WO2004019376A2 - Procede de raccordement metallurgique d'un tube a un element - Google Patents

Procede de raccordement metallurgique d'un tube a un element Download PDF

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Publication number
WO2004019376A2
WO2004019376A2 PCT/US2003/024035 US0324035W WO2004019376A2 WO 2004019376 A2 WO2004019376 A2 WO 2004019376A2 US 0324035 W US0324035 W US 0324035W WO 2004019376 A2 WO2004019376 A2 WO 2004019376A2
Authority
WO
WIPO (PCT)
Prior art keywords
flange
tube
contact
welding
annular
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2003/024035
Other languages
English (en)
Other versions
WO2004019376A3 (fr
Inventor
Venkatasubramanian Anathanaraynan
Dharmendra Ramachandra (Dharam), M.
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Delphi Technologies Inc
Original Assignee
Delphi Technologies Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US10/226,179 external-priority patent/US6847001B2/en
Application filed by Delphi Technologies Inc filed Critical Delphi Technologies Inc
Priority to AU2003257098A priority Critical patent/AU2003257098A1/en
Publication of WO2004019376A2 publication Critical patent/WO2004019376A2/fr
Publication of WO2004019376A3 publication Critical patent/WO2004019376A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/06—Resistance welding; Severing by resistance heating using roller electrodes
    • B23K11/065—Resistance welding; Severing by resistance heating using roller electrodes for welding curved planar seams
    • B23K11/066—Resistance welding; Severing by resistance heating using roller electrodes for welding curved planar seams of tube sections
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/0004—Resistance soldering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/02—Pressure butt welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/20—Bonding
    • B23K26/21—Bonding by welding
    • B23K26/24—Seam welding
    • B23K26/28—Seam welding of curved planar seams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K33/00—Specially-profiled edge portions of workpieces for making soldering or welding connections; Filling the seams formed thereby
    • B23K33/002—Crimping or bending the workpieces at the joining area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K33/00—Specially-profiled edge portions of workpieces for making soldering or welding connections; Filling the seams formed thereby
    • B23K33/004—Filling of continuous seams
    • B23K33/006—Filling of continuous seams for cylindrical workpieces
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L13/00—Non-disconnectable pipe joints, e.g. soldered, adhesive, or caulked joints
    • F16L13/02—Welded joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/04—Tubular or hollow articles
    • B23K2101/06—Tubes

Definitions

  • the present invention relates generally to metallurgy, and more particularly to a method for metallurgically joining a tube to a member.
  • Resistance welding also known as electric-resistance welding
  • electric-resistance welding is a known metallurgical process wherein metal is heated by its own resistance to a semi-fiised (i.e., soft) or fused (i.e., molten) state by the passage of very heavy electric currents for very short lengths of time and then welded by the application of pressure.
  • Gas metal arc welding uses a consumable metal wire as one electrode and the parts as another electrode, and moves the consumable metal wire (or the parts) to draw an arc and weld the parts together.
  • the welding is accompanied by a gas (such as a mixture of argon and carbon dioxide) to prevent oxidation and stabilize the arc.
  • gas such as a mixture of argon and carbon dioxide
  • Such gas metal arc welding is well known.
  • solid metal wire or metal core wire i.e., an annular-solid wire whose core is filled with metal powder such as a mixture of metal, alloy and/or oxide powders
  • the wire at a positive electrical welding potential and with the parts electrically grounded.
  • the welding arc creates a molten weld puddle which results in the welding together of the parts.
  • Gas metal arc welding requires expensive welding equipment, the molten weld puddle tends to flow away from the joint area depending on weld position resulting in welds of inconsistent quality, and the process requires a long cycle time between welds.
  • Conventional methods for attaching parts together also include friction welding.
  • To join two tubes together end to end one of the tubes is rotated about its longitudinal axis, and the tube ends are pressed together, wherein fidction causes heating of the ends creating the weld.
  • To join a tube to a plate the tube is rotated about its longitudinal axis, and the tube end and the plate are pressed together, wherein friction causes heating creating the weld.
