Skip to main content
Fachgebiete
Automobil + Motoren Bauwesen + Immobilien Business IT + Informatik Elektrotechnik + Elektronik Energie + Nachhaltigkeit Finance + Banking Management + Führung Marketing + Vertrieb Maschinenbau + Werkstoffe Versicherung + Risiko
DE
EN
Bücher
Zeitschriften
Themenseiten
Organisationspsychologie Projektmanagement Marketing Smart Manufacturing
Weitere Formate
Podcasts Webinare Technik Webinare Wirtschaft Kongresse Veranstaltungskalender Awards MyNewsletter Firmensuche
Jetzt Einzelzugang starten
Zugang für Unternehmen
Referenzkunden
Automotive Acoustics Conference 2025

Call for Papers - Deadline: 13. Januar 2025.

Wir möchten Sie dazu einladen, Ihre Vorschläge für einen Vortrag auf der Automotive Acoustics Conference 2025 einzureichen und mit uns neue Verfahren der nachhaltigen Lärmminderung zu erforschen. Wir freuen uns auf Ihre Anregungen für innovative, umweltfreundliche und intelligente Verfahren zur Gestaltung der Zukunft der Fahrzeugakustik.
Erweiterte Suche
Anmelden
nach oben
Erschienen in:
Kapitel lesen Erstes Kapitel lesen

2023 | OriginalPaper | Buchkapitel

4. Welding and Joining

verfasst von : Yoshinori Hirata, Hidetoshi Fujii, Chiaki Sato, Hisashi Serizawa

Erschienen in: Innovative Structural Materials

Verlag: Springer Nature Singapore

Einloggen

Aktivieren Sie unsere intelligente Suche, um passende Fachinhalte oder Patente zu finden.

search-config
loading …

Abstract

As mentioned in Chap. 2, the Project has been conducting materials development of ultra-high strength steel sheets of medium- and high-carbon steel, aluminum alloys, magnesium alloys, titanium alloys, CFRTP and other materials that will contribute to reduction of the car body weight. At the same time, it has been also developing welding and joining methods for ultra-high strength steel sheets and 3 combinations of dissimilar materials: steel to aluminum alloy, aluminum alloy to CFRTP, and steel to CFRTP. In this chapter, 6 types of joining processes, which are welding, brazing, friction joining, interface-melt joining, adhesive bonding and mechanical fastening, are described for multi-material structure car body consisting of the newly-developed materials and existing materials. The joint strengths of the feasible joining processes developed are mainly focused together with the target values for joining of ultra-high strength steels and dissimilar materials respectively.

Sie haben noch keine Lizenz? Dann Informieren Sie sich jetzt über unsere Produkte:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

  • über 102.000 Bücher
  • über 537 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Maschinenbau + Werkstoffe
  • Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

Jetzt informieren

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 390 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Maschinenbau + Werkstoffe




 

Jetzt Wissensvorsprung sichern!

Jetzt informieren
Vorheriges Kapitel Materials Integration—Data-Driven Approach to Materials Design Using Simulation and Database
Nächstes Kapitel Analysis and Evaluation
Fußnoten
1
Resistance spot welding: Used for spot joints of thin sheets of a few millimeters in car bodies, railroad bodies, and house construction. Metals such as steel sheets are overlapped and pressurized for several kN. At the same time, an electric current of several kA to 20 kA is passed between copper alloy electrodes for around 0.5 s, depending on the type of material and thickness of the sheet, to heat and melt the metal by resistance heat generation to make the joint.
 
2
Joint type: When joining technologies including welding, bonding, and mechanical fastening are adopted to assemble parts and products, the connecting shape (called a joint) varies depending on the load of the relevant parts to be subjected, construction method, productivity, and other factors. The joint types applicable to car bodies are as follows: lap joint, butt joint, flange joint, flare joint and T joint.
 
