. 675-677, pp. 731-734 (Feb. 2011)].
    In order to improve the mechanical properties of the tool material, especially at high temperatures, it is possible, by means of techniques known per se for monolithic refractory metals, to use pattern-stabilizing dispersoids, i. fine carbides, oxides, nitrides or borides having an average particle diameter in the nanometer range, ie <1 pm, are added, which increase the hot hardness and heat resistance and reduce the tendency of in particular Mo and also W for microstructural coarsening at higher temperatures [see e.g. G. Leichtfried, G. Thurner, R. Weirather, Proc.14th Int. Plansee Seminar, Reutte, Vol. 4, pp. 26-43 (1997)].
    Furthermore, carbides and other high temperature resistant materials are added in certain amounts to increase the heat resistance and reduce wear. For example, in GB 2,402,905 A of 2004, a friction stir welding tool made of tungsten or a tungsten-based alloy described above is disclosed, preferably a strength-increasing material selected from rhenium, molybdenum, tantalum and niobium, in particular rhenium in solid solution, preferably in an amount of about 40% by weight, and in addition may also comprise one or more refractory carbides in a concentration of about 0.25 to about 2% by weight. Examples of the latter include carbides of hafnium, zirconium, tantalum and niobium. The production takes place i.a. by cold isostatic pressing.
    In EP 2,076,352 B1 and the underlying WO 2008/102209 A2, a friction stir welding tool having a shoulder portion of optionally alloyed W, Mo, Ta, Nb and / or Hf and a pin portion of one or more of Mo, W, Hf, Zr , Ta, Rh, Nb, Ir, V, alloys, carbides and oxides thereof, the latter in particular comprising 0.001 to 5 wt .-% of carbides and / or nitrides of La, Hf and / or Zr. Both sections may also have a coating, e.g. a coating of ruthenium, silicides or carbides. However, any oxides and carbides are mainly superficial and sometimes only in the coating of the corresponding section and are produced for example by magnetron sputtering or thermospraying. Particle sizes of such oxides and carbides are not indicated.
    US 2014/299651 A1 discloses friction stir welding tools based on Mo, which optionally comprise one or more refractory carbides of Hf, Zr, Ta and / or Nb analogously to the above GB 2,402,905 A. Neither, however, the amounts of these refractory carbides are further specified, nor are particle sizes reported.
    The purpose of these known additives of carbides and oxides, which usually have particle sizes <1 pm ("dispersoids") is, as mentioned above, a stabilization of the microstructure or increasing the temperature resistance of the respective base alloy. Of course, significant effects on the wear resistance or the coefficient of friction of the tool are not sufficient.
    For the latter purpose, as the only documents known to the inventors, US 2002/011509 A1 and other members of the patent family disclose a friction stir welding tool having a coating of an abrasive material, specifically polycrystalline cubic boron nitride (PCBN) or polycrystalline diamond (PCD) having particle sizes in the range of below 1 pm up to 50 pm. By such a coating with abrasive material, however, the friction between the tool and the workpiece is not increased, but on the contrary due to the lower coefficient of friction of PCBN and PCB compared to steel, for example, even lowered, but at the same time the heat dissipation must be increased (see the paragraphs [0098] and [0099] US 2002/011509 A1). In order to maintain a sufficient temperature at the weld therefore sometimes thermal barriers can be provided below the Abrasivstoff coating. As a method for producing such coatings, chemical and physical vapor deposition (CVD, PVD) and ion implantation are mentioned. However, US 2002/011509 A1 does not disclose a single concrete exemplary embodiment of such a friction stir welding tool, which is why the invention and disclosure there appear to be of a purely theoretical nature.
    A disadvantage of such friction stir welding tools is, however, would be - in addition to the need for thermal barriers - the continued high wear due to lack of chemical stability of Abrasivstoff-coatings, as the inventors have discovered in the course of their research.
    Against this background, the object of the invention was to provide a friction stir welding tool with which the above disadvantages can be at least partially eliminated.