  • Friction welding requires expensive welding equipment, and the process requires a long cycle time between welds. Also, friction welding may not be applicable if no part to be welded can be rotated.
  • a method of the invention is for metallurgically joining a tube to a member and includes steps a) through e).
  • Step a) includes obtaining a first tube having a flange
  • step b) includes obtaining a member.
  • Step c) includes, after steps a) and b), positioning the first tube and the member with the flange contacting the member directly and/or indirectly through an inte ⁇ rening welding/brazing joining material, wherein at least one of the flange and the member is segmented, and wherein the contact between the flange and the member is a segmented contact at a plurality of spaced-apart contact areas between the flange and the member.
  • Step d) includes, after step c), creating a resistance welding/brazing current path through the tube and the member at a first one of the plurality of contact areas creating a first weld/braze zone which includes at least some of the flange and at least some of the member.
  • Step e) includes, after step d), creating a resistance welding brazing current path through the tube and the member at a different second one of the plurality of contact areas creating a second weld/braze zone which includes at least some of the flange and at least some of the member.
  • Another method of the invention is for metallurgically joining a tube to a member and incudes steps a) through e).
  • Step a) includes obtaining a first tube having a flange
  • step b) includes obtaining a member
  • Step c) includes, after steps a) and b), positioning the first tube and the member with the flange contacting the member directly and/or indirectly through an mtervening welding joining material, wherein at least one of the flange and the member is segmented, and wherein the contact between the flange and the member is a segmented contact at a plurality of spaced-apart contact areas between the flange and the member.
  • Step d) includes, after step c), creating a resistance welding current path through the tube and the member at one of the plurality of contact areas creating a weld zone which includes at least some of the flange and at least some of the member.
  • Step e) includes repeating step d) once for each of the remaining ones of the contact areas each time creating a different weld zone which includes at least some of the flange and at least some of the member.
  • An additional method of the invention is for metallurgically joining a tube to a member and includes steps a) through e).
  • Step a) includes obtaining a first tube having a flange
  • step b) includes obtaining a member.
  • Step c) includes, after steps a) and b), positioning the first tube and the member with the flange contacting the member indirectly through an inte- ⁇ ening brazing Tro-ning material, wherein at least one of the flange and the member is segmented, and wherein the contact between the flange and the member is a segmented contact at a plurality of spaced-apart contact areas between the flange and the member.
  • Step d) includes, after step c), creating a resistance brazing current path through the tube and the member at one of the plurality of contact areas creating a braze zone which includes at least some of the flange and at least some of the member.
  • Step e) includes, repeating step d) once for each of the remaining ones of the contact areas each time creating a different braze zone which includes a least some of the flange and at least some of the member.
  • the tube flange and the member be segmented providing a segmented contact between the flange and the member allows a smaller current to be used to resistance weld/braze together the tube flange and the member by resistance welding/brazing only at one segmented contact at a time.
  • Figure 1 is a block diagram of the first method of the invention for metallurgically joining a tube to a member
  • Figure 2 is a schematic, side cross-sectional view of the first embodiment of first and second tubes and welding electrodes used in a first example of the second method, showing the tubes aligned;
  • Figure 3 is a view, as in Figure 2, but showing the two tubes metallurgically joined together with the welding electrodes removed;
  • Figure 4 is a view, as in Figure 2, but showing a second embodiment of the tubes and welding electrodes used in a second example of the second method;
  • Figure 5 is a view, as in Figure 2, but showing a third embodiment of the tubes and welding electrodes used in an alternate second example of the second method;
  • Figure 6 is a schematic, side cross-sectional view of an embodiment of a tube, a plate, and welding electrodes used in the third method, showing the tube aligned with the plate;
  • Figure 7 is a schematic, side cross-sectional view of an embodiment of two tubes positioned for joining together by a particular method of the invention;
  • Figure 8 is a view, as in Figure 7, but of a tube having a non-folded end flange positioned for joining to a plate and with the welding/brazing electrodes omitted for clarity
  • Figure 9 is a view, as in Figure 7, but of a tube having a folded end flange positioned for joining to a plate and with the welding brazing electrodes omitted for clarity;
  • Figure 10 is a view, as in Figure 7, but of a tube having a folded end flange positioned for joining to a thicker solid having a through hole and with the welding/brazing electrodes omitted for clarity;
  • Figure 11 is a view, as in Figure 7, but of a tube having a non-folded end flange positioned for joining to a thicker solid having a through hole and with the welding brazing electrodes omitted for clarity;
  • Figure 12 is a view, as in Figure 7, but with an welding/brazing joining material disposed between the flange of the first tube and the member and with the welding/brazing electrodes omitted for clarity;
  • Figure 13 is a- view, as in Figure 7, but showing both a "transverse- folded" flange and a “centerline-folded” flange and with the welding/brazing electrodes omitted for clarity;
  • Figure 14 is a view, taken along lines 14-14 in Figure 7 showing the annular segments of the flange of the first tube of Figure 7;
  • Figure 15 is a view, taken along lines 15-15 in Figure 7 showing the end flange of the second tube of Figure 7 to be a non-segmented end flange; and Figure 16 is a view, taken along lines 16-16 in Figure 7 showing the first-tube welding/brazing electrode of Figure 7 to be a single annular-segment electrode spanning a single annular segment of the flange of the first tube.