3
Classification of joining methods
The six types of joining methods are classified here based on the joining mechanism.
[1] Welding
The metals to be joined are heated and melted in a molten state. Then melted part is solidified and joined followed by cool down.
[2] Brazing
Brazing is performed by supplying a brazing material, which has a lower melting point than that of the materials to be joined, to the joining part, and melting the brazing material to join them.
[3] Friction joining
The temperature of the local area of the material is raised by frictional heat generated by rubbing the materials against each other or by frictional heat generated when a rotating tool or the like is pressed against the materials to be joined from the outside, and the both materials are joined in a solid-phase state with plastic flow.
[4] Interface-melt joining
Laser or ultrasonic waves are used to concentrate energy on the joining interface, causing melting in the sub-millimeter order.
[5] Adhesive bonding
This is performed by applying an adhesive to the materials to be bonded.
[6] Mechanical fastening
This is performed to mechanically join the materials to be fastened by using rivets, bolts, nuts, screws, etc.
 
4
TSS and CTS
In resistance spot welding, an overlap joint as shown in Fig. 4.8 is applied, and the test methods of tensile shear testing and cross tensile testing are roughly shown in the figure to examine the joint strength. A tensile load is applied in the direction of the arrow, and the load value (unit: N) at which the base material or joint fractures is called tensile shear strength (TSS) and cross tensile strength (CTS), respectively.
 
5
Diffusible hydrogen content
In welds of low-alloy steel and high-tensile steel, moisture in the atmosphere or crystalline water in the coating material of covered electrode may penetrate into the weld metal and cause cracking. In measurements of the hydrogen content, the amount of hydrogen that diffuses from the weld and is released from the bead surface, etc., is called the diffusible hydrogen content.
 
6
Anchor effect: The surface of the base material is treated to create complex irregularities to help the adhesive penetration into the indentations on the surface of the base material, and the shear force working between the base material and the adhesive is used to develop joint strength. However, the influence of anchor effect on joint strength cannot be expressed only by the roughness of the surface irregularities. It has been reported that adhesive bonding strength varies significantly depending on the size, length and distribution of cavities inside just below the surface, but no quantitative evaluation method has been established at present.
 
7
Sealer: To prevent moisture and dust from penetrating through the joints of constituent materials of car body, including joints, and to ensure rustproofing of edges of steel plates, it is applied manually or robotically in the painting process and hardened in a baking furnace.
 
8
Plasticizers: A substance added to a polymer material to lower its viscosity, glass transition temperature, modulus of elasticity, etc., and to give the material flexibility. Plasticizing polymers causes a decrease in the cohesive force of polymer chains, etc., and increases flexibility, which allows the sealer to fit in the joint surface and seams, contributing to waterproof and dustproof performance.
 
9
Flame treatment: A surface treatment method for improving wettability and adhesion by exposing the material surface to a flame for a short period of time.
 
10
Plasma treatment: A surface treatment method for improving wettability and adhesion by removing contaminants and introducing functional groups by irradiating the material surface with plasma.
 
11
Graft polymerization: Polymerization (grafting) of graft chains (branch polymers) onto a polymer base material (trunk polymer).
 
12
Primer treatment: A surface treatment method that aims to improve adhesion by thinly applying a primer that has an affinity for both the adhesive and the adherend.
 
13
Fatigue limit: The maximum value of stress amplitude at which an object does not break under repeated cyclic loading applied a large number of times. Experimentally, the fatigue limit refers to the stress amplitude at which fracture does not occur after 106–107 loading cycles.
 
