Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
211A~~7
- I -
RESISTANCE WELDING PROCESS FOR ALUMINUM AND
ALUMINUM ALLOY MATERIALS
BACKGROUND OF THE INVENTION
Field of the Invention:
This invention generally relates to a resistance
welding process for aluminum and aluminum alloy
materials, and more particularly, to a resistance
welding process which enables the remarkable improvement
of the electrode life in case of joining aluminum or
aluminum alloy materials together by means of resistance
spot welding.
Description of the Prior Art:
A resistance spot welding process includes the
steps of pressurizing an overlap portion of overlapped
materials to be welded by upper and under electrodes to
apply current to the materials, then exothermally fusing
a contact portion of the materials in part due to the
electrical resistance of the materials to form a nugget
in the contact portion, and joining the materials
together.
The resistance spot welding process as described
above has been often used as a joining process for
rolled steel sheets in the assembly line for mass
production of automobiles or the like for the reasons as
follows. That is, the thermal influence on the
21~.~~~'~
2
materials to be welded is small to result in small
deformation of a product, the time required for welding
is short to be adaptable to the mass production, and if
the welding conditions are determined once, the stable
and uniform joint strength can be obtained easily
regardless of the skill of a welding worker or even by
use of a robot.
The resistance spot welding process has the
characteristics described above. However, in case of
joining aluminum or aluminum alloy materials together by
means of resistance spot welding, this process has such
a problem as the electrode life is extremely short, in
comparison with that in case of joining rolled steel
sheets together by means of resistance welding.
The electrode life herein is defined as the
number of times of continuous spot welding which enables
to continuously carry out spot welding with
predetermined efficiency by using electrodes which are
preliminarily subjected to dressing (which means that
the tip end of the electrode is arranged by cutting in a
predetermined shape or polishing up to a predetermined
surface roughness) once prior to the start of welding.
In general, the electrode life is evaluated on the basis
of the number of times of continuous spot welding up to
not more than a regular value in nugget diameter or
shear strength of welded spot, or the number of times of
continuous spot welding up to the occurrence of such a
3 - 211094
phenomenon as the electrodes are deposited to the
materials to be welded so as to be never removed
therefrom.
When the electrode life is evaluated on the basis
of the standards as described above, the electrode life
generally exceeds 10000 times of spot welding in case of
joining rolled steel sheets together by means of
resistance spot welding, whereas the electrode life
comes up to several hundred times of spot welding at
most in case of joining aluminum or aluminum alloys
together by means of resistance spot welding.
As the material of the electrode, use is normally
made of chrome-copper alloy and chrome-zirconium-copper
alloy which have satisfactory thermal conduction and
high conductivity (refer to the first or second group of
"Copper Electrode Materials for Resistance Welding"
shown in JIS Z 3234-1977 edition). However, in case of
using aluminum or aluminum alloy as the materials to be
welded, it has been considered that the electrode life
is shortened for the following reasons.
Namely, one of the reasons is the fact that the
aluminum and aluminum alloy have far low melting points
and far high thermal and electrical conductivities, in
comparison with those of the rolled steel sheet, and
therefore, the aluminum and aluminum alloy have to be
welded at high current and high pressure for a short
period of time, in comparison with the conditions of
_ 21109 ~'~
joining the rolled steel sheets together by means of
resistance welding.
Another reason is considered as follows: the
consumption of the electrode becomes remarkable since
aluminum and aluminum alloy have the surface covered
with an insulating oxide film having a high melting
point, the calorific values between the electrodes and
the materials in the resistance spot welding become
excessive due to the presence of the oxide film
described above when bringing the electrodes into
contact with the materials to apply current to the
materials, and ultimately the electrodes are heated up
in excess to fuse or alloy the electrodes and the
materials.
For instance, in order to improve the fuel
efficiency for automobiles, as materials for auto body
sheets, it has been tried to use aluminum alloys instead
of rolled steel sheets. However, as described above,
in case of joining aluminum or aluminum alloy materials
together by means of resistance spot welding, the
electrode life is extremely short, in comparison with
that in case of joining rolled sheet sheets together by
means of resistance welding. Thus, it has been
necessary to frequently dress the electrodes, and the
resultant productivity is degraded. In this respect,
there is a hindrance to the use of aluminum or aluminum
alloy sheets as the materials for automobiles.
- 5 - 211094
In order to improve the electrode life in case of
joining aluminum or aluminum alloy materials together by
means of resistance spot welding, there has been
proposed a process of welding by interposing an insert
material consisting of the foil of metal other than the
aluminum or aluminum alloy between each material to be
welded and each of upper and under electrodes.
For instance, as shown in Fig. 7, Japanese Patent
Laid-open No. 61-159288 has disclosed a process for
joining aluminum or aluminum alloys together by means of
resistance spot welding by interposing insert materials
14 and 15 (e. g., Cu or Ag) having electrical
conductivity higher than those of upper and under
electrodes 1 and 2 respectively between the upper and
under electrodes 1 and 2 and materials to be welded 11
and 12. According to this process, even though the
aluminum or aluminum alloys are welded under
considerable heat input in excess, the aluminum alloys
themselves are welded together without generating any
surface crack and without bringing the weld penetration
of the material up to the surface. This welding process
can improve the electrode life to a certain degree as
well.
However, when the insert materials each
consisting of Cu or Ag are used and the materials to be
welded are pressurized by the electrodes at about 200°C,
the insert materials and aluminum are easily subjected
~1I~94~
- 6 -
to diffusion bonding, since Cu or Ag has good affinity
with aluminum by reason of the common property in
crystal structure (i.e., face-centered cubic lattice)
between aluminum and Cu or Ag and the similarity in
lattice constant thereof, even though Cu or Ag has high
electrical conductivity and also has a melting point
higher than that of aluminum.
Further, these insert materials are easily
subjected to diffusion bonding to Cu in the metal
structure of the electrodes. Then, the insert materials
and the electrodes are fused and alloyed due to the
diffusion bonding between the insert materials and the
electrodes, so that the electrode life is shortened.
Furthermore, the corrosion due to the potential
difference is caused by the diffusion bonding between
the materials to be welded and the insert materials, and
therefore, the external appearance of a product is
damaged.
For instance, Japanese Utility Model Laid-open
No. 3-116276 has disclosed a welding process using iron
foil as insert materials in case of joining aluminum or
aluminum alloys together by means of resistance welding.
However, when the same iron foil is continuously
reused (e.g., continuously about two or three times) as
the insert materials, such iron foil insert materials
gradually begin the diffusion bonding to the aluminum
used as materials to be welded. Then, when the iron is
211~94~
deposited to the materials by the diffusion bonding, the
corrosion due to the potential difference between the
iron and the materials to be welded is caused to result
in damaging the external appearance of the product.
SUMMARY OF THE INVENTION
It is an object of the present invention to
provide a resistance welding process for aluminum and
aluminum alloy materials for enabling the remarkable
improvement of the electrode life.
Another object of the present invention is to
provide a resistance welding process for aluminum and
aluminum alloy materials for enabling the welding
without damaging the external appearance of a welded
product by preventing the corrosion of the welded
product.
In order to achieve the objects described above,
a resistance welding process according to the first
invention comprises the steps of preparing an insert
material having an overall thickness of 0.02 to 1 mm
including a sheet-like core material consisting of any
one of iron, steel, copper and copper alloy and coated
layers each having a thickness of 1 to 100 um,
consisting of any one of Ni, Ni alloy, Ti, Ti alloy, Nb,
Nb alloy, Mo, Mo alloy, W, W alloy, Cr, Cr alloy, Co and
Co alloy and formed on both surfaces of the sheet-like
core material; interposing the insert material between
-- - 8 - 2110947
each portion of mutually overlapped materials to be
welded consisting of aluminum or aluminum alloy and each
of upper and under electrodes; and pressurizing the
materials to be welded by the upper and under electrodes
to join the materials to be welded together.
The coated layers on both surfaces of the core
material in each insert material may consist of the same
metal or different metals of all the metals described
above. Further, the coated layers on both surfaces of
the core material may be different from each other in
thickness so long as the thickness of each coated layer
is in the range of 1 to 100 um.
The coated layer can be formed on both surfaces
of the core material in each insert material
industrially by means of electroplating, hot dipping,
chemical vapor deposition, cladding or the like.
According to the welding process described above,
the welding current is applied from the upper and under
electrodes to the materials to be welded through the
insert materials, and the pressurizing portion of the
mutually overlapped materials to be welded is fused
exothermally due to the electrical resistance between
the overlapped materials to be welded. Then, the nugget
is formed in each pressurized portion of the materials
to be welded, so that the materials to be welded are
joined together.
When the thickness of each coated layer in the
2110947
9 -
insert material for use in the resistance welding
process described above is less than 1 um, the coated
layers are fused even by such an appropriate welding
current as the satisfactory nugget is formed, and
therefore, the resultant coated layers come to be
respectively deposited to the materials to be welded and
the electrodes. On the other hand, when the thickness
of each coated layer exceeds 100 um, the calorific value
of each insert material becomes large at the time of
welding, and the materials to be welded are exothermally
fused in excess. Therefore, the nuggets formed between
the overlapped materials to be welded are exposed to the
surfaces of the materials described above to result in
giving a defective product. Further, in this case, the
materials to be welded are respectively deposited to the
insert materials.
Accordingly, it is necessary that the thickness
of each coated layer is set to be within the range of 1
to 100 a m.
When the overall thickness of each insert
material including the core material and the coated
layers is less than 0.02 mm, the insert materials are
easily fused even by the appropriate welding current,
and thus respectively deposited to the electrodes and
the materials to be welded. On the other hand, when the
overall thickness of each insert material exceeds 1 mm,
any nugget having a predetermined size cannot be formed
211~94~1
- 10 -
by the appropriate welding current between the materials
to be welded to result in lowering the strength of a
joint portion. Further, it becomes difficult to
automatically and smoothly feed the insert materials
between the electrodes and the materials to be welded.