  • a first method of the invention is for metallurgically joining a tube to a member and is shown in block diagram form in Figure 1.
  • the first method includes steps a) through d).
  • Step a) is labeled as Obtain Tube Having A Fold" in block 10 of Figure 1.
  • Step a) includes obtaining a tube having a longitudinal axis and having an end portion, wherein the end portion includes a fold, and wherein the fold includes longitudinally-spaced-apart first and second fold portions.
  • a "fold" of an end portion of a tube is a fold of the tube wall of an end portion of the tube.
  • Step b) is labeled in block 12 of Figure 1 as "Obtain Member".
  • Step b) includes obt-i-r-ing a member.
  • Step c) is labeled in block 14 of Figure 1 as "Dispose Tube and Member”.
  • Step c) includes, after steps a) and b), disposing the tube and the member with the end portion contacting the member.
  • Step d) is labeled as "Create Weld Zone" in block 16 of Figure 1.
  • Step d) includes, after step c), creating a resistance welding current path through the tube and the member proximate the end portion and relatively moving the end portion deformingly against the member creating a weld zone which includes at least some of the end portion and at least some of the member.
  • proximate includes, without limitation, the term “at”.
  • relatively moving is meant moving the end portion with the member stationary or moving the member with the end portion stationary or moving both the end portion and the member, as is within the level of skill of the artisan.
  • step d) does not melt any of the end portion and does not melt any of the member.
  • step d) melts at least some of the end portion or at least some of the member or melts at least some of the end portion and at least some of the member.
  • the tube is a substantially right- circular cylindrical tube.
  • the tube has a cross section which has a substantially rectangular shape, wherein the cutting plane for the cross section is perpendicular to the longitudinal axis of the tube.
  • Other examples of the tube are left to the artisan.
  • the member is a second tube having a straight second end portion, having a second end portion having a second fold with longitudinally-spaced-apart fold portions, or having a second end portion of arbitrary shape, wherein step c) coaxially aligns the tubes end-to- end and disposes the tubes with end portion to end portion contact.
  • the second tube is a substantially right-circular cylindrical tube.
  • the second tube has a cross section which has a substantially rectangular shape, wherein the cutting plane for the cross section is perpendicular to the longitudinal axis of the second tube.
  • the member is a plate. Other examples of members and variations of second tubes are left to the artisan.
  • the fold is an annular fold substantially coaxially aligned with the longitudinal axis, and step d) creates an annular (or non-annular) weld zone.
  • the annular fold is a racUaUy-outwarc-ly-protmding annular fold.
  • the annular fold is a radially-inwardly-protruding annular fold.
  • the end portion includes at least one additional annular fold coaxially aligned with the longitudinal axis and having two longitudinally spaced-apart fold portions.
  • step d) uses a resistance- welding first electrode contacting the tube proximate the fold and a resistance- welding second electrode contacting the member.
  • a non- electrode support is disposed inside or outside the tube, and in one example extends around the other end of the tube, to radially support the tube and/or to axially support or push the tube during step d).