Literatur
1.
Y. Kuriyama, K. Yamazaki, K. Hashimoto, H. Ohashi, Progress in ULSAB-AVC project. J. Jpn. Weld. Soc. 71(8), 554–558 (2002)CrossRef
2.
For example, LEXUS LC500h/LC500 homepage
3.
4.
S. Kuroda, K. Saida, K. Nishimoto, Microstructure and properties of directly bonded joint of A6061 aluminum alloy to SUS316 stainless steel. Q. J. Jpn. Weld. Soc. 17(3), 484–489 (1999)CrossRef
5.
M. Goede, Sustainable production technologies of emission reduced lightweight car concepts (SuperLIGHT-CAR)—Publishable Final Activity Report (2009)
6.
Data taken from the Joining in Car Body Engineering 2021 and drawings prepared
7.
8.
R. Ikeda, Weld joint properties and welding technologies in resistance spot welding of ultra-high strength steel sheets. J. Jpn. Weld. Soc. 84(6), 441–446 (2015)CrossRef
9.
10.
S. Furusako, M. Tokunaga, M. Yasuyama, Improvement of crashworthiness in a hat-shaped component made of 0.44% carbon steel through arc spot welding. SAE World Congress Experience (WCX 17) No. 2017–01–0476
11.
T. Murakami, Application of laser welding to medium-high carbon steel strength high ductility steel sheets. Weld. Technol. 65, 52–56 (2017)
12.
S. Hirano, Recent trends in friction stir welding tools for high temperature materials. J. Jpn. Weld. Soc. 30(4), 9–11 (2011)
13.
Y. Morisada, K. Lei, H. Fujii, M. Matsushita, R. Ikeda, Effect of deformation resistance of steel on material flow behavior in friction stir welding—direct observation by high brightness X-ray transmission system. Tetsu-to-Hagane 102(2), 14–19 (2015)
14.
M. Matsushita, M. Takada, K. Taniguchi, H. Matsuda, R. Ikeda, H. Fujii, Development of hybrid FSW technique using high frequency induction heating for preheating, in Proceedings of the National Conference of Japan Welding Society (2018), p. 102
15.
T. Wada, Y. Morisada, G. Sun, H. Fujii, Y. Kawahito, M. Matsushita, R. Ikeda, Friction stir welding of medium carbon steel using laser preheating method. Tetsu-to-Hagané 104(7), 368–376 (2018)CrossRef
16.
D. Yamagishi, M. Matsushita, H. Matsuda, Y. Murakami, Analysis of plastic flow in double-sided friction stir welding of ultra-high tensile strength steel, in Proceedings of the National Conference of the Japan Welding Society (2019), p. 105
17.
M. Matsushita, S. Iwata, D. Yamagishi, S. Igi, Development of advanced high strength steel tailor welded blank by means of double-sided friction stir welding, in Proceedings of the National Conference of the Japan Welding Society (2021), p. 109
18.
C. Cheng, K. Kadoi, S. Tokita, H. Fujii, K. Ushioda, H. Inoue, Effects of carbon and chromium on microstructure evolution and mechanical properties of friction stir weldment in medium-carbon steel. Mater. Sci. Eng. A 762, 138060 (2019)CrossRef
19.
K. Kadoi, C. Cheng, S. Tokita, K. Ushioda, H. Fujii, H. Inoue, Effect of Cr and C on microstructure evolution of medium carbon steels during friction stir welding process and their mechanical property, in 7th International Conference on Recrystallization and Grain Growth (2019)
20.
Y. Sato, M. Miyake, H. Kokawa, T. Omori, K. Ishida, S. Imano, I. Sugimoto, S-H.C. Park, S. Hirano, Tool material factors for suppression of wear in Co-based alloy tool during friction stir welding of 0.45 C steel, in Proceedings of 10th International Symposium on Friction Stir Welding (2014)
21.
Y. Sato, M. Miyake, S. Susukida, H. Kokawa, T. Omori, K. Ishida, S. Imano, S-H.C. Park, I. Sugimoto, S. Hirano, Performance enhancement of co-based alloy tool for friction stir welding of ferritic steel, in Friction Stir Welding and Processing VIII (2015), pp. 39–46
22.