Therefore, it is necessary that the overall
thickness of each insert material is set to be within
the range of 0.02 to 1 mm.
In order to achieve the objects described above,
a resistance welding process according to the second
invention comprises the steps of preparing an insert
material having an overall thickness of 0.02 to 1 mm
including a sheet-like core material consisting of iron
or steel and a coated layer having a thickness of 1 to
100 um, consisting of Ti and formed on one surface of
the sheet-like core material; interposing the insert
material between each portion of mutually overlapped
materials to be welded consisting of aluminum or
aluminum alloy and each of upper and under electrodes in
such a state that the coated layer faces the material to
be welded; and pressurizing the materials to be welded
by the upper and under electrodes to join the materials
to be welded together.
The coated layer can be formed on one surface of
the core material in each insert material industrially
by means of electroplating, hot dipping, chemical vapor
deposition, cladding or the like.
11
According to the welding process of the second
invention described above, the welding current is
applied from the upper and under electrodes to the
materials to be welded through the insert materials, and
the pressurizing portion of the mutually overlapped
materials to be welded is exothermally fused due to the
electrical resistance between the materials to be
welded. Then, the nugget is formed in each pressurized
portion of the materials to be welded, so that the
materials to be welded are joined together.
When the thickness of the coated layer in the
insert material for use in the resistance welding
process of the second invention described above is less
than 1 um, the coated layer is fused even by such an
appropriate welding current as the satisfactory nugget
is formed, and therefore, the resultant coated layer
comes to be deposited to the material to be welded.
On the other hand, when the thickness of the coated
layer exceeds 100 um, the calorific value of each insert
material becomes large at the time of welding, and the
materials to be welded are exothermally fused in excess.
Therefore, the nuggets formed between the overlapped
materials to be welded are exposed to the surfaces of
the materials described above to result in giving a
defective product. Further, in this case, the
materials to be welded are respectively deposited to the
insert materials.
~~9~~~4'~
- 12 -
Accordingly, it is necessary that the thickness
of the coated layer is set to be within the range of 1
to 100 um.
When the overall thickness of each insert
material including the core material and the coated
layer is less than 0.02 mm, the insert materials are
easily fused even by the appropriate welding current,
and thus respectively deposited to the electrodes and
the materials to be welded. On the other hand, when
the overall thickness of each insert material exceeds 1
mm, any nugget having a predetermined size cannot be
formed by the appropriate welding current between the
materials to be welded to result in lowering the
strength of a joint portion. Further, it becomes
difficult to automatically and smoothly feed the insert
materials between the electrodes and the materials to be
welded.
Accordingly, it is necessary that the overall
thickness of each insert material is set to be within
the range of 0.02 to 1 mm.
In order to achieve the objects described above,
a resistance welding process according to the third
invention comprises the steps of preparing an insert
material consisting of Ti foil or Ni foil; interposing
the insert material between each portion of mutually
overlapped materials to be welded consisting of aluminum
or aluminum alloy and each of upper and under
2~1Q94r1
- 13 -
electrodes; and pressurizing the materials to be welded
by the upper and under electrodes to join the materials
to be welded together. The thickness of each insert
material is preferably set to be within the range of 10
to 100 um.
According to the welding process of the third
invention described above, the welding current is
applied from the upper and under electrodes to the
materials to be welded through the insert materials, and
the pressurizing portion of the mutually overlapped
materials to be welded is exothermally fused due to the
electrical resistance between the materials to be
welded. Then, the nugget is formed in each pressurized
portion of the materials to be welded, so that the
materials to be welded are joined together.
In each of the resistance welding processes
described above according to the invention, it is
necessary that the welding current is set to a such a
value as to obtain a heat input which makes it possible
to fuse the materials to be welded so as to form nuggets
satisfactorily, and which is in such a degree that the
surface of each insert material is not fused.
As for a welding machine for use in each process
described above, use may be made of any one of a single
phase AC resistance welding machine, a single phase DC
resistance welding machine, a three phase low frequency
resistance welding machine, a three phase DC resistance
211~~~'~
- 14 -
welding machine, a condenser resistance spot welding
machine, and an inverted resistance spot welding machine
or the like.
When the insert materials used for each welding
process described above are respectively fed between the
materials to be welded and the electrodes, each insert
material may be cut in an appropriate size prior to the
welding, and then, the cut insert material may be put on
a portion of each material to be welded or stuck
thereon. In order to feed the insert materials most
smoothly, it is preferable that each insert material is
prepared in a tape-like shape, then wound around a reel,
and continuously fed to a weld portion every time when
one or several spots are welded while rolling each
insert material round another reel.
With reference to the insert materials used for
each welding process according to the invention,
particularly, the metal constituting the surface of each
insert material has a melting point far higher than
those of aluminum and aluminum alloy, and also has
thermal and electrical conductivities far lower than
those of aluminum and aluminum alloy. Further, the
metal described above is hardly subjected to the
diffusion bonding to general electrode materials.
Because of the above-mentioned characteristics of
the metal constituting the surface of each insert
material, when the current is applied by the upper and
_ 21109 ~'~
under electrodes to the materials to be welded, the
materials to be welded can be heated and fused more
speedily to help the more speedy formation of nuggets
between the materials to be welded, and the coated
layers and the electrodes can be sufficiently restrained
from being fused and alloyed. Therefore, the electrode
life can be remarkably improved.
Further, since the metal constituting the surface
of each insert material is hardly subjected to the
diffusion bonding to aluminum or aluminum alloy used as
materials to be welded, the corrosion hardly occurs on
the welded product, and the external appearance of the
welded product is hardly damaged.
Each resistance welding process according to the
invention relates to a process for welding aluminum or
aluminum alloy materials, and otherwise is suitably used
for joining alloy materials mainly such as A1-Si alloy,
A1-Mg alloy, A1-Mg-Si alloy, A1-Cu-Mg alloy, A1-Zn-Mg
alloy and A1-Zn-Cu-Mg alloy by means of resistance
welding.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a fragmentary enlarged-scale sectional
view showing an insert material for use in a resistance
welding process according to the invention;
Fig. 2 is a fragmentary sectional view showing a
resistance welding apparatus as an embodiment for use in
21109~r~
a resistance welding process according to the invention;
Fig. 3 is a front view showing a peeling load
measuring device for insert materials;
Fig. 4 is a perspective view showing a peeling
tool for measuring a nugget with respect to a product
resulting from the resistance spot welding according to
an embodiment of the invention;
Fig. 5 is a fragmentary sectional view showing a
resistance welding apparatus as another embodiment for
use in a resistance welding process according to the
invention;
Fig. 6 is a fragmentary sectional view showing a
resistance welding apparatus as a further embodiment
for use in a resistance welding process according to the
invention; and
Fig. 7 is a fragmentary sectional view of a
welding apparatus for explaining a prior art resistance
welding process for aluminum and aluminum alloy
materials.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A resistance welding process according to the
invention will now be specifically described on the
basis of examples as follows.
As shown in Fig. 1, each of insert materials 9
and 10 for use in a resistance welding process according
to the invention comprises a sheet-like core material 9a
1~ - 211097
consisting of iron, steel, copper or copper alloy and
coated layers 9b and 9c respectively fixed to both
surfaces of the core material 9a. The overall thickness
T of each of the insert materials 9 and 10 is in the
range of 0.02 to 1 mm. The material of the coated
layers 9b and 9c is any one of Ni, Ni alloy, Ti, Ti
alloy, Nb, Nb alloy, Mo, Mo alloy, W, W alloy, Cr, Cr
alloy, Co and Co alloy, and each of the thicknesses tl
and t2 of the coated layers is in the range of 1 to
100 um.
The coated layers 9b and 9c on both surfaces may
consist of different metals from each other so long as
the material thereof is any one of the metals described
above. Further, both the coated layers 9b and 9c may be
different from each other in thickness so long as the
thickness of each coated layer is in the range of 1 to
100 um.
The coated layers 9b and 9c are fixed to both
surfaces of the core material 9a by means of
electroplating, hot dipping, chemical vapor deposition,
cladding or the like.
When the metal constituting the coated layer is
Ti and the metal constituting the core material 9a is
iron or steel, either of the coated layers 9b and 9c may
be omitted.
Further, the insert materials 9 and 10 may
consist of Ti foil or Ni foil.
18 _ 211U9~7
Example 1
As shown in Table 1, 17 kinds of samples of
insert materials (which are samples prepared by
electroplating both surfaces of a sheet-like Fe core
material with Ni or Ni alloy as coated layers, and other
samples prepared by electroplating respectively one
surface of the Fe core material with Ni or Ni alloy and
the other surface thereof with any one of Ti, Nb, Mo, W,
Cr and Co as the coated layers) were prepared for use in
the process of the invention. Also, 5 kinds of samples
of insert materials other than those used for the
example of the invention were prepared as comparative
examples.
Then, the resistance spot welding was carried out
according to.the following procedure as to both the
cases where the sample of each insert material described
above was used and not used.
The insert materials 9 and 10 each having the
size of 30 x 200 mm were interposed respectively between
the upper and under electrodes 1 and 2 and the
overlapped materials to be welded 11 and 12 each having
the size of 30 X 200 mm, and a single phase AC welding
machine having the structure shown in Fig. 2 was used to
carry out the welding up to 12000 times of continuous
spot welding on welding conditions of welding current:
28000A, electrode force: 3920N, weld time: 5 cycles and
30 mm pitch: 5 spots.