  • step d) does not melt any of the end portion and does not melt any of the member. In another execution of the first method, step d) melts at least some of the end portion or at least some of the member or at least some of the end portion and at least some of the member.
  • a second method of the invention is for metallurgically joining one tube to another tube and includes steps a) through d).
  • Step a) includes obtaining a first tube 118 having a longitudinal axis 120 and having a first end portion 122, wherein the first end portion includes a first annular fold 124 substantially coaxially aligned with the longitudinal axis 120, and wherein the first annular fold 124 includes longitudinally-spaced-apart first and second fold portions 126 and 128.
  • Step b) includes obtaining a second tube 130 having a second end portion 132.
  • Step c) includes, after steps a) and b), coaxially ahgning the first and second tubes 118 and 130 and disposing the first and second tubes 118 and 130 with the first end portion 122 contacting the second end portion 132.
  • Step d) includes, after step c), creating a resistance welding current path through the first and second tubes 118 and 130 proximate the first and second end portions 122 and 132 and relatively longitudinally moving the first end portion 122 defonningly against the second end portion 132 creating an annular weld zone 134 which includes at least some of the first end portion 122 and at least some of the second end portion 132.
  • the second end portion 132 includes a second annular fold 136 having longitudinally spaced-apart third and fourth fold portions 138 and 140, wherein the wall thicknesses of the first and second tubes 118 and 130 are substantially equal, and wherein step c) disposes the first and second tubes 118 and 130 with the second annular fold 136 longitudinally contacting the first annular fold 126.
  • the first and second annular folds 124 and 136 each are radially-outwardly-protmding annular folds.
  • step d) uses an annular resistance- welding first electrode 142 longitudinally contacting the first annular fold 124 and uses an annular resistance-welding second electrode 144 longitudinally contacting the second annular fold 136.
  • Unnumbered arrows in the figures indicate the direction of relative longitudinal movement of the electrodes during step d).
  • the first electrode 142 longitudinally contacts the second electrode 144 at the completion of step d). This ensures that no overheating of the weld zone will occur, as can be appreciated by those skilled in the art.
  • the first and second tubes 118 and 130 comprise low carbon steel such as AISI 1008 to 1010 having an outside diameter of generally 6 millimeters and a thickness of generally 2 millimeters.
  • pulses (totaling 1/3 of a second) of electric current of generally 5,000 amperes (and in one variation 15,000 to 20,000 amperes) are applied while applying a force of generally 300 to 800 pounds to the electrodes/support.
  • the first, second, and/or third methods are not limited to specific materials, dimensions, electric current, and forces, as is understood by those skilled in the art. Any weldable materials such as copper, aluminum alloy, stainless steel, etc. can be used, as can be appreciated by the artisan. The particular choice of electric current, forces, and part dimensions, etc. are within the ordinary level of skill of the artisan.
  • the second end portion 232 of the second tube 230 is a substantially straight end portion having a substantially-longitudinally-facing annular end 246, wherein the second tube 230 has a greater wall thickness than the first tube 218, and wherein step c) disposes the first and second tubes 218 and 230 with the annular end 246 longitudinally contacting the first annular fold 224.
  • the second tube 230 is a nut.
  • the first annular fold 224 is a radially-outwardly-protruding annular fold.
  • step d) uses an annular resistance-welding first electrode 242 longitudinally contacting the first annular fold 224 and uses a resistance- welding second electrode 244 disposed in radial contact with the second end portion 232.
  • the first electrode 242 longitudinally contacts the second electrode 244 at the completion of step d).
  • a non-electrode support 248 contacts the other end of the second tube 230.
  • an annular electrode, not shown, is added inside the second tube. Other arrangements of electrodes and non-electrode supports are left to the artisan.
  • the first annular fold 324 of the first end portion 322 of the first tube 318 protrudes radially outward and longitudinally upward as shown in the figure.
  • the first electrode 342 is disposed outside the first tube 318
  • the second electrode 344 is disposed outside the second tube 330.