    DISCLOSURE OF THE INVENTION
    This object is achieved in a first aspect of the present invention by providing a friction stir welding tool comprising a rotationally symmetric shaft having a proximal end for contact with joining members and an opposite distal end and a pin concentric about the axis of rotation having a smaller diameter than the shaft has its proximal end and thus protrudes with respect to a thus defined shoulder region of the shaft, wherein the shaft at least in this shoulder region as well as the pin each consist of a material selected from high temperature resistant metals and alloys, the optionally gefügestabilisierende dispersoids, eg Carbide, oxides, nitrides or borides, with a particle diameter in the nanometer range contains, with the mark that the pin and / or the shaft in the shoulder region consists of a composite material or is / is / is coated, the a) substantially Molybdenum, tungsten, niobium or tantalum or consists of an alloy based on at least one of these metals; and b) a reinforcing phase embedded therein of at least one hard material having a Mohs hardness> 6, a particle size in the micrometer range and a free formation enthalpy at 1300 K of less than -350 kJ / mol O2.
    By incorporating the reinforcing phase according to the invention into a friction stir welding tool consisting essentially of molybdenum, tungsten, noib and / or tantalum or a coating of the tool in the shoulder region, the wear resistance of the tool can be considerably increased compared with the prior art. By embedding the relatively coarse-grained particles of the reinforcement phase, which preferably comprises one or more hard materials having a particle size in the range of 3 to 200 μm, preferably 5 to 200 μm, more preferably 10 to 200 μm, these are uniformly distributed in the metal base and secured against breaking much better than is the case with only superficially generated hard materials according to the prior art. In addition, the particle size increased by several powers of ten compared to dispersoids causes an even greater increase in the surface area, which considerably increases the mechanical stability of the composite and leads to drastically extended tool life. The chemically inert behavior of the hard material compared to the workpieces to be joined due to the strongly negative free enthalpy of formation (more negative than -350 kJ / mol O2) significantly reduces the tendency to weld workpiece materials to the tool and thereby minimizes the associated damage as well as the formation of undesired ones Phases after entry in the material to be joined.
    Of the metals and alloys thereof which are suitable for use as the basis for the composite of the invention because of their high melting points of over 2300 K, i. Mo, W, Nb, and Ta (and principally Os, which, due to its high price, is unlikely to be considered), become Mo, W, and alloys based thereon, because of their low solubility both for and in iron and aluminum, two of the most common components Friction stir welding as well as the low diffusion coefficients and velocities of the individual metals in such combinations as main constituents of the composite material are particularly preferred in the joining partners, since the formation of undesirable phases and the welding of workpiece material on the tool can be further reduced.
    In preferred embodiments, the at least one hard material in the material in a proportion of 5 to 30 vol .-%, preferably 10 to 20 vol .-%, and thus contained in an amount which is far above that in the previously fine-grained hard materials have been used as dispersoids, and further enhances the wear-inhibiting effect of the invention.
    The at least one reinforcing phase hard material is preferably selected from alumina, zirconia, yttria, and mixtures thereof, since these materials have a particularly high thermodynamic stability and thus do not or only minimally react with the workpiece materials such as steel, stainless steel, aluminum and superalloys. Despite their particularly high hardness, the abrasives PCBN and PCD disclosed in the aforementioned US 2002/011509 A1 are wholly unsuitable for tools according to the present invention, since they have a (much) too high formation enthalpy (standard enthalpy of formation AHt0: boron nitride -254.4 kJ / mol, diamond +1.9 kJ / mol; AHt for CBN at 1300 K: -2 -265 kJ / mol) and therefore (very) easily undergo reactions with the material of the joining partners in friction stir welding.
    Furthermore, the material of the friction stir welding tool according to the invention may comprise, in a manner known per se, dispersions with particle diameters in the nanometer range in an amount of up to 5% by weight, in order to take advantage of the structure-stabilizing effect of these additives.