19 _ 21 ~. 0 ~ 9~'~
As for each of the upper and under electrodes 1
and 2, use was made of a radiused electrode consisting
of Cr-Cu alloy (which corresponds to the second group of
JIS Z 3234) of 16 mm in diameter and having the radiused
tip end (R = 80 mm). The tip end of each electrode was
subjected to dressing by use of an emery cloth #1000
prior to the start of welding.
Cooling holes 3 and 4 of each 9 mm in diameter
were opened respectively in the electrodes 1 and 2, and
water 7 and 8 was poured to the holes 3 and 4 through
conduits 5 and 6 at a flow rate of 3 Q/min. to cool the
electrodes 1 and 2.
Each of the materials to be welded 11 and 12 was
5182-O material consisting of A1-Mg alloy and having the
thickness of 1 mm. The materials to be welded were used
as they were kept in surface condition when received.
With respect to each test piece welded as
described above, while assuming that the maximum
allowance value is 150 g, the peeling load was measured
by a spring balance 18 as shown in Fig. 3, when the
insert material 9 was peeled from weld portions 20 of
the materials to be welded 11 and 12. Further, as
shown in Fig. 4, one end of the material to be welded 11
was pinched by a peeling tool 21, and then peeled off
while rounding. Thereafter, the long and short
diameters of a nugget 13 were measured by slide
calipers, and the nugget diameter was calculated by the
_ - 20 - 2~,1Q9~'~
following equation to evaluate the electrode life.
Nugget diameter = (long diameter
+ short diameter)/2 mm
Incidentally, the minimum nugget diameter of 4 mm
in the A class of JIS Z 3140 was adopted as the limit
nugget diameter for the evaluation of the electrode
life.
The results thus obtained are shown in Table 1
with other data.
210947
- 21 -
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21.0947
- 22 -
As shown in Table 1, according to the example of
the process of the invention, any electrode life was not
less than 12000 times of spot welding, the peeling load
of the insert material was not more than 150 g, and any
nugget diameter was not less than 4 mm. When the state
of the electrode tip after 12000 times of spot welding
was examined by use of a pressure sensitive paper, there
was almost no difference between the shape of the
electrode tip prior to the start of welding and that
after the welding.
On the other hand, in case of using the insert
material in the comparative example, in which the
thickness of each coated layer (Ni or Ni alloy) is less
than 1 um, the coated layers of the insert materials
were fused at 1302 times of spot welding and deposited
to the electrodes and the materials to be welded.
In this case, the nugget diameter was not more than
4 mm.
In case of using the insert material in the
comparative example, in which the thickness of each
coated layer exceeds 100 um, the insert materials were
not deposited to the electrodes, while the nuggets were
formed up to the surfaces of the materials to be welded
at 1083 times of spot welding, and the materials to be
welded were thus.deposited to the insert materials.
In case of using the insert material in the
comparative example, in which the overall thickness is
_.. - 23 -
less than 0.02 mm, the insert materials were fused by
welding, and the electrode life was no more than 253
times of spot welding. On the other hand, in case of
using the insert material in the comparative example, in
which the overall thickness exceeds 1 mm, it was
impossible to carry out the welding.
In case of using the insert material consisting
of Cu element, the electrode life was 759 times of spot
welding.
In case of welding without using any insert
material, the nugget became smaller in diameter than
that of a standard size at 451 times of spot welding.
At this time, the center portions of the tip ends of the
upper and under electrodes have been already formed
concavely at 50 times of spot welding. The more the
number of times of spot welding was, the larger the
electrode diameter became, and the contact with the
materials to be welded became worse.
As described above, according to the resistance
welding process in the example of the invention, the
electrode life was not less than 10 times as much as
that in case of any comparative examples.
Example 2
As shown in Table 2, 17 kinds of samples of
insert materials (which are samples prepared by .
electroplating both surfaces of a sheet-like Fe core
24 _ 2~~0~4~
material with Ti or Ti alloy as coated layers, and other
samples prepared by electroplating respectively one
surface of the Fe core material with Ti or Ti alloy and
the other surface with any one of Ni, Nb, Mo, W, Cr and
Co as the coated layers) were prepared for use in the
process of the invention. Further, 5 kinds of samples
of insert materials other than those used for the
example of the invention were prepared as comparative
examples.
The resistance spot welding was carried out
according to the following procedure as to both the
cases where the sample of each insert material was used
and not used.
The insert materials 9 and 10 each prepared in a
tape-like shape of 16 mm in width were respectively fed
to between the upper and under electrodes 1 and 2 and
the overlapped materials to be welded 11 and 12 each
having the size of 30 x 200 mm, and a single phase DC
welding machine having the structure shown in Fig. 5 was
used to carry out the welding up to 12000 times of
continuous spot welding on welding conditions of welding
current: 28000A, electrode force: 3920N, weld time: 5
cycles and 30 mm pitch: 5 spots.
The insert materials 9 and 10 were respectively
held by hold reels 22 and 23 and then automatically fed
to between the upper and under electrodes 1 and 2 and
the materials to be welded 11 and 12, while rolling the
21109 4~
- 25 -
insert materials round take up reels 24 and 25 through
guide rollers 28, 29, 30 and 31. Reference numerals 26
and 27 respectively designate drive motors for the take-
up reels 24 and 25.
As for each of the upper and under electrodes 1
and 2, use was made of a dome-radiused electrode as a
new product consisting of Cr-Cu alloy (which corresponds
to the second group of JIS Z 3234) of 16 mm in diameter
and having the dome-radiused tip end. The electrodes 1
and 2 were cooled similarly to the case of example 1.
Each of the materials to be welded 11 and 12 was
5052-O material consisting of A1-Mg alloy and having the
thickness of 1 mm. These materials to be welded were
used as they were kept in surface condition when
received.
With respect to each case, the electrode life was
evaluated similarly to the case of example 1. The
results thus obtained are shown in Table 2 with other
data.
21109 ~~
o.
Q
0
U N U
H
rl
M u'1 .~ O O~
cW
N <C .~ O ~t Y O
'W
w ~ _ _ _ - _ _ _ _ _ _ _ ~ _ N O N rl I~M
b0 _ _
wl 1-1 ~ ~ N
G
Hw 3
p
v
~
25 v
a~
0 .-I
3
a
v 0
o
a~ z
r.~
w
..
0
a
a
x .~ o o ~ o o ~ o o .-a -~ ~n 0 0 ~n
~ o ~ u, 0 0 o
.' U rl Q .-1 O r-1 Q ,--1 r-1 W nf1
v
O rl .~ ~
N ,~
-I H
T3
N
E rl v v v rl rl rl .-~
,~
c~ co W ~, w ~ ~ ~ ~
w w a~ a. a~ a~ as as a
N >'.aN N N N N N N
1~
1 I I 1 I I I
c0 J-~ rl rl rl ra ri ~ O N O ri ~ rl rl r-I
J-1 rl r-I r-1 r-I r-I ri
H H H z H z ~ ~ U U H H H H H H H H
H H H
rl
N
H
x O O O O O O O O O O O O O O O O o0
~ O O O O
m N N O O N O O N O O O N O O N M O ~ O
U O O O
~
'-~I~ ~.~ O .-~ O mn O .~ O -~ ,~ m O
wl O
~.
N ftfa .~ ~ ~ ..-~ ,~ N
.~
rl O
1a
4J U
H
p lC r-1
r~
~C ~ tt3
v
(d
H ri
S..I
rl
1-~ N N N d N v N v N v N N N v d N d N
O N d d
1-~
J-~N !s. fs. fs. fs. f=. G2. G~. f~. W fs.
U f=. G~. fs. fs. fs, f=. fs. fs.
v fs. L~-~ Lj.
~.11~
+~
N ctf ..
w
cb
O
~
H
O N
r N
W
G (n11
~
x ~ O O ~ O O .-a O O O .~ O O O u1 N O
8 O N O O ~ O
U .~ p r--1 O ~ O ~ ~ O M ~f1 lf1 ~ .~.L:
~
o ~ ,~ .-~ ,~ ~ ,~ x
"
v ; U N
,~ H raSi
H .~N
~
c~
tn
d N
~
'L1r-1 N d N r~ ri ,.~ ~--I N ri r~H
o n~ w~.r~~~~~ ~.~ ~10
Ts ,~ a a a' 3s a~ as ds ae a o w
sa
N i.~ N N N N N N N N N w
~
U N 1 I I I I I I I I >,
N a.t rl r-1 rl rl ri r-i rl rl rl ri rl rl ~ F'
d rl r-I rl .Q O I-a O r-1
H H H H H H H H H H z H z ~ H H H H U
3 U U
d
N
w
O G
O a~
v W c~
a~ ~ H
a a ~a a
c ~ >
a ~
x s~ o X
U W rl U N
- 27 -
Example 3
As shown in Table 3, 17 kinds of samples of
insert materials (which are samples prepared by
electroplating both surfaces of a sheet-like Fe core
material with Nb or Nb alloy as coated layers, and other
samples prepared by electroplating respectively one
surface of the Fe core material with Nb or Nb alloy and
the other surface thereof with any one of Ni, Ti, Mo, W,
Cr and Co as the coated layers) were prepared for use in
a process of the invention. Further, 5 kinds of
samples of insert materials other than those used for
the example of the invention were prepared as
comparative examples.
The resistance spot welding was carried out
according to the following procedure as to both the
cases where the sample of each insert material was used
and not used.
The insert materials 9 and 10 each having the
size of 30 x 200 mm were interposed respectively between
the upper and under electrodes 1 and 2 and the
overlapped materials to be welded 11 and 12 (6009-T4
materials each consisting of A1-Mg-Si alloy and having
the thickness of 1 mm) each having the size of 30 x 200
mm, and the single phase AC welding machine having the
structure shown in Fig. 2 was used to carry out the
welding up to 12000 times of continuous spot welding on
welding conditions of welding current: 28000A, electrode
28 - 2~~~~4'~
force: 3920N, weld time: 8 cycles and 30 mm pitch: 5
spots.
