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Welding and Joining

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Innovative Structural Materials

Part of the book series: Springer Series in Materials Science ((SSMATERIALS,volume 336))

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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.

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Notes

  1. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 11.

    Graft polymerization: Polymerization (grafting) of graft chains (branch polymers) onto a polymer base material (trunk polymer).

  12. 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. 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.

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Authors and Affiliations

  1. Osaka University, 2-1, Yamada-Oka, Suita, 565-0871, Osaka, Japan

    Yoshinori Hirata

  2. Osaka University, 11-1, Mihogaoka, Ibaraki, 567-0047, Osaka, Japan

    Hidetoshi Fujii & Hisashi Serizawa

  3. Tokyo Institute of Technology, G2-20, 4259, Nagatsuda, Midori-Ku, Yokohama, 226-8503, Kanagawa, Japan

    Chiaki Sato

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  1. Yoshinori Hirata
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  1. Innovative Structural Materials Association, Tokyo, Japan

    Teruo Kishi

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Hirata, Y., Fujii, H., Sato, C., Serizawa, H. (2023). Welding and Joining. In: Kishi, T. (eds) Innovative Structural Materials. Springer Series in Materials Science, vol 336. Springer, Singapore. https://doi.org/10.1007/978-981-99-3522-2_4

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