Y. Sato, S. Susukida, H. Kokawa, T. Omori, K. Ishida, S. Imano, S-H.C. Park, I. Sugimoto, S. Hirano, Wear of cobalt-based alloy tool during friction stir welding of Ti–6Al–4V alloy, in Proceedings of 11th International Symposium on Friction Stir Welding (2016)
23.
T. Nakazawa, Y. Sato, H. Kokawa, K. Ishida, T. Omori, K. Tanaka, K. Sakairi, Performance of iridium containing nickel base superalloy tool for friction stir welding of Ti-6Al-4V alloy, in Proceedings of 11th International Symposium on Friction Stir Welding (2016)
24.
K. Tanaka, T. Nakazawa, K. Sakairi, Y. Sato, H. Kokawa, T. Omori, K. Ishida, Feasibility of iridium containing nickel based superalloy tool to friction stir spot welding of high strength steel, in Friction Stir Welding and Processing IX (2017), pp. 29–35
25.
S. Hirano, I. Sugimoto, A. Sato, Y. Sato, H. Kokawa, K. Ishida, Mechanical properties of Ti–6Al–4V alloy joints by FSW, in Proceedings of the National Conference of the Japan Welding Society (2017), p. 101
26.
R. Kuroiwa, Y. Aoki, H. Fujii, G. Murayama, M. Yasuyama, Linear friction welding of medium carbon steel, in 11th International Symposium on Friction Stir Welding, vol. 11 (2016), pp. 12–1–6
27.
R. Kuroiwa, Y. Aoki, H. Fujii, G. Murayama, M. Yasuyama, Application of linear friction welding to the thin carbon steel plate, in Proceedings of 10th International Conference on Trends in Welding Research & 9th International Welding Symposium of Japan Welding Society (9WS) (2016), pp. 862–865
28.
Y. Aoki, R. Kuroiwa, H. Fujii, G. Murayama, M. Yasuyama, Linear friction stir welding of medium carbon steel at low temperature. Tetsu-to-Hagané 103(7), 422–428 (2017)CrossRef
29.
R. Kuroiwa, H. Liu, Y. Aoki, S. Yoon, H. Fujii, G. Murayama, M. Yasuyama, Microstructure control of medium carbon steel joints by low-temperature linear friction welding. Sci. Technol. Weld. Joining 25, 1–9 (2020)CrossRef
30.
Y. Aoki, R. Kuroiwa, H. Fujii, G. Murayama, M. Yasuyama, Linear friction stir welding of medium carbon steel at low temperature. ISIJ Int. 59(10), 1853 (2019)
31.
M. Goede, SLC Publishable Final Activity Report (2009)
32.
Welding Handbook, vol. 2, 8th edn. (American Welding Society, 1991)
33.
A. Hirose, F. Matsui, H. Imaeda, K.F. Kobayashi, Mater. Sci. Forum 349, 475–479 (2005)
34.
K. Tanaka, Y. Sugimoto, K. Nishiguchi, Development of resistance spot welding process for steel/aluminum. Mazda Tech. Rep. 33 (2016)
35.
T. Uchikawa, T. Matsuda, T. Sano, A. Hirose, Influence of microstructure on the fracture behavior of friction stir spot welded joint between aluminum alloy and galvanized steel, in European Congress and Exhibition on Advanced Materials and Processes (EUROMAT 2019)
36.
M. Ohata, H. Shoji, A. Hirose, Numerical simulation of strength and fracture behavior of Friction Stirred Point Welded joints of aluminum alloy and steel, in Society of Automotive Engineers of Japan, Proceedings of Spring Conference (2019)
37.
A. Hirose, Effect of interfacial intermetallic compound layer on joining strength of aluminum alloy/steel dissimilar material joint, in Society of Automotive Engineers of Japan, Proceedings of Spring Conference (2019)
38.
T. Inagaki, Y. Aoki, K. Liu, M. Kamai, H. Fujii, Low temperature linear friction joining of dissimilar materials, in Proceedings of 176th Iron and Steel Institute Autumn Meeting (2019)
39.
R. Chen, R. Suzuki, Dissimilar metal joining method—element arc spot welding (Report 4), in Proceedings of National meeting of Japan Welding Society (2017)
40.
T. Oshida, S. Shimoda, R. Suzuki, Dissimilar metal joining method—element arc spot welding (Report 5), in Proceedings of National meeting of Japan Welding Society (2022)