The additional conditions were similar to those
in the case of example 1.
Then, with respect to each case, the peel test
for the insert materials was made and the electrode life
was evaluated similarly to the case of example 1.
The results thus obtained are shown in Table 3
with other data.
- 29 -
~ o
0
N
H
.Q
W O M N d5 N 0p
N fC lIW O v? f1M
'LW
W ~ _ _ _ _ _ _ _ _ _ _ _ _ _ u1
b0 _ _ _ ~ rl a0M
ri J-1 ~ ~
r.. N
r-f
ri G
N fn
r~
'b
v
O r-i
3
+~
a~
U O
O
a~ z
a
(r7
v
N 00
~
G
x ~ o o ~ o o .~ o o ~ ~ ~n o 0 0 ~n
~. mn o 0 o
U ~ O .-, O .-~ O .~ .-m mn
~
O ri .-r .-r .-a
N
I H
't~
c~
ri
O _
N
r-1r-I rl rl n-I Sa 1a 1.r 1a
H H H N N N N
't~wl , o~ 3W dv ~ dv ds
rl
41 H N N N N N N N
I~
I I I I I I I
l~ !-1 ~ p .~ rl rl p O f..~ O 'i3 ,fl .~
J.~ 'i~ 'L3 TS 't~ "Cf 't7 .Q
zzzzHZ~~UC~zzzzzzz zzzz
~a 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 00
x 0 0 0 0
~
fn N N O O N O O N O O O N O O N M O -r
U O O O O
~
r-1~ ~ O .~ O ..r V1 O .-~ O .-~ vr1 O
rl u1 O
~
M 1C ' ~ ~ .--) .-) ..-~ N
~
rl O
N N
H ~
p fd H
r~
cd 6 cU
v
cd
H rl
i.~
rl
Ir N N N d N ~ d d N N N v v N d N G)
O N d O N
La
1-~N f~. f=. fs. fs. f=. f=. f~. fs. W Gt.
U fs. fs. Lt. fs f=. fs. L=. fs.
v GL. !s. fs.
>~ ~
N c~ ,
W
cC
E
H
O N
~
x -~ O O ~ O O ~ O O O .-~ O O O ~n O O
E O N O O .--i O
U ~ O ..r O ~ p tr1 .-a
~ O M ~f1
v -1 .~ ,~
O r' U N
N
(~ H rlH
H ~
~
cC ct1
U) H
N ~
N
'L3r-I r-I rl rl 1..~ /..i 1-1 S~1 rl 1-I rlrl
O ~ H H H N N N N H N rlO
'L3rl o~ 3 dw 3v 3E 3 dy 3' O W
1a
41 !.i N N N N N N N N N W
l.~
U d 1 I I 1 I I I I I ~,
cC)1-~ p p ~ ~ 'Lf 'L1 '~ ':~ T1 ":~ ~ ~ ~ Q ~
v r~ ri ~ O f.-~ O
z z z z z z z z z z z H z ~ z z z z U
3 U U
m
x
W
a a
o a
sa ~
a a ~s A,
a ~ > p. a
U w ~ O ~C
U 4J
~1~.~~ ~~
- 30 -
Example 4
As shown in Table 4, 17 kinds of samples of
insert materials (which are samples prepared by
electroplating both surfaces of a sheet-like Fe core
material with Cr or Cr alloy as coated layers, and other
samples prepared by electroplating respectively one
surface of the Fe core material with Cr or Cr alloy and
the other surface thereof with any one of Ni, Ti, Nb,
Mo, W and Co as the coated layers) were prepared for use
in the process of the invention. Further, 5 kinds of
samples of insert materials other than those used for
the example of the invention were prepared as
comparative examples.
Then, the resistance spot welding was carried out
according to the following procedure as to both the
cases where the sample of each insert material was used
and not used.
The insert materials 9 and 10 each having the
size of 30 x 200 were interposed respectively between
the upper and under electrodes 1 and 2 (radiused
electrodes each consisting of Cr-Zr-Cu alloy of 16 mm in
diameter, which corresponds to the second group of JIS Z
3234, and having the radiused tip end of 80 mm in R) and
the overlapped materials to be welded 11 and 12 (5182-O
materials each consisting of A1-Mg alloy and having the
thickness of 1 mm), and the single phase AC welding
machine having the structure shown in Fig. 2 was used to
~~~Q9~~
- 31 -
carry out the welding up to 12000 times of continuous
spot welding on welding conditions of welding current:
28000A, electrode force: 3920N, weld time: 7 cycles and
30 mm pitch: 5 spots.
The additional conditions were similar to those
in the case of example 1.
Then, with respect to each case, the peel test
for the insert materials was made and the electrode life
was evaluated similarly to the case of example 1.
The results thus obtained are shown in Table 4
with other data.
- 32 -
o
0
0
d N N
E -a
p
F: V1 00 M I
00 t0
d td O~ N O~ 0000
'i~
4-I ,~ _ _ _ _ _ _ _ _ _ _ _ _ ~ O .-~ ~ON
b0 _ _ _ _ r1
r~ 1~ ,~ .-~
F..' N
.,..1
'L3 (n
N O
ri
't~ N
N
O ri
$
H
1~ l~
l~
U O
O
a~ z
a.
w..
a~ 00
--
a
a
x ~ o o ~ o o .~ 0 0 0 .-, o 0 0 u,
~. o .--~ 0 0 0 o
p U .~ p ~ u'1 ~ u1 -i .~ O .-i yt1
~ O .-
O rl .--~
N ,C
r-I H
'L3
ri
N
~ .-1 v v v .~-1 .r.t .r.l .r.l
r-1
~a w w w z z z z
~cs ~1 a. a~ a. a ~ a. a~ ae
~~1
1 1 1 1 1 I I
~s ~ s~ >.~ sa .~ .~1 ~ o N o s~ s~ s~
a s~ sa s~ N 1~ sa s~ s~
N U U U z H z ~ ~ U U U U U U U U U
O U U U U
~ ~
~
tn
r~
N
H
~c 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 00
x 0 0 0 0
~
tn,4 N O O N O O N O O O N O O N M O -~
U O O O O
~
~"~N .~ O .-) O .-r u1 O -~ O ~ ~t1 O
rl ~ O
~
~? cd> .--) ~ .~ (--~ ~) N
.C
rlO
J~
N
N N
p cCri
ra
cC ~ l~
N
c0
H rl
1-i
rl
i-i v N N N U N d N a) N a) a) N N N
O N a) N d N d
1-i
~ a~ w w w w w w w w w w w w w w w w w
U w w w w
a~
~ a
+~
a ma ~.
w
ca
o
~
o a~
rn
v
x -r O O ~ O O ~ O O O ~ O O O O ~ N O
E N u1 umn O
U .-~ O ..r O ~ O -i ~ O tn .~ ~ G
~
.~ ,--, ,--~ .-~ (~ x
O .G U N
O
T3 H rlS-~
"o~o
H
...cn
N O
N
'Z3 ~-I d N d ri r-1 rl r-I u) N rl ~--Ir-I
r1
o ~u w w w z z z z w w z ~~10
z
'a .~ a~ as a. a~ a~e a. a. a. a. o ~
s~ ae a.
J~ N I I I I I I I I 1 I ~,
U I
N IJ 1-.~ i-W..~ f-i 1-~ 1-~ 1-~ 1-i i-~ ~
N 1-a H S-~ ni rl p O 1.~ O L~ S-i
U U U U U U U U U U z H z ~ U U U U
~ U U U
d
W >
O >r
O a
N 'rl cd U
r-1 i.1 1..1 ra
O O. C c0 p.
~ a 8
ca >
i~ ~ O >C
U W rl U
- 33 -
Example 5
As shown in Table 5, 17 kinds of samples of
insert materials (which are samples prepared by
electroplating both surfaces of a sheet-like Fe core
material with Co or Co alloy as coated layers or other
samples prepared by electroplating respectively one
surface of the Fe core material with Co or Co alloy and
the other surface thereof with any one of Ni, Ti, Nb,
Mo, W and Cr as the coated layers) were prepared for use
in the process of the invention. Further, 5 kinds of
samples of insert materials other than those used for
the example of the invention were prepared as
comparative examples.
Then, the resistance spot welding was carried out
according to the following procedure as to both the
cases where the sample of each insert material was used
and not used.
The insert materials 9 and 10 each having the
size of 30 x 200 mm were interposed respectively between
the upper and under electrodes 1 and 2 (dome-radiused
electrodes each consisting of Cr-Cu alloy of 16 mm in
diameter, which corresponds to the second group of JIS Z
3234, and having the dome-radiused tip end) and the
overlapped materials to be welded 11 and 12 (5182-O
materials each consisting of A1-Mg alloy and having the
thickness of 1 mm), and the single phase AC welding
machine having the structure shown in Fig. 6 was used to
- 34 -
carry out the welding up to 12000 times of continuous
spot welding on welding conditions of welding current:
28000A, electrode force: 3920N, weld time: 5 cycles and
30 mm pitch: 5 spots.
The additional conditions were similar to those
in the case of example 1.
Then, with respect to each case, the peel test
for the insert materials was made and the electrode life
was evaluated similarly to the case of example 1.
The results thus obtained are shown in Table 5
with other data.