  • a non-electrode first support 350 is disposed inside the first tube 318 and extends around the other end of the first tube 318
  • a non-electrode second support 352 is disposed inside the second tube 330 and extends around the other end of the second tube 330.
  • the positions of the first electrode and the first support are interchanged, and the positions of the second electrode and the second support are interchanged.
  • a third method of the invention is for metallurgically joining a tube to a plate and includes steps a) through d).
  • Step a) includes obtaining a tube 418 having a longitudinal axis 420 and having an end portion 422, wherein the end portion 422 includes an annular fold 424 substantially coaxially aligned with the longitudinal axis 420, and wherein the annular fold 424 includes longitudinally-spaced-apart first and second fold portions 426 and 428.
  • Step b) includes obtaining a plate 454 having first and second sides 456 and 458.
  • Step c) includes, after steps a) and b), aligning the tube 418 substantially perpendicular to the plate 454 and disposing the tube 418 and the plate 454 with the end portion 422 contacting the second side 458.
  • Step d) includes, after step c), creating a resistance welding current path through the tube 418 and the plate 454 proximate the end portion 422 and relatively longitudinally moving the end portion 422 deformingly against the plate 454 creating an annular weld zone which includes at least some of the end portion 422 and at least some of the plate 454.
  • step d) uses an annular resistance-welding first electrode 442 longitudinally contacting the annular fold 424.
  • step d) uses an annular resistance-welding second electrode 444 which is substantially coaxially aligned with the longitudinal axis 420 and which longitudinally contacts the first side 456 of the plate 454 only outside an area on the first side 456 corresponding to the area on the second side 458 of the plate 454 where the annular fold 424 contacts the second side 458 of the plate 454.
  • the plate 454 is a sheet metal plate.
  • Other implementations and constructions are left to the artisan.
  • enable ents, etc. of the first method applicable to tube-to-plate joining are equally applicable to the third method.
  • each electrode is formed from two sections which are brought together around the tube or on the plate and engage that tube or plate.
  • the electrode sections have surfaces generally corresponding to the shape of the engaged portion of that tube or plate. The electrode sections are attached together before installing the electrode in the corresponding upper or lower one of the "T"-shaped electrode holders of the resistance welding machine.
  • resistance welding is less expensive than gas metal arc welding or friction welding. Resistance welding also has a shorter cycle time between welds than does gas metal arc welding or friction welding.
  • Figures 7-13 give examples of first tubes and members (including members which are second tubes and including members which are non-tubular members with and without through holes).
  • Figure 7 gives an example showing a first tube 510 having a flange 514, wherein the flange 514 is an annular outwardly- extending end flange disposed proximate an end 516 of the first tube 510.
  • the flange 514 is a folded flange having contacting first and second fold portions 518 and 520
  • the member 512 is a second tube 522 having a flange 524 which is an annular outwardly-extending and non-folded end flange.
  • Figure 8 gives another example showing a first tube 526 having a flange 528 which is an annular outwardly-extending and non-folded end flange and showing a member 530 which is a non-tubular member and in particular is a plate (such as a sheet metal plate).
  • Figure 9 gives another example showing a first tube 532 having a flange 534 which is an annular outwardly-extending and folded end flange having spaced-apart first and second fold portions 536 and 538 and showing a member 540 which is a non-tubular member and in particular is a plate (such as a sheet metal plate).
  • Figure 10 gives another example showing a first tube 542 having a flange 544 which is an annular outwardly-extending and folded end flange having contacting first and second fold portions 546 and 548 and showing a member 550 which is a non-tubular member and in particular is a thicker solid having a through hole 552.
  • Figure 11 gives another example showing a first tube 554 having a flange 556 which is an annular outwardly-extending and non- folded end flange and showing a member 558 which is a non-tubular member and in particular is a thicker solid having a through hole 560
  • Figure 12 gives another example showing a first tube 562 having a flange 564, wherein the flange 564 is an annular outwardly-extending end flange.
  • the flange 564 is a folded flange having contacting first and second fold portions 566 and 568
  • the member 570 is a second tube 572 having a flange 574 which is an annular outwardly-extending and non-folded end flange.