41.
T. Ogura, R. Wakazono, S. Yamashita, K. Saida, Dissimilar joining between aluminum alloy and galvannealed (GA) steel using laser brazing, in Proceedings of 72th Annual Assembly of International Institute of Welding (IIW2019)
42.
Co-translation by Uno et al., Introduction to Kittel Solid State Physics, 8th edn. (Marubeni Corporation, 2005)
43.
Co-translation by Daimon et al., Barlow Physical Chemistry, 6th edn. (Tokyo Kagaku Doujin Publishing Co., Ltd., 1999)
44.
K. Nishiguchi, K. Tanaka, Y. Morita, Y. Sugimoto, Spot joining technology for aluminum/dissimilar materials. Mazda Tech. Rep. 35 (2018)
45.
Y. Sugimoto, Automotive multi-materialization and dissimilar material joining technologies. J. Jpn. Weld. Soc. 87(1), 66–70 (2018)
46.
K. Nagatsuka, S. Yoshida, A. Tuchiya, K. Nakata, Direct joining of carbon fiber-reinforced plastic to an aluminum alloy using friction lap joining. Compos. B Eng. 73, 82–88 (2015)CrossRef
47.
K. Nagatsuka, H. Sho, M. Tsukamoto, K. Nakata, A. Tuchiya, Direct joining of carbon fiber reinforced plastic to an aluminum alloy using friction lap joining. Trans. JWRI 4, 9–14 (2015)
48.
K. Nagatsuka, H. Shoh, K. Nakata, A. Tsuchiya, Effect of silane coupling treatment on dissimilar material joining properties of aluminum alloy and carbon fiber reinforced resin by friction lap joining. Q. J. Jpn. Weld. Soc. 33, 317–325 (2015)CrossRef
49.
K. Naito, Development of joining technologies for steel plates and resin materials-multi materialization for car body weight reduction. Weld. Tech. 68(9), 66–71 (2020)
50.
M. Toyoda, Interface Mechanics (Rikogakusha Publishing Co., Ltd, 1991)
51.
Journal of the Adhesion Society of Japan, Special Issue, “Characterization of Surfaces and Interfaces: Astonishing New Facts Revealed from State-of-the-Art Analysis Technology 51(5) (2015)
52.
53.
54.
H. Akiyama, Adhesion of acrylic adhesive to PP using borane-based polymerization initiator, in 1st Symposium on Adhesion and Joining Technology (Tsukuba, 2018)
55.
S. Horiuchi, Analysis of metal/adhesive interface by electron microscope, in Annual Meeting of the Adhesion Society of Japan (Tokyo, 2016)
56.
S Horiuchi, The Joining Revolution: Weight Reduction 2.0 Begins with “Visualization” of Adhesion (Nikkei XTECH, 2020)
57.
S Horiuchi, et al., Pacifichem, online, 2021/12
58.
S Horiuchi, et al., 2nd IAA, online, 2022/3
59.
60.
C. Sato, Winning the “Joining Revolution” by Utilizing Next-Generation Adhesives (Nikkei Monozukuri, 2019)
61.
Y. Himuro, M. Asakawa, K. Yamamoto, Structural adhesion technology in automobiles—technical trends and issues of vehicle body adhesion, and development of market deterioration prediction technology. J. Adhes. Soc. Jpn. 53(8), 283–289 (2017)CrossRef
62.
Y. Himuro et al., Elucidation of water absorption degradation mechanism of structural adhesives. JSAE Proc. 43(2), 543–548 (2012)
63.
64.
65.
66.
67.
68.
69.
N. Toyama et al., Adv. Compos. Mater. 28, 23–35 (2017)
70.
71.
72.
T. Koseki, Materials data and materials integration System. J. Inf. Process. Manag. 59(3), 165–171 (2016)
73.
M. Demura, T. Koseki, SIP-materials integration projects. Mater. Trans. 61(11), 2041–2046 (2020)CrossRef
74.
M. Demura, Materials integration for accelerating research and development of structural materials. Mater. Trans. 62(11), 1669–1672 (2021)CrossRef
75.
76.
M. Yasuyama, K. Ogawa, T. Taka, Spot welding of aluminum and steel sheet with insert of aluminum clad steel sheet - spot welding of aluminum and steel sheet (i) - quarterly journal of the japan welding society. 14(2), 314–320 (1996)
77.