    The arrangement of the composite in or on the tool according to the invention is not particularly limited, and both the pin and the shoulder area or the entire shaft, i. the entire tool, consist of the composite material. Mainly for cost reasons, however, only parts of the tool, preferably the pin, will consist entirely of the composite material, while other parts, preferably the shoulder region of the shaft, will be coated only with a layer consisting of the composite material. Particularly preferably, the composite material is provided on all those parts which come into contact with the joining partners during the welding process.
    The production of the tool according to the invention can be carried out by per se known powder metallurgy methods, for example analogously to the production of the industrially produced materials TZM or MHC, so that the new tools can be manufactured in existing production facilities. An exemplary method is given in the later examples.
    In a second aspect, the invention provides the use of the friction stir welding tool according to the first aspect in a welding process, i. a method for friction stir welding, which is characterized in that such a friction stir welding tool is used as a tool.
    BRIEF DESCRIPTION OF THE DRAWINGS
    In the following examples, the present invention will be further described with reference to the accompanying drawings, which show the following.
    FIG. 1 is a photograph of the surface of a prior art friction stir welding tool of Comparative Example 1. FIG.
    FIG. 2 is a photograph of the surface of a prior art friction stir welding tool of Comparative Example 2. FIG.
    3 is a photograph of the surface of a friction stir welding tool of Example 1 according to the present invention.
    EXAMPLES
    General process description
    In the following comparative example and an example of the present invention, friction stir welding tools were first produced by the same well-known method, the method comprising: mixing the base metal powder with the hard powder (optionally mixing optional dispersions with the latter), e.g. by means of a tumble mixer for 30 min; Consolidating the powder mixture by cold isostatic pressing, e.g. at 300 MPa; - precint in a reducing atmosphere, e.g. in hydrogen at 1200 ° C for 60 minutes; - Capsules in gas-tight steel containers, evacuation and welding; hot isostatic compaction, e.g. at 1300 ° C; - removal of the capsule by machining (turning off); Hot forming, e.g. Hot rolling at 1,200 ° C preheating temperature; wherein the last two steps can also be performed in the reverse order.
    The tools thus obtained were then subjected to a life test. For this purpose, different tool materials were tested under the same conditions on an aluminum alloy. The welding parameters were identical for all tools and oriented towards a specific industrial application. After a certain welding path, the tools were examined for wear.
    The resulting surfaces were visually checked and compared. Photographs of the respective surfaces are shown in the accompanying figures 1 to 3.
    Comparative Examples 1 and 2
    In these examples, tools were made, on the one hand, from EN X40CrMoV5-1 hot working steel, which was subsequently cured to 54 HRC (Comparative Example 1) and, on the other hand, from Inconel® Alloy 718, NiCr19NbMo, a nickel-based alloy (Comparative Example 2). These materials are often referred to in the literature for use as friction stir welding tools (see, eg, YN Zhang, X. Cao *, S. Larose and P. Wanjara, "Review of tools for friction stir welding and processing", Can. 51 (3), 250-261 (2012)).
    Photographs of the resulting surfaces of the tools are shown in Figs. 1 and 2, respectively.
    From Fig. 1, a recording of Rührreibschweißwerkzeugs from Comparative Example 1 after 650 m welding path, the formation of chatter marks on the shoulder is clearly evident. These chatter marks are in contact with the workpiece material due to poor chemical resistance of the tool material during the friction stir welding process. As a result of the stirring movement, a composite material is formed locally from portions of the tool and of the workpiece, whereby volume fractions of the tool material are torn out of the tool. Fig. 1 shows in addition to the chatter marks and this volume loss quite clearly.
    FIG. 2 shows the corresponding surface of the friction stir welding tool from Comparative Example 2 after a welding path of 400 m. Again, corresponding chatter marks and chemical wear are clearly visible.
    example 1
    An illustrative friction stir welding tool of the present invention was made by the above method from the following components: molybdenum powder (0 <32 pm); -10% by volume fused corundum (blocky, 0 25-63 μm); 0.5 mass% HfC (0 <1 pm; dispersoid).
    The thus obtained friction stir welding tool according to the invention was subjected to an analogous test as the tools of the comparative examples.