  • a welding/brazing joining material 576 is shown disposed on the flange 564 of the first tube 562. In one construction, the welding/brazing joining material 576 is either unattached to the flange and the member or is plated to at least one of the flange and the member.
  • welding/brazing j oining materials include welding brazing materials and/or welding joining materials.
  • the flange 564 has at least one groove containing at least some of the welding brazing joining material 576, wherein the flange 564 outside the groove is in direct contact with the member 570 to facilitate the passage of current between the flange 564 and the member 570.
  • Figure 13 gives another example showing a first tube 578 having a flange 580, wherein the flange 580 is an annular outwardly-extending end flange which is a folded flange folded along a transverse direction which is substantially transverse to the centerline of the tube.
  • the member 582 is a second tube 584 having a flange 586, wherein the flange 586 is an annular outwardly-extending end flange which is a folded flange folded along a direction which is substantially parallel to the centerline of the tube.
  • a particular method of the invention is for metallurgically joining a first tube 510 to a member 512 and includes steps a) through e).
  • Step a) includes obtaining a first tube 510 having a flange 514, and step b) includes obt-iining a member 512.
  • Step c) includes, after steps a) and b), disposing the first tube 510 and the member 512 with the flange 514 contacting the member 512 directly and or indirectly through an intervening welding/brazing joining material 576 (seen in Figure 12), wherein at least one of the flange 514 and the member 512 is segmented, and wherein the contact between the flange 514 and the member 512 is a segmented contact at a plurality of spaced-apart contact areas 588 between the flange 514 and the member 512.
  • Step d) includes, after step c), creating a resistance weldingbrazing current path through the first tube 510 and the member 512 at a first one of the plurality of contact areas 588 creating a first weld/braze zone which includes at least some of the flange 514 and at least some of the member 512.
  • Step e) includes, after step d), creating a resistance welding /brazing current path through the first tube 510 and the member 512 at a different second one of the plurality of contact areas 588 creating a second weld braze zone which includes at least some of the flange 514 and at least some of the member 512.
  • welding/brazing includes welding or brazing or partially welding and partially brazing.
  • step c) the welding/brazing joining material 576 (seen in Figure 12) is either unattached to the flange and the member or is plated to at least one of the flange and the member.
  • the weldmg/brazing material 576 is not used, and in a different enablement, the welding/brazing material 576 is used.
  • the flange 514 is an annular outwardly-extending end flange disposed proximate an end 516 of the first tube 510.
  • step d) there is also included, during step d), the step of applying a force to relatively move the flange 514 defo ⁇ ningly against the member 512 at, and only at the first one of the contact areas 588, and there is further included, during step e), the step of applying a force to relatively move the flange 514 deformingly against the member 512 at, and only at, the second one of the contact areas 588.
  • steps d) and e) are performed without applying a force to relatively move any portion of the flange 514 deformingly against the member 512.
  • the flange 514 is an end flange including a plurality of spaced-apart annular segments 590, and the contact between the end flange and the member is a contact between each of the annular segments 590 of the end flange and the member 512.
  • the member 512 is a second tube 522.
  • the second tube 522 has a flange 524 which is an annular outwardly-extending end flange, and step c) disposes the first tube 510 and the second tube 522 with each of the annular segments 590 of the flange 514 of the first tube 510 contacting the end flange of the second tube 522 either directly and/or indirectly through an intervening welding/brazing joining material.
  • the end flange of the second tube 522 is a non-segmented end flange.
  • the member 550 is a non-tubular member.
  • the member 550 is a non-tubular member having a through hole 552, and step c) coaxially aligns the first tube 542 with the through hole 552 of the non-tubular member with each of the annular segments of the flange of the first tube contacting the non-tubular member either directly or through an inte-veriing welding brazing joining material.
  • An additional particular method of the invention is for metallurgically j oining a first tube 510 to a member 512 and includes steps a) through e) .
  • Step a) includes obtaining a first tube 510 having a flange 514
  • step b) includes obtaining a member 512.
  • Step c) includes, after steps a) and b), disposing the first tube 510 and the member 512 with the flange 514 contacting the member 512 directly and/or indirectly through an intervening welding joining material, wherein at least one of the flange 514 and the member 512 is segmented, and wherein the contact between the flange 514 and the member 512 is a segmented contact at a plurality of spaced-apart contact areas 588 between the flange 514 and the member 512.