35 _ 2iias47
0
~ o
0
N N N
ri
.~ N N N 00
cSf
N N .-a u1 M O~
N 'L~
4-I ,C - ~ _ ~ _ _ _ _ _ ~ ~ ~ N O ~"~ 00 V1
b0 _ ~ _ ~ rl
r~ i~ .~ .~
.~. N
,...I
.,..I
fn
v ~n a
rl
a~ a~
0 rl
3
U O
O
v z
c~
w
..
v 00
~
a
a
x .-~oo~oo.~.ooo.-.~oo.-~ooo oo~no
~
:r a ,~ o .-, u, ....~ ~n ...~ ,~ ~r,
... p .~ o .~
o .~I .~ ,-a
a~ x
~~ H
~
.~,
v
a ~ s~ 1~ >-~ s~ a ~ a
~I
~C U U U
rl ri ~aadv~3sds
d Wr W utW1 W tW1 u1
L
+~ N I I I I I I I
v
ftS 1~ O O O rl rl .a O 1-~ O O O O O O
~ O O O O O O
V U U z H z ,'~ 3 U U U U U U U U
U U U U U
N
r-1
~
~
co o 0 0 0 0 0 0 0 0 0 0 0 0 0 0 o ao
x 0 0 0 0
a
m N N O O N O O N O O O N O O N M O ~
U O O O O
~
~-IN ~ O .-a O .mn O ~ O ~ ~ O ~n O
'rl
~
m N 9 .-~ .-.~ ~ -.~ ,~ N
.~
rlO
1~
d N
_..
fTfr-I
r~
N ~ ctf
N
c~
H rl
is
rl
s.~ a~ a~ v a~ a~ d a~ v a~ v a~ a~ a~
o v v a~ v v a~ v a~
>a
N a~ ~. ~. w ~. c~ ~. ~. ~. ~. ~. w ~. c~
a ~, ~. ~, w ~. ~. ~. ~,
n~
H ~
t~
N cC ..
w
cC
O 8
~
H
O U
r
tn
N Op m
F: fn LJ
~
x .~ O O ~ O O .~ O O O .~ O O O u1 a~ O
6 O N nn ~n u~ O
U .-~ O .-~ O .~ O --~ ..-~ O m1
~
,~ ...-) .., x
o .G a v
a~
-~ H
H
N m
d
8 r-I S~ i-~ N L: L: .~.. F." L~ S-~ r-Ir~
'L1 .~..
~.,"'
O cd U U U ,F~' '~."' ,'~,' ,F.~' U U (~"' rl O
,~,"
1.r ra dW dW 3E dv 3 ~ a 3 O w
~
a~ 1a umn ~n u~ umrw mm un w
a
1-~ O 1 I 1 1 I I I I I I ?,
U I
O ~ U U U U U U U U U U z H z ~ U U U U
3 U U U
~
v
d
W
O L." rl
O i..~
N rl cd N
.-i t~ 1r ri
p. p N A.
k G O x
U W .'1 V N
_ 36 _
Example 6
As shown in Table 6, 17 kinds of samples of
insert materials (which are samples prepared by
electroplating both surfaces of a sheet-like Cu or Cu
alloy core material with Ni or Ni alloy as coated
layers, and other samples prepared by electroplating
respectively one surface of the Cu or Cu alloy core
material with Ni or Ni alloy and the other surface
thereof with any one of Ti, Nb, Mo, W, Cr and Co as the
coated layers) were prepared for use in the process of
the invention. Further, 5 kinds of samples of insert
materials other than those used for the example of the
invention were prepared as comparative examples.
Then, the resistance spot welding was carried out
according to the following procedure as to both the
cases where .the sample of each insert material was used
and not used.
The insert materials 9 and 10 each having the
size of 30 x 200 mm were interposed respectively between
the upper and under electrodes 1 and 2 (radiused
electrodes each consisting of Cr-Cu alloy of 16 mm in
diameter, which corresponds to the second group of JIS Z
3234, and having the radiused tip end of 80 mm in R) and
the overlapped materials to be welded 11 and 12 (5182-O
materials each consisting of Al-Mg alloy and having the
thickness of 1 mm) each having the size of 30 x 200 mm,
and the single phase AC welding machine having the
_3~_ 21109"l
structure shown in Fig. 2 was used to carry out the
welding up to 12000 times of continuous spot welding on
welding conditions of welding current: 23000A, electrode
force: 2940N, weld time: 5 cycles and 30 mm pitch: 5
spots.
The additional conditions were similar to those
in the case of example 1.
Then, with respect to each case, the peel test
for the insert materials was made and the electrode life
was evaluated similarly to the case of example 1.
The results thus obtained are shown in Table 6
with other data.
21~.~94'~
- 38 -
0
0
m o
N
E
ri
J, ~., N ~ M O to
tC3
N cts u1 Cp p w1
--~ W
W ,~ - _ _ _ _ _ _ _ _ _ _ _ _ ~? ~ u1 I~~
h0 _ _ _ r-i
ri 1~ .--i .-~
~..' .--i
v
.a g
G
v u~
,~
a~ a~
0 .-i
3
sa
a~
U O
O
v z
a
w
.-
v 00
..
E
x -. o o ~ o o ~ o o .~ .~ .n 0 o m
~ o .-a ~n o 0 o
<r U ~ O ~ O .-a O .~ .mn ~n
~
O ,~ r, .~ .-i .-a
N ,C
-I H
'~
fC
r{
a~
N
d N N N S-~ 1a 1.-a
E rl fs. (z. ~T. F". f." U U U
H
~C c0 ds dw ~ N N ~ ~ ds
't3 rl W in in ~ ~2 O O O
rl
p ~ ~ ~ ~ ~ ~ ~ ~ ~r
~
i~ N I I 1 I 1 I 1 I
a1
cCS a-~ rl rl rl rl rl .Q O 1-r O r1 r~ ri
a r-I rl rl 1 r1 rl ri rl
z z z z H z ~ 3 U U Z z z z ~ z z
z z z z
U ~
8
m
r1
p
r-1
f"'-.
i.
~ o 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 00
x 0 0 0 0
E
m 1-~ N O O N O O N O O O N O O N M O ~~
U O O O O
~
.-1N .--~ O ~ O .-m1 O ~ O .-a vl ~n O
rl O
~
v0 fd> ~ .~ .-a .-~ .~ N
~
rlO
H
y
r-I ~ Ir La Ir S-~ f-i N S-~ 1-i
t~rl U U U U U U U U
'I
~c E cv a as a~e ae as as as as
a~
ca
H rl .-~ .-~ .~ .-i .-~ .-r
is
ri
y..i I I I I I I I I
O
Lr
J.~p ~ ~ ~ ~ ~ ~ ~ ~ O O O ~ p ~ ~ O ~
U ~ ~ ~ O
N
>a~ V U U U U U U U U U U U U U U U U
1.~ V U U U
N ~ ~.
4a
~
~n~ E
O
E
H
O d
N r
N
N Op tO
F', (ON
~
x ~ O O --~ O O .-a O O O .-~ O O m N O
E O O N O O -~ O
U '' O ~ O .-a p m1 .~ O M u1 u1 .-r ~
~
.- ,~ .-~ .~ r, .-~ x
O ,~ U N
N
'O H .-11-a
H
W
c~ H
o
a ..u~
v m a~ a~ a~ sa s~ s~ v la
v
E -I Gi. G. W G C: U U U (s. G r-1ri
'C1 U
O lC 3s dv dE N N 8v d2 8 ~ N dv rlO
b .1 ~n ~n u1 3E a. O O O w ae O O W
~
N ~, .-.i ,~ ,~ u1 u1 -~ -a .-i .--mn W
a ~
U d I I I I I I 1 I 1 I I >,
N J-1 rl r-I r-I rl rl rl rl rl rl rl rl ~
N rI rl rl .Q O S-a O 'I r-I
z z z z z z z z z z z H z ~ z z z U
3 U U z
W >
o a
0
v rl cC d
~n a c ~c a
E a~ Q. E
ca ca > E ca
x a o x
U W r1 U N
- 39 - 211Q94?
Example 7
As shown in Table 7, 17 kinds of samples of
insert materials (which are samples prepared by
electroplating both surfaces of a sheet-like Cu or Cu
alloy core material with Ti or Ti alloy as coated
layers, and other samples prepared by electroplating
respectively one surface of the Cu or Cu alloy core
material with Ti or Ti alloy and the other surface
thereof with any one of Ni, Nb, Mo, W, Cr and Co as the
coated layers) were prepared for use in the process of
the invention. Further, 5 kinds of samples of insert
materials other than those used for the example of the
invention were prepared as comparative examples.
Then, the resistance spot welding was carried out
according to the following procedure as to both the
cases where the sample of each insert material was used
and not used.
Similarly to the case of example 2, while the
tape-like insert materials 9 and 10 each having the
width of 16 mm were automatically fed to between the
upper and under electrodes 1 and 2 (dome-radiused
electrodes each consisting of Cr-Cu alloy of 16 mm in
diameter, which corresponds to the second group of JIS Z
3234, and having the dome-radiused tip end) and the
overlapped materials to be welded 11 and 12 (5052-O
materials each consisting of A1-Mg alloy and having the
thickness of 1 mm) each having the size of 30 x 200mm,
~~~~94'~
- 40 -
the single phase DC resistance welding machine having
the structure shown in Fig. 5 was used to carry out the
welding up to 12000 times of continuous spot welding on
welding conditions of welding current: 25000A, electrode
force: 2940N, weld time: 5 cycles and 30 mm pitch: 5
spots.
The additional conditions were similar to those
in the case of example 2.
Then, with respect to each case, the electrode
life was evaluated similarly to the case of example 2.
The results thus obtained are shown in Table 7
with other data.
21~.~)947
- 41 -
0
0
0
d N O
'-i
~Y O N N ~
c~
ma 00 N ~ O
'~
= ~ ~ _ _ _ ~ _ _ _ _ ~ _ _ M W1 vT f~~?
_ ~ r-1
es
rl y v
.~". .)