    Fig. 3 is a photograph of the surface of the tool of the invention after 1500 m of welding. Here, in contrast to the prior art only relatively minor abrasive wear can be seen. Due to the better chemical resistance, there were hardly any interactions with the workpiece.
    Such a tool according to the invention thus enables significantly longer service lives than could be achieved according to the prior art.
    Other tests with additional embodiments of the present invention are currently being conducted.
    The invention thus provides in its chemical stability significantly improved friction stir welding tools which offer extraordinary economic advantages in the field of friction stir welding.
    权利要求:
    Claims (8)
    [1]
    A friction stir welding tool comprising a rotationally symmetric shaft (1) having a proximal end (1a) for contact with joining partners and an opposite distal end (1b) and a pin (2) concentric with the axis of rotation and having a smaller diameter than the shaft at its proximal end (1a) and thus protruding with respect to a shoulder region (3) of the shaft defined thereby, the shaft at least in this shoulder region (3) and the pin (2) each made of a material selected from metals and alloys resistant to high temperatures, consist of optionally gefügestabilisierende dispersoids, eg Carbide, oxides, nitrides or borides, having a particle diameter in the nanometer range, characterized in that the pin (2) and / or the shaft in the shoulder region (3) consist of a composite material / is or is / are coated, which is a) consists essentially of molybdenum, tungsten, niobium or tantalum or of an alloy based on at least one of these metals; and b) a reinforcing phase embedded therein of at least one hard material having a Mohs hardness> 6, a particle size in the micrometer range and a free formation enthalpy at 1300 K of less than -350 kJ / mol O2.
    [2]
    2. Tool according to claim 1, characterized in that the reinforcing phase comprises one or more hard materials having a particle size in the range of 3 to 200 pm, preferably 5 to 200 pm, more preferably 10 to 200 pm.
    [3]
    3. Tool according to claim 1 or 2, characterized in that the at least one hard material in the material in a proportion of 5 to 30 vol .-%, preferably 10 to 20 vol .-%, is included.
    [4]
    4. Tool according to one of claims 1 to 3, characterized in that the at least one hard material of the amplification phase of alumina, zirconia, yttria and mixtures thereof is selected.
    [5]
    5. Tool according to one of the preceding claims, characterized in that the composite material consists essentially of Mo and / or W or of an alloy based thereon.
    [6]
    6. Tool according to one of the preceding claims, characterized in that the material comprises dispersoids with particle diameters in the nanometer range in an amount of up to 5 wt .-%.
    [7]
    7. Tool according to one of the preceding claims, characterized in that the pin (2) consists of the composite material and the shoulder region (3) of the shaft (1) is coated with a layer consisting of the composite material.
    [8]
    8. A method for friction stir welding, characterized in that a friction stir welding tool according to one of claims 1 to 7 is used as a tool. Vienna, 30.10.2015 Vienna University of Technology STIRTEC GmbH
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    WO2017070725A1|2017-05-04|
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    US20180311761A1|2018-11-01|
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    CA3003198A1|2017-05-04|
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    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    ATA702/2015A|AT517894B1|2015-10-30|2015-10-30|friction stir welding|ATA702/2015A| AT517894B1|2015-10-30|2015-10-30|friction stir welding|
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    US15/769,781| US10960490B2|2015-10-30|2016-10-31|Friction stir welding tool|
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    AU2016345050A| AU2016345050A1|2015-10-30|2016-10-31|Friction stir welding tool|
    PCT/AT2016/060093| WO2017070725A1|2015-10-30|2016-10-31|Friction stir welding tool|
    CA3003198A| CA3003198C|2015-10-30|2016-10-31|Friction stir welding tool|
    JP2018512427A| JP6879515B2|2015-10-30|2016-10-31|Friction stir welding tool|
    AU2019203541A| AU2019203541A1|2015-10-30|2019-05-20|Friction Stir Welding Tool|
    AU2021201789A| AU2021201789A1|2015-10-30|2021-03-22|Friction Stir Welding Tool|
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