  • Step d) includes, after step c), creating a resistance welding current path through the first tube 510 and the member 512 at one of the plurality of contact areas 588 creating a weld zone which includes at least some of the flange 514 and at least some of the member 512.
  • Step e) includes, repeating step d) once for each of the remaining ones of the contact areas 588 each time creating a different weld zone which includes at least some of the flange 514 and at least some of the member 512.
  • step c) disposes the first tube 510 and the member 512 with the flange 514 contacting the member 512 directly.
  • step c) disposes the first tube 562 and the member 570 with the flange 564 contacting the member 570 indirectly through an intervening welding joining material, and wherein the intervening welding joining material is a filler metal ring disposed between and directly contacting the flange 564 and the member 570.
  • the flange 514 is an annular outwardly-extending end flange having a plurality of spaced-apart annular segments 590, wherein the contact between the end flange and the member is a contact between each of the annular segments 590 of the end flange and the member 512.
  • the member 512 is a second tube 522 having a flange 524 which is an annular outwardly- extending end flange, wherein the end flange of the second tube 522 is a non- segmented end flange, and step c) disposes the first tube 510 and the second tube 522 with each of the annular segments 590 of the flange 514 of the first tube 510 contacting the end flange of the second tube 522 either directly or through an intervening welding joining material.
  • a further particular method of the invention is for metallurgically joining a first tube 562 to a member 570 and includes steps a) through e).
  • Step a) includes obtaining a first tube 562 having a flange 564
  • step b) includes obtaining a member 570.
  • Step c) includes, after steps a) and b), disposing the first tube 562 and the member 570 with the flange 564 contacting the member 570 indirectly through an inte- ⁇ ening brazing joining material, wherein at least one of the flange 564 and the member 570 is segmented, and wherein the contact between the flange 564 and the member 570 is a segmented contact at a plurality of spaced-apart contact areas between the flange 564 and the member 570.
  • Step d) includes, after step c), creating a resistance brazing current path through the first tube 562 and the member 570 at one of the plurality of contact areas creating a braze zone which includes at least some of - the flange 564 and at least some of the member 570.
  • Step e) includes repeating step d) once for each of the remaining ones of the contact areas each time creating a different braze zone which includes at least some of the flange 564 and at least some of the member 570.
  • the brazing joining material is a brazing ring.
  • the flange 564 is an annular outwardly-extending end flange having a plurality of spaced-apart annular segments, and the contact between the end flange and the member 570 is an indirect contact between each of the annular segments of the end flange and the member 570 through the brazing joining material.
  • the member 570 is a second tube 572 having a flange 574 which is an annular outwardly-extending end flange, wherein the end flange of the second tube 572 is a non-segmented end flange, and wherein step c) disposes the first tube 562 and the second tube 572 with each of the annular segments of the flange 564 of the first tube 562 contacting the end flange of the second tube 572 indirectly through the inte-vening brazing joining material.
  • Figures 7 and 16 disclose a first welding/brazing electrode embodiment, wherein first-tube electrode 592 is a single annular-segment electrode - ⁇ anning a single annular segment 590 of the flange 514 of the first tube 510.
  • first-tube electrode 592 is moved to the next annular segment 590 to create the next weld braze zone.
  • the first-tube electrode 592 is stationary, and the first tube 510 and the member 512 are rotated as a unit to bring the next annular segment 590 into welding/brazing alignment with the first-tube electrode 592.
  • the first-tube electrode includes the same number of spaced-apart annular-segment electrodes as there are annular segments 590 of the flange 514 of the first tube 510, wherein each annular-segment electrode is activated, in sequence, to sequentially create the weld/braze zones.
  • an annular- segment electrode substantially exactly overlays an annular segment 590 of the flange 514 of the first tube 510.
  • the overlay of an annular-segment electrode is smaller than or larger than an annular segment 590.
  • the member electrode 594 is a split ring electrode (to allow the member electrode 594 to surround the second tube 522) whose two welding/brazing segments are in electrical contact with each other at all times during welding brazing.