3
v
~
v
0 ~-1
3
w
+~
U 0
o
a~ z
a.
w
.-
m
v ao
~
x .-~ o o ~ o o .~ o o .-~ .~ 0 0 ~n
~ ~n Q wn o 0 o
U ~ O ~ O ~ O ~ -r u m1
~
O r-i -a ~ ~ r,
rl H
~
ctf
rl
v
8 ~ v a~ v ~ rl ~ rl
~
c~ c~ w ~ ~ ~ ~
w w a~a~o a.a~ea.aQ
N N N N N N N N N
I I 1 I I 1 I
ftf1~ rl ri rl rl r~ .fl O 1-~ O ri ri rl
J.~ rl rl rl ri rl rl rl rl
U ~ H H H z H z ~ ~ U U H H H H H H H H
~ H H H
N
N
r1
N
ra
~o o 0 0 0 0 0 0 0 0 0 0 0 0 0 0 o ao
x 0 0 0 0
a
fn la N O O N p O N O O O N O O N M O ~ O
U O O O
~
r-IN -~ O .--) O .-, W O -r O -mn u1 O
ri O
~
r ~0 > .--i .-i .~ ,...) ,~ N
.C
.~ O
+~
to
.-i a~ 4a fa Sa 1~ 1a Sa La !a
tC r-I U U U U U U U U
rl
ca E to a~ 3v aw 3v as a~ 3 as
N
ro
H rl -~ ~ .-~ .-i --~ .~ ,-i
1r
rl
Li I I 1 I I I I I
O
S.a
+~ v
U
d
>r ~ U U U U U U U U U U U U U U U U U U
~ U U U
N fd
W
N
tn ~
O
H
Q U
N
r N
N
~ (ni-~
x .--~ O O ~ O O .-~ O O O .-a O O m O a~O
8 O O N O O -~
,~ O ~ p u1 --~ O M u1 in --i G G
~ x
o .G U v
v
,~ H ri5..~
H .Cc0
~
cd
O
d
'L3e-1 N U d rl ri ri r~ d r~ r~rl
O c3 f~. fs. fs. ~ d' ~ ~ fs. ~ .-IO
'CSrl 3s d~ a' ~ 3~ dv dv dv ~ O W
1r
N 1-a N N N N N N N
J-1 N N W
I 1 1 I I 1 I I I >,
c~fi.~ rl rl ri rl rl r-1 ri r-1 rI rI r-I ~
N rI r~ rI .Q O i-~ O ri rl
H H H H H H H H H H z H z ~ H H H H U
3 U U
v
W >
O ~
O y
d w ro v
.-1 a~
G1 G c~ A.
a N ' A E
c
n
V W O X
~
U
- 42 - 2~~,094'~
Example 8
As shown in Table 8, 17 kinds of samples of
insert materials (which are samples prepared by
electroplating both surfaces of a sheet-like Cu or Cu
alloy core material with Nb or Nb alloy as coated
layers, and other samples prepared by electroplating
respectively one surface of the Cu or Cu alloy core
material with Nb or Nb alloy and the other surface
thereof with any one of Ni, Ti, Mo, W, Cr and Co as the
coated layers) were prepared for use in the process of
the invention. Further, 5 kinds of samples of insert
materials other than those used for the example of the
invention were prepared as comparative examples.
Then, the resistance spot welding was carried out
according to the following procedure as to both the
cases where the sample of each insert material was used
and not used.
The insert materials 9 and 10 each having the
size of 30 x 200 mm were interposed respectively between
the upper and under electrodes 1 and 2 (radiused
electrodes each consisting of Cr-Cu alloy of 16 mm in
diameter, which corresponds to the second group of JIS Z
3234, and having the radiused tip end of 80 mm in R) and
the overlapped materials to be welded 11 and 12 (6009-T4
materials each consisting of Al-Mg-Si alloy and having
the thickness of 1 mm) each having the size of 30 x 200
mm, and the single phase AC welding machine having the
- 43 -
structure shown in Fig. 2 was used to carry out the
welding up to 12000 times of continuous spot welding on
welding conditions of welding current: 27000A, electrode
force: 2450N, weld time: 8 cycles and 30 mm pitch: 5
spots.
The additional conditions were similar to those
in the case of example 1.
Then, with respect to each case, the peel test
for the insert materials was made and the electrode life
was evaluated similarly to the case of example 1.
The results thus obtained are shown in Table 8
with other data.
- ~~~.Q947
p
~ p
0
N N O
.Q
C.' ~ .--i V1O~
.-~ c(S
N c~ 00 If1 vf1M
M '[f
4-i ,~ _ _ _ _ _ _ _ _ _ ~ _ ~ ~!1 f~ I~~T
bD _ _ ~ _ ~O r-I
rl J-~
.("',
,..I
G
v m
rl
' N
N
0 .-I
3
v 0
o
~ z
I~
w
..
~ ~o
~
a
x ~ o o ~ o o ~ o o ~ .~ ~n p 0 o m o
~ .-~ ~n o 0
O U .-~ O ~ O ,~ O .-a ,~ u mn
.J
O 'i ~ r1 ,~
N ,~
r1 H
'L3
N
rl
N
8 r-I ri r-1 rI N 1-i la la
~
H H H N N N N
'~ W dv d~ ds dv 3v 3s 3
W
41 1-i N N N N N N N
1.r
f~ J~ ~ .a S~ ri ri .a O 1-i O ~ (
L~ TS 'CS ' b '~ 'LS
O ~ '.~. z '7-n '7-~ H z ,'~,' -,"T. z
~ 3 U U '~., Z z r2-. 2 z z 'Z. 'T-.
C
J
ri
r-~
O
~
~s 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 00
x 0 0 0 0
~
(n 1.r N O O N O O N O O O N O O N M O -~
U O O O O
~
~ ~ '~ O --m1 O .--~ O ,~ V1 m1 O
O
a0 c~ ~ N
,~
d N
r-1 l~ H N H f-r ~ S-i 5..~
p tC r-I U U U U U U U U
r-I
cG 8 ctf 3~ ~ d~ dv 32 dv
N
ct5
H rl .-a .--i .-i ,~ .-i .-~ --i .-a
H
rl
S-iOla II1 III I 1
1.~N ~ ~ ~ ~ ~ O ~ ~ ~ O ~ O ~
U
N
1a ~ U U U U U U U U U U U U U U U U U U
i~ U U U
d cC ~
4-~
c0
E
H
'O
o v
G ~na~
~
x ~ o o .-~ o o .-a o 0 0 --~ o o ~n a~o
8 o o N o o .-~ o
~ ~ O ~ O ~ O ~ ~ M M t!1 .-) ~ G
O x
o ~ V N
a~
"C3H rlL.~
,~c~
tC H
N
N cn
N
'L3r-I r~ r-I rl ~ 1.~ i-~ 1a rl 1a r-1r1
H H H N N N N H N rlO
'b ra ~~~3'~a'3' ~d O w
Ir
4J y.~ N N N N N N N N N W
J,
U d I I I I I I I I 1
N L.1 ~ .Q .O 'L3 ' 'Lf 'L3 !~ 'L3 ~ .>a .a ~ G."
'L3 r~ rl ~ O 1-~ O .Q
z z z z z z z z z z z H z ~ z z z z U ~
~ U U
v
W
o ~
0
v
H .-I
tn O. ~ cd G1
as
x ~ o x
U W rl U N
2110947
- 45 -
Example 9
As shown in Table 9, 17 kinds of samples of
insert materials (which are samples prepared by
electroplating both surfaces of a sheet-like Cu or Cu
alloy core material with Mo or Mo alloy as coated
layers, and other samples prepared by electroplating
respectively one surface of the Cu or Cu alloy core
material with Mo or Mo alloy and the other surface
thereof with any one of Ni, Ti, Nb, W, Cr and Co as the
coated layers) were prepared for use in the process of
the invention. Further, 5 kinds of samples of insert
materials other than those used for the example of the
invention were prepared as comparative examples.
Then, the resistance spot welding was carried out
according to the following procedure as to both the
cases where the sample of each insert material was used
and not used.
The insert materials 9 and 10 each having the
size of 30 x 200 mm were interposed respectively between
the upper and under electrodes 1 and 2 (dome-radiused
electrodes each consisting of Cr-Cu alloy of 16 mm in
diameter, which corresponds to the second group of JIS Z
3234, and having the dome-radiused tip end) and the
overlapped materials to be welded 11 and 12 (5083-O
materials each consisting of A1-Mg alloy and having the
thickness of 1 mm) each having the size of 30 x 200 mm,
and the single phase AC welding machine having the
X110947
- 46 -
structure shown in Fig. 2 was used to carry out the
welding up to 12000 times of continuous spot welding on
welding conditions of welding current: 25000A, electrode
force: 2650N, weld time: 5 cycles and 30 mm pitch: 5
spots.
The additional conditions were similar to those
in the case of example 1.
Then, with respect to each case, the peel test
for the insert materials was made and the electrode life
was evaluated similarly to the case of example 1.
The results thus obtained are shown in Table 9
with other data.
2110947
0
0
0
d N N
ri
~1 '~..,' If1 M N v0
.-1 c~
N cd N u'1 M r-i
N "O
4-1 ~ : _ _ _ _ _ _ _ _ _ _ _ _ M u1 ~T 1~V1
b0 _ _ _ '-1
ri 1-1 .-v
G
r~
ri
O G
O fn
r~
O N
O '-1
3
H
4~
U O
O
N
~1
cn
W
O
N
N 00
n
x .-~ o o .-a o o ~ 0 0 0 ~ o 0 0 ~n
~ o ~ 0 0 0 o
G a .-, a .~ ~r, ,~ u, ~ ~ p .~ ~r,
.. o .~
o .,~ ~ .-a .~ .,
a~ x
r-1 H
'L3
lCS
rl
a~
v~
N
r~ r~ rl rI r~ I-~ N 1a la
c0 c~ H H H N N N N
'~',frl 3E 3 ds ~ ~ 3Z ds
ri
N 1.r .-a ~ .-.~ .-~ ..-i ~ .-a
la
41 U 1 I I 1 I I I
cC 1, O O O rl rl ~ O 1-~ O O O O O O O
J~ O O O O O
O cd ~ ~ ~ z H z ~ 3 U U ~
tC
U
N
G
i.