T. Sakiyama, G. Murayama, Y. Naito, K. Saita, Y. Miyazaki, H. Oikawa, T. Nose, Dissimilar metal joining technologies for steel sheet and aluminum alloy sheet in auto body. Shinnittetsu giho 393, 91–98 (2012)
78.
R. Suzuki, Steel and aluminum dissimilar metals joining process -element arc spot welding- and its automation. J. Jpn. Weld. Soc. 88(4), 240–246 (2019)
79.
H. Serizawa, M. Iyota, T. Ogura, M. Kimura, T. Satsuta, T. Yasui, T. Ikeshoji, Second part, Recent trend in welding/bonding engineering III committee of joining and materials processing for light structures. J. Jpn. Weld. Soc. 90(5), 373–383 (2021)
80.
G.F. Qin, J.Z. Na, W.L. Mu, W. Tan, Effect of thermal cycling on the degradation of adhesively bonded CFRP/aluminum alloy joints for automobiles. Int. J. Adhes. Adhes. 95, 102439 (2019)CrossRef
81.
S. Fujita, T. Kozaki, H. Serizawa, Galvanic corrosion and its reliability evaluation in joining dissimilar materials, Journal of the Japanese Society for Strength and Fracture of Materials, special issue, in The 63rd Proceedings of Japan National Symposium on Strength, Fracture and Fatigue, vol. 55 (2022), pp. 19–26
82.
The Iron and Steel Institute of Japan, Committee on Environmental Strength of Steels, Proceeding of the third symposium—steel ocean environmental common test and its analysis (1987) steel environmental strength sectional meeting-type corrosion fatigue standard test method (1)–(9)
83.
R. Ebara, Best corrosion test method—third, the case of repeated load (corrosion fatigue test method and influential factor of corrosion fatigue strength). Soc. Nav. Arch. Jpn. 703, 35–43 (1988) (in Japanese)
84.
D. Thierry, F. Vucko, G. Luckeneder, B. Weber, L. Dosdat, T. Bschorr, K. Rother, Fatigue behavior of spot-welded joints in air and under corrosive environments Part II: Fatigue under alternating and combined corrosion and fatigue load. Weld. World 60, 1231–1245 (2016)CrossRef
85.
H. Serizawa, S. Fujita, Development of evaluation method for corrosion fatigue properties of multi-materials weld-bonded lap joint. Prepr. Natl. Meet. JWS 111, 46–47 (2022)
86.
Y. Masunaga, Introduction to the database, 2nd edn. (SAIENSU - SHA Co., Ltd., 2021)
87.
T. Mizutani, Bug was Really an Insect (Impress Corporation, 2017)
88.
H. Serizawa, K. Nogi, Potentiality of digital technique in welding. Weld. Tech. 49, 62–67 (2001)
89.
K. Tanabe, Introduction to the neural network by Neurosim/L, Nikkan Kogyo Shimbun, Ltd. (2003)
90.
Y. Yoshitomi, Neutral Network (Asakura Publishing Co., Ltd, 2002)
91.
K. Saitoh, Producing Deep Learning from Zero—Learning Theory And Implementation of Deep Learning by Python, O'Reilly Japan, Inc. (2016)
92.
T. Nomura, Introduction to Deep Learning Implementation Starting with TensorFlow (Impress Corporation, 2018)
93.
94.
H. Serizawa, K. Inose, R. Ohashi, Y. Sugimoto, T. Minoda, T. Murakami, Study on tensile shear strength of dissimilar lap joints for multi-material structures, in Proceedings of the International Symposium on Joining Technologies in Advanced Automobile Assembly 2021(JAAA2021) (2021), pp. 130–136
Metadaten
Titel
Welding and Joining
verfasst von
Yoshinori Hirata
Hidetoshi Fujii
Chiaki Sato
Hisashi Serizawa
Copyright-Jahr
2023
Verlag
Springer Nature Singapore
Buch
Innovative Structural Materials

Print ISBN: 978-981-9935-21-5

Electronic ISBN: 978-981-9935-22-2

Copyright-Jahr: 2023

DOI
https://doi.org/10.1007/978-981-99-3522-2_4

Premium Partner

    Marktübersichten

    Die im Laufe eines Jahres in der „adhäsion“ veröffentlichten Marktübersichten helfen Anwendern verschiedenster Branchen, sich einen gezielten Überblick über Lieferantenangebote zu verschaffen. 

    Zur Marktübersicht
    Bildnachweise