  • the member and the member electrode are segmented. Particular segmented first tube, segmented first-tube electrode, member, and member electrode shapes are left to the artisan.
  • a flange such as flange 514, is not an annular flange but has a plurality of widely-circumferentially-separated flange segments at the same or different tube heights.
  • the flange is an inwardly-extending flange.
  • the flange is not an end flange disposed proximate an end of the tube but is a flange disposed at a location which is not proximate an end of the tube.
  • the flanges of the first tubes and/or the members of Figures 8-13 are segmented, similar to the segments (shown in Figure 14) of the flange 514 of the first tube 510 (shown in Figures 7) but in an annular or non-annular manner. Other variations of flanges are left to the artisan.
  • the first tube such as first tube 510, is a straight tube or is a curved tube (not shown). In the same or another modification, the first tube is a round tube, a square tube, or a rectangular tube. Other shapes of first tubes are left to the artisan.
  • a tube flange unjoining a tube to a member provides a stronger joint and allows easier joining of thin walled tubes.
  • By having at least one of the tube flange and the member be segmented providing a segmented contact between the flange and the member allows a smaller current to be used to resistance weld/braze together the tube flange and the member by resistance welding/brazing only at one segmented contact at a time.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • General Engineering & Computer Science (AREA)
  • Plasma & Fusion (AREA)
  • Butt Welding And Welding Of Specific Article (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

L'invention concerne un procédé permettant de raccorder métallurgiquement un tube à un élément. Ce procédé consiste à utiliser un tube présentant une bride, et un élément. Le tube et l'élément sont positionnés de sorte que la bride entre en contact avec l'élément de manière directe et/ou indirecte au moyen d'un matériau de raccordement de soudage/de brasage intermédiaire. La bride et/ou l'élément sont segmentés et leur point de contact est segmenté au niveau de zones de contact espacées entre la bride et l'élément. Un chemin de courant de soudage/de brasage par résistance est créé dans le tube et l'élément au niveau d'une première zone de contact, créant ainsi une première zone de soudage/de brasage qui comprend au moins une partie de la bride et au moins une partie de l'élément. Ensuite, un chemin de courant de soudage/de brasage par résistance est créé dans le tube et l'élément au niveau d'une deuxième zone de contact différente, créant ainsi une deuxième zone de soudage/de brasage qui comprend au moins une partie de la bride et au moins une partie de l'élément.
PCT/US2003/024035 2002-08-22 2003-08-01 Procede de raccordement metallurgique d'un tube a un element Ceased WO2004019376A2 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2003257098A AU2003257098A1 (en) 2002-08-22 2003-08-01 Method for metallurgically joining a tube to a member

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US10/226,179 US6847001B2 (en) 2002-08-22 2002-08-22 Method for metallurgically joining a tube to a member
US10/226,179 2002-08-22
US10/603,948 2003-06-25
US10/603,948 US6953907B2 (en) 2002-08-22 2003-06-25 Method for metallurgically joining a tube to a member

Publications (2)

Publication Number Publication Date
WO2004019376A2 true WO2004019376A2 (fr) 2004-03-04
WO2004019376A3 WO2004019376A3 (fr) 2004-05-06

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Country Status (2)

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AU (1) AU2003257098A1 (fr)
WO (1) WO2004019376A2 (fr)

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2809644A1 (de) * 1978-03-06 1979-09-20 Hilti Ag Duebel zum befestigen an hohlraeumen
US20020008387A1 (en) * 2000-01-14 2002-01-24 Vasudeva Kailash C. Exhaust system flanges
US6693251B1 (en) * 2002-08-22 2004-02-17 Delphi Technologies, Inc. Method for manufacturing a metallic tubular assembly
US6689981B1 (en) * 2002-09-09 2004-02-10 Delphi Technologies, Inc. Method for metallurgically capping an end of a tube

Also Published As

Publication number Publication date
WO2004019376A3 (fr) 2004-05-06
AU2003257098A8 (en) 2004-03-11
AU2003257098A1 (en) 2004-03-11

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