N O O O O O O O O O O O O O O O O o0
x O O O O
8
f01-~ N O O N O O N O O O N O O N M O -~
U O O O O
~
rl~ ~ O -~ O ~ tr1 O ~ O .~ u1 tt'1 O
ri O
~
O~ fd> .~ .-a .~ ~ ~ N
.~
rlO
N
d
rl l~ H ~ S-i 1~ N f-r 1-~ 1a
.Q ldrl U U U U U U V U
.-i
N 6 c0 ~2 ~ 2.E dv dv d~E 3~ dv
N
cd
H rl .~ -.a ~ ~ .a .-~
1-~
rl
H 1 I I I I I I I
O
H
1~N ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ O ~ ~ ~ ~ ~
U ~ ~ ~ O
N
faN U U U U U U U U U U U U U U U U U
~ U U U U
N ~ ~.
w
cC
m ~ E
O
E
~
H 'Z3
O
O
fn
N 00
n fn1J
x .-aOO-nOO~OOO.-~OON~lltn V1 OOmIO d O
E
U ~ O ~ O ~ O ~ ~ O m ~ G G
~
, ,-.~ ,~ .-~ -, ~ x
O ~ U U
N
'~ H riIr
rl ~"..N
r~
a5 H
rn
(n
N tn ri
N
'~ rI rl rl rl ?-i Sa la la ri 1.a ~ rl
O ~ H H H N N N N H N r-1O
'Lf ri 2~ 3s dv d2 3E 3w ~ 3v 3 O W
N
N la .-i .-~ ~ .-~ .-i .~ --i .--i .-~ w
4~
U N 1 I I I I 1 1 I I >,
ftf JJ O O O O O O O O O O rl rl p O O O ~ G'
~ O 1-~ O O
~ ~ ~ ~ ~ ~ ~ ~ ~ ~ Z H Z ~ ~ ~ ~ U
3 U U ~
U ~
U
t~
N
w >
O C rl
O N
N r-I c4 N
r1 ~ fa ri
tn R. G ~C R.
m ~ ~r a ~
ro ~s > ~ ~s
.-r x a o x
U W rl U v
_ _ 48 - 2~I0947
Example 10
As shown in Table 10, 17 kinds of samples of
insert materials (which are samples prepared by
electroplating both surfaces of a sheet-like Cu or Cu
alloy core material with W or W alloy as coated layers,
and other samples prepared by electroplating
respectively one surface of the Cu or Cu alloy core
material with W or W alloy and the other surface thereof
with any one of Ni, Ti, Nb, Mo, Cr and Co as the coated
layers) were prepared for use in the process of the
invention. Further, 5 kinds of samples of insert
materials other than those used for the example of the
invention were prepared as comparative examples.
Then, the resistance spot welding was carried out
according to the following procedure as to both the
cases where the sample of each insert material was used
and not used.
While the insert materials 9 and 10 each having
the width of 16 mm were automatically fed to between the
upper and under electrodes 1 and 2 (radiused electrodes
each consisting of Cr-Zr-Cu alloy of 16 mm in diameter,
which corresponds to the second group of JIS Z 3234, and
having the radiused tip end of 80 mm in R) and the
overlapped materials to be welded 11 and 12 (5182-O
materials each consisting of A1-Mg alloy and having the
thickness of 1 mm) each having the size of 30 X 200mm,
the single phase DC resistance welding machine having
- 211fl94'~
the structure shown in Fig. 5 was used to carry out the
welding up to 12000 times of continuous spot welding on
welding conditions of welding current: 26000A,
electrode force: 2650N, weld time: 5 cycles and 30 mm
pitch: 5 spots.
The additional conditions were similar to those
in the case of example 2.
Then, with respect to each case, the electrode
life was evaluated similarly to the case of example 2.
The results thus obtained are shown in Table 10
with other data.
~zzo94~
0
~ p
m o
N N v
O~ ~1W N v0
Y c~
N f~ O~ N ~ 00O~
'O
4-I .~ - _ _ _ - _ _ - - _ _ _ ~Y 1~ ~D I~d
b0 _ _ _ _ ri
H L~ .--i .--~
C: ~ U
'b fO f~
d
'a~ N
~
0 rl
3
H
a.~
a~
U O
O
v z
o.
Wv
N
~ 00
.~. '
~
x ~ o o -~ o o .-~ 0 0 0 .-a 0 0 ~n
~. o o ~ 0 0 0 o
U .~ O .-~ u1 mt1 .-~ .-.~ O y1
~ ~ O .-
O .~ .~ .-.~ .-r
N (C
rl H
'
fC
rl
O
p
~~~zzzz
v H a~ a~ a. a2 ae as a.
H
y~ ~ u, vmn u, wm u,
~
cC ~ rl rl .Q o S-i o I i t I 1
~ I I
O cri 3 3 3 z H Z ~ 3 U U ~ 3 3 3 3 3 3 3
ca 3 3 3
U
r-1
N
r-I
~
~
m o 0 0 0 0 0 0 0 0 0 0 0 0 0 0 o ao
x 0 0 0 0
ar
fn H N O O N O O N O O O N O O N ~''~ O
U O O O ~ O
~
O r-IN .~ O .--~ O ~ V1 O ~ O .'-~ ~ O
rl u1 O
v
of ' .-~ .~ .~ ~ .~ N
.C
r1 O
H
N N
rl t~ H f-i H Ir 1-i f..~ H Ir
p ~ rl U U U U U U U U
'-I
N 6 cd 3 ~ ~ ds 2~ ~ ds ds d
N
N
H rl .-~ .~ ~ -, .-a .~
S-~
rl
H I I 1 I I I I I
O
1.-~
L.~N ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ O ~
U
N
H a~ U U U U U U U U U U U U U U U U U U
a.~ U U U
W C ~
W
N
m ,~ E
O
~
~ '
H b
O N
n ~
y ~ tn
~ . fn1.7
x ~ O O -~ O O ~ O O O ~ O O O O ~n v O
F3 N u1 v~ u~ O
U .-, p ,~ O .~ p ~ ,~ p ~n ~ G ~
~
.~ .-~ r, ~ .~ x
O .~
N
'~ H r-IS-~
r-I
rl
c~ H
m
v !n
N tn
N
'Lyr~ ri rir~
o ~c o 0 0 ~ .~I .~, .,~ o z ~Io
~ ~ ~~~zz.zz
H
v H a. ae a~e a. ae a. a~e a. m w
~
a~ N W u, W u, u, W n u, I >,
U
N ~ I I I I I I I ml rl ~ 0 1-i I o
v o
o cu 3 3 3 3 3 3 3 3 3 3 z H z ~ 3 3 U 3
~-~I 3 U U
U
v
N
v
w
O G W
O
v rl c~
H rl
U~ p. C cC A.
~
N 9 6
r-I i< ~ O >C
U W rl U N
- 51 - 21~p947
Example 11
As shown in Table 11, 17 kinds of samples of
insert materials (which are samples prepared by
electroplating both surfaces of a sheet-like Cu or Cu
alloy core material with Cr or Cr alloy as coated
layers, and other samples prepared by electroplating
respectively one surface of the Cu or Cu alloy core
material with Cr or Cr alloy and the other surface
thereof with any one of Ni, Ti, Nb, W, Mo and Co as the
coated layers) were prepared for use in the process of
the invention. Further, 5 kinds of samples of insert
materials other than those used for the example of the
invention were prepared as comparative examples.
Then, the resistance spot welding was carried out
according to the following procedure as to both the
cases where the sample of each insert material was used
and not used.
The insert materials 9 and 10 each having the
size of 30 x 200 mm were interposed respectively between
the upper and under electrodes 1 and 2 (radiused
electrodes each consisting of Cr-Zr-Cu alloy of 16 mm in
diameter, which corresponds to the second group of JIS Z
3234, and having the radiused tip end of 80 mm in R) and
the overlapped materials to be welded 11 and 12 (5182-O
materials each consisting of A1-Mg alloy and having the
thickness of 1 mm) each having the size of 30 x 200 mm,
and the single phase AC welding machine having the
-52- 211094r1
structure shown in Fig. 2 was used to carry out the
welding up to 12000 times of continuous spot welding on
welding conditions of welding current: 25000A, electrode
force: 2950N, weld time: 7 cycles and 30 mm pitch: 5
spots.
The additional conditions were similar to those
in the case of example 1.
Then, with respect to each case, the peel test
for the insert materials was made and the electrode life
was evaluated similarly to the case of example 1.
The results thus obtained are shown in Table 11
with other data.
