Multistage joining process with thermal sprayed layers

Patent metadata

Field	Value
Publication number	US-11524351-B2
Application number	US-201816955865-A
Country	US
Kind code	B2
Filing date	Dec 19, 2018
Priority date	Feb 24, 2017
Publication date	Dec 13, 2022
Grant date	Dec 13, 2022

Abstract

Method for joining of at least two unweldable materials, non-weldable directly to each other with thermal joining processes in a lap joint configuration, where a two step sequence is used consisting of a first step to apply a thermomechanical or mechanical surface protection layer on the surface of an unweldable material and a second step, where a thermal joining process is used to joint the sprayed layer with an applied layer sheet.

First claim

The invention claimed is:

1. A method for joining of at least two materials that are non-weldable directly to each other with thermal joining processes in a lap joint configuration, the method consisting of:
in a first step, applying a surface protection layer on a surface of a substrate material; and
in a second step, using a thermal joining process to join the surface protection layer with an applied layer sheet by forming a weld nugget therebetween; and
wherein a ratio of a thickness of the surface protection layer to a reached weld diameter of the weld nugget is equal to or lower than 0.25.

2. The method according to the claim 1 , further comprising:
applying the surface protection layer by a thermal spraying method.

3. The method according to claim 1 , wherein the surface protection layer is made of a metal based alloy or a combination of metal with carbides.

4. The method according to claim 1 , wherein the thermal joining process is a resistance welding method.

5. The method according to claim 1 , wherein a total sheet thickness including the substrate material, the surface protection layer, and the applied layer sheet, is between 1.5 mm up to 6.0 mm.

6. The method according to claim 1 , wherein a thickness of the surface protection layer is from 0.25 mm up to 1.5 mm.

7. The method according to claim 1 , wherein the substrate surface is pretreated by cleaning and blasting.

8. The method according to claim 1 , wherein:
the applied layer sheet is made of a metallic material; and
the surface protection layer is made of an alloy related to the metallic material.

9. The method according to claim 1 , wherein the thermal joining process is a hybrid joining process combining bonding with mechanical joining.

10. The method according to claim 1 , wherein the surface protection layer is operable as a barrier for corrosion medium.

11. The method of claim 1 , wherein the substrate material is a metallic layer.

12. The method of claim 1 , wherein:
the substrate material is one of a stainless steel or a high-carbon alloyed steel; and
the applied layer sheet is one of a copper, magnesium, or titanium material.

13. The method of claim 1 , wherein:
the substrate material is a stainless steel alloy;
the surface protection layer is a thermal sprayed aluminum; and
the applied layer sheet is an aluminum material.

14. The method of claim 1 , wherein
the substrate material is a ferritic steel;
the surface protection layer is a low carbon austenitic alloy; and
the applied layer sheet is a low alloy steel.

15. The method of claim 1 , wherein the substrate material is a non-metallic material.

16. The method of claim 15 , wherein the non-metallic material includes at least one of a glass, wood, carbon fiber, or plastic material.

17. The method of claim 15 , wherein a contact temperature of the surface protection layer in contact with the substrate material is lower than 250° C.

18. The method of claim 4 , wherein the resistance welding method includes at least one of weldbonding, spot welding, projection welding or roller seam welding.

19. Use of at least two materials that are non-weldable directly to each other with thermal joining processes in a lap joint configuration, wherein in a two step sequence:
in a first step, a surface protection layer is applied on a surface of a substrate material; and
in a second step, a thermal joining process is used to join the surface protection layer with an applied layer sheet by forming a weld nugget therebetween; and
wherein a ratio of a thickness of the surface protection layer to a reached weld diameter of the weld nugget is equal to or lower than 0.25.

Assignees

• Outokumpu Oy

Inventors

• Hündgen Thomas
• Lindner Stefan

Classifications

• B23K11/06 Primary

  using roller electrodes · CPC title

• C23C4/06

  Metallic material · CPC title

• B23K9/232

  of different metals · CPC title

• C23C4/10

  Oxides, borides, carbides, nitrides or silicides; Mixtures thereof · CPC title

• B23K26/323

  involving parts made of dissimilar metallic material · CPC title