- 211097
p
p
~n o
N N
,-i
W !1 N .-~ 00--i
(~
G7 IC I~ N O~ .-1N
Tf
W (~ _ _ _ _ _ _ _ _ _ _ _ _ _ M ~O ~T I~V1
b0 _ _ _ r-I
v~ l~ .~ .~
.y~. ~ N
w 3
G
v
~
a~ m
0 ~-I
3
H
1~
a
U O
O
a~ z
a
w
.~
v 00
-~
a
ar
x .-a o o .-~ o o .-a o 0 0 ~ 0 0 ~n
~ o o --~ 0 0 0 o
O U ~ O mt1 .-a V1 .~ .~ p .-~ O u1 .-i
~ ~
O rl ~ ~--~ .~ .-a
rl H
'~
rtf
rl
a
N
8 r-iG) v N r1 rI rl r1
r-I
wwwzzzz
a~ ae a. a. a~e a. a~e
N N .-a
i-a
I I I I I I I
ccf ~ t.r 1-i 1-i rl rl ~ O S-a O 1.-i !-~
~..~ Ir S~ 1-i i~ 1r f.r f-i Sr i-~
U U U z H z ~ ~ U U U U U U U U U
U U U U
ri
d
~o 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 o ao
x 0 0 0 0
~
f01.~ N O O N O O N O O O N O O N M O .~
U O O O O
~
rr 1-iv .-~ O -~ O .mf1 O ~ O ~ ~n O m1 O
rl
~
N ~ ..~ ,~ ~ .-i ..~ N
.s~
W O
H
U N
r-I ~ N Ir 1-i f-i f-i N 1..~ S-i
p ~ -I U U V U U U U U
rl
ld 6 to a 3 3' o ds ~ ~ 3~
d
c0
H ri ..-) -, ~ .-,
N
rl
H I I I 1 I t I i
O
H
U
N
H ~ U U U U U V U U V U U U U U U U U
~ U U U U
N t~
W
N
E
~
H
'Z3
O v
W
fn
tn+~
x .~ O O ~ O O .-~ O O O ~ O O O O ~n d O
6 N u1 u1 in O
U '~ O ~ O .--~ O ~ .-w O (--~ >~S~
r x
l
o .a U N
a~
rlH
H .CtC
m
cC
~ tO
N V7 r~
v
T3 r-I~ N d r1 rl rl rl N N r-I r~rl
r-I
o ~a ~. ~. w z z z z ~. w z ~Io
z
H .~t~ a. a~e a~e a. a. a~ a. a. o W
a. a~
N y--i r-1 .-~ r-1 r-1 .-i r-1 ~-1 r-1 W
lJ .--~
..a
U v I I I I I I I I I I >,
I
~a ~ H H H H H H H H H H .~ ..~ .n H H H ~ a
a~ o H o H
O t~ U U U U U U V U U U z H z '~."'U U U U C,
ri 3 U U U
U
N
N
d
W
O t; ,-1
O
H ~ v
ra a H ,~
A. O ~0 Q.
o ~ > p. a
W O k
~
U U N
- 54 - 2z~o9~7
Example 12
As shown in table 12, 17 kinds of samples of
insert materials (which are samples prepared by
electroplating both surfaces of a sheet-like Cu or Cu
alloy core material with Co or Co alloy as coated layers
and other samples prepared by electroplating
respectively one surface of the Cu or Cu alloy core
material with Co or Co alloy and the other surface
thereof with any one of Ni, Ti, Nb, W, Mo and Cr as the
coated layers) were prepared for use in the process of
the invention. Further, 5 kinds of samples of insert
materials other than those used for the example of the
invention were prepared as comparative examples.
Then, the resistance spot welding was carried out
according to the following procedure as to both the
cases where the sample of each insert material was used
and not used.
The insert materials 9 and 10 each having the
size of 30 x 200 mm were interposed respectively between
the upper and under electrodes 1 and 2 (dome-radiused
electrodes each consisting of Cr-Cu alloy of 16 mm in
diameter, which corresponds to the second group of JIS Z
3234, and having the dome-radiused tip end) and the
overlapped materials to be welded 11 and 12 (5082-O
materials each consisting of A1-Mg alloy and having the
thickness of l mm) each having the size of 30 X 200 mm,
and the single phase AC welding machine having the
- 55 - 211p94'~
structure shown in Fig. 6 was used to carry out the
welding up to 12000 times of continuous spot welding on
welding conditions of welding current: 24500A, electrode
force: 2940N, weld time: 8 cycles and 30 mm pitch: 5
spots.
The additional conditions were similar to those
in the case of example 1.
Then, with respect to each case, the peel test
for the insert materials was made and the electrode life
was evaluated similarly to the case of example 1.
The results thus obtained are shown in Table 12
with other data.
56
0
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0
N U
~i
G N u1 00 W ?
<C
N c0 N u'1 .~ w 0
~
w ,C : _ _ _ _ _ _ _ _ _ _ _ u'1 W o 00u1
b0 _ _ _ _ r-I
r~ 1-) r-1 .--1
~'.. r-1
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r-I
't~ N
G~
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3
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a ,.~
a
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a~ z
a
w
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a
a
x .~ o o .-a o o ..~ 0 0 0 ~ 0 0 ~n
~ o o --~ 0 0 0 o
"..U .-~ Q -~ tf1 .-y1 ~ ~ p .-~ ll1
yr O ~
O rl
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H
U U U
W W 3dv~3Eao~dv
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c~ ~ O O O rl .-i .Q O 1-i O O O O O O O
a.~ O O O O O
U U U z H z ~ ~ U U U U U U U U U U
U U V
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ra
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x O O O O
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fn 1.-~ N O O N O O N O O O N O O N M O -~
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rl
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r-I a~ S.a t-i ~ t-i I-~ 1-i N 1..,
c0 r-I U U U U U CJ U U
rl
N 8 td d~ ~2 ~ d2 dW d' 3
N
cd
H ri .-~ ,-i .-~ ~ .-, .--i .-~ ..r
H
rl
1.-i 1 1 I I I I I I
O
t-i
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U V V U U U U U U V U U U V U U U U
U U V
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w
tts
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p
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LS
O N
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n O
W
(n1-1
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0
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'-' '~ ~ x
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Ti H raN
H
m tn
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E r-I S-~ 1a S-~ ~ ~ ~ ~ >r 1a ~ r-Ira
'~ ~
O cC U U U
~ ~
't3rl o~ dv dv 3E dv 3v ~ 3s dv O w
1-~ d
~
U ~ u1 W W nr1 W uW nr1 uW 4~
a~ 1 V1
U U I I I I 1 1 I I I I 1 >,
cd 1~ O O O O O O O O O O rl rl ~ O O O O ~
a1 O 1-a O
O ~ U V U U U U U U U U z H z ~ U U U U U
3 U U
~
N
i~
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w >
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41 ''a tQ N
ri 1..~ S-i r-1
a, a w a
ro ~
W O X
0
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1
- -5~- 211094'
Example 13
As shown in Table 13, 4 kinds of samples of
insert materials (which are samples prepared by
electroplating one surface of a sheet-like core material
consisting of Fe and stainless steel with Ni as a coated
layer, and other samples consisting of Ni foil and Ti
foil) were prepared for use in the process of the
invention. Further, 2 kinds of samples of insert
materials (Cu and Ag) other than those used for the
example of the invention were prepared as comparative
examples.
Then, the resistance spot welding was carried out
according to the following procedure as to both the
cases where the sample of each insert material was used
and not used.
The insert materials 9 and 10 each having the
size of 30 x 200 mm were interposed respectively between
the upper and under electrodes 1 and 2 (radiused
electrodes each consisting of Cr-Cu alloy of 16 mm in
diameter, which corresponds to the second group of JIS Z
3234, and having the radiused tip end of 150 mm in R)
and the overlapped materials 11 and 12 (5182-O materials
each consisting of A1-Mg alloy and having the thickness
of 1 mm) each having the size of 30 x 200 mm, and the
single phase DC resistance welding machine having the
structure shown in Fig. 1 was used to carry out the
welding up to 12000 times of continuous spot welding on
- 58 - 211094
welding conditions of welding current: 22000A, electrode
force: 1960N, weld time: 8 cycles and 30 mm pitch: 5
spots.
The additional conditions were similar to those
in the case of example 1.
Then, with respect to each case; the electrode
life was evaluated similarly to the case of example 1.
The results thus obtained are shown in Table 13
with other data.
0
0
0
N
G
N N
4-i ,G O O
b0
rl J, _ _ _ ~f1 M
G:
rl ~l1 ~D N
rl
N
N 1a
H
'~ O
N
O
3
H
1~ 4~
1~
U O
O
a~ z
a.
w
.-
00
G
0 0
a~ G O O
U
r-I ~ 00 00
rl
o
N O
~
W
c~ tn
rl W
H N
x ~ ~ -,
H
N
3 H
0
a~
a~ .-i E
~
ro ~ G
~
o
H c~
v ~ H H
a
M N '
b0
G
N ~ r1 a~ m O O ~ M O
~
.-I H J~ p u1 O M I~ a0 vp
U
p d r-I ~ a0 uW ? O o~
rl
o
ccf fn v O .~ ~ ~ ,--i
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H
d
'O N
G ~
x
U ~ O O tn u1 O O
d ri ~ ~f1 u1 N N uW !1
'L3
O H
H
H
v ~n N
rl r1 8 ~ R.
W ~ ~ r-1 O
ri '-I rl C'.. U E..~
I-~ N L: ri N
r-I
a~ x ~o G
v +~ o ~s H
a~
~ H
z H H cn w cn
cn
H
H a~ H
b
_ ~ _
a
v~ o ~n
!.-i 4-~ U Ir
O rl d rl O
fs, f~, cn w z
G
0
O
G
d
N cb
~ N
~ H
G
a ~a
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v~ 6 A.
8
ro ~
a~ ro
o
x
U W U
~ N
2I~094'~
- 60 -
As apparent from Tables 2 to 13, Examples 2 to 13
have a tendency to obtain approximately similar results
to that of Example 1 (provided that no peel test for the
insert materials was made in Examples 2, 7 and 10).
Namely, in any example of the resistance welding process
according to the invention, the electrode life could
attain to not less than 12000 times of spot welding.
However, in each comparative example, the electrode life
could not reach 1800 times of spot welding.
As has been described above, according to the
resistance welding process for aluminum and aluminum
alloy materials of the invention, the electrode life can
be remarkably improved, and the resistance spot welding
can be carried out without damaging the surface of the
product.
