U.S. patent application number 09/969066 was filed with the patent office on 2003-04-03 for method for metallurgically attaching together two members.
Invention is credited to Ananthanarayanan, Venkatasubramanian, Herbst, Desra N., Szeszulski, Kevin J..
Application Number | 20030062343 09/969066 |
Document ID | / |
Family ID | 25515128 |
Filed Date | 2003-04-03 |
United States Patent
Application |
20030062343 |
Kind Code |
A1 |
Ananthanarayanan,
Venkatasubramanian ; et al. |
April 3, 2003 |
METHOD FOR METALLURGICALLY ATTACHING TOGETHER TWO MEMBERS
Abstract
A first method for metallurgically attaching together two
members. A first member is obtained having a through hole and
having a longitudinally-projecting flange surrounding the through
hole. A second member is obtained having a transversely-projecting
annular rim. The second member is at least partially positioned in
the through hole of the first member with the flange of the first
member projecting away from the rim. The first and second members
are resistance welded together, wherein after the weld is created,
the rim of the second member is seated on the first member. In an
other method, which is similar to the first method, the second
member has no rim.
Inventors: |
Ananthanarayanan,
Venkatasubramanian; (Beavercreek, OH) ; Herbst, Desra
N.; (Dayton, OH) ; Szeszulski, Kevin J.; (Bay
City, MI) |
Correspondence
Address: |
Scott A. McBain
Delphi Technologies, Inc.
P.O. Box 5052
Mail Code: 480-414-420
Troy
MI
48007-5052
US
|
Family ID: |
25515128 |
Appl. No.: |
09/969066 |
Filed: |
October 2, 2001 |
Current U.S.
Class: |
219/107 ;
219/117.1; 219/59.1 |
Current CPC
Class: |
B23K 11/002 20130101;
B23K 33/006 20130101; B23K 33/00 20130101 |
Class at
Publication: |
219/107 ;
219/117.1; 219/59.1 |
International
Class: |
B23K 009/02 |
Claims
1. A method for metallurgically attaching together two members
comprising the steps of: a) obtaining a first member including a
through hole having a longitudinal axis and first and second
longitudinal ends and including a longitudinally-projecting flange
surrounding the through hole; b) obtaining a second member
including a transversely-projecting annular rim; c) after steps a)
and b), at least partially disposing the second member in the
through hole of the first member with the flange of the first
member projecting away from the rim of the second member; and d)
after step c), resistance welding together the first and second
members so as to create a weld, wherein after the weld is created,
the rim of the second member is seated on the first member at the
first longitudinal end of the through hole.
2. The method of claim 1, wherein the first member is a plate, and
wherein the through hole is a substantially circular through
hole.
3. The method of claim 2, wherein the second member is a tube.
4. The method of claim 3, wherein the tube and the through hole do
not have an interference fit, and wherein step c) fully disposes
the tube in the through hole of the plate with the rim of the tube
seated on the plate at the first longitudinal end of the through
hole.
5. The method of claim 4, wherein step d) includes longitudinally
engaging the flange of the plate with a first electrode shaped to
create interference between the flange and the tube, longitudinally
engaging the rim of the tube with a second electrode, passing
electric current between the first and second electrodes through
the plate and the tube, and relatively moving the first and second
electrodes longitudinally toward each other.
6 The method of claim 5, wherein step d) creates a resistance weld
between the flange of the plate and the tube.
7 The method of claim 6, wherein step d) also creates a resistance
weld between the plate and the rim of the tube after creating the
resistance weld between the flange of the plate and the tube.
8. The method of claim 4, wherein step d) includes longitudinally
engaging the plate with a first electrode, longitudinally engaging
the rim of the tube with a second electrode, and passing electric
current between the first and second electrodes through the plate
and the tube, wherein the first electrode does not longitudinally
engage the flange of the plate.
9 The method of claim 8, wherein step d) creates a resistance weld
between the plate and the rim of the tube.
10. The method of claim 3, wherein the tube and the through hole
have an interference fit, and wherein step c) only partially
disposes the tube in the through hole of the plate.
11 The method of claim 10, wherein step d) includes longitudinally
engaging the flange of the plate with a first electrode,
longitudinally engaging the rim of the tube with a second
electrode, passing electric current between the first and second
electrodes through the plate and the tube, and relatively moving
the first and second electrodes longitudinally toward each other
until the rim of the tube is seated on the plate at the first
longitudinal end of the through hole.
12. The method of claim 11, wherein step d) creates a resistance
weld between the flange of the plate and the tube.
13. The method of claim 12, wherein step d) also creates a
resistance weld between the plate and the rim of the tube.
14. The method of claim 3, wherein step d) creates a resistance
weld between the flange of the plate and the tube.
15. The method of claim 14, wherein step d) also creates a
resistance weld between the plate and the rim of the tube.
16. The method of claim 3, wherein step d) creates a resistance
weld between the flange of the plate and the tube.
17. A method for metallurgically attaching together a first member
and a second member comprising the steps of: a) creating a through
hole in the first member so as to produce an annular flange
surrounding the through hole, wherein the through hole has a
longitudinal axis, first and second longitudinal ends, and
substantially matches a first portion of the second member, and
wherein the flange projects longitudinally away from the first
member; b) creating an annular rim in the second member proximate
the first portion, wherein the rim projects transversely away from
the first portion; c) after steps a) and b), at least partially
disposing the second member in the through hole of the first member
with the flange of the first member projecting away from the rim of
the second member; and d) after step c), resistance welding
together the first and second members so as to create a weld,
wherein after the weld is created, the rim of the second member is
seated on the first member at the first longitudinal end of the
through hole.
18. The method of claim 17, wherein the first member is a plate,
wherein the through hole is a substantially circular through hole,
wherein the second member is a tube, and wherein the first portion
of the tube has a substantially circular outside diameter.
19. The method of claim 18, wherein step d) creates a resistance
weld between the flange of the plate and the tube.
20. The method of claim 18, wherein step d) creates a resistance
weld between the plate and the rim of the tube.
21. A method for metallurgically attaching together an inlet/outlet
tube to a vehicle fuel tank cover comprising the steps of: a)
obtaining a vehicle fuel tank cover including a through hole having
a longitudinal axis and first and second longitudinal ends and
including a longitudinally-projecting flange surrounding the
through hole; b) obtaining an inlet/outlet tube including a
transversely-projecting annular rim; c) after steps a) and b), at
least partially disposing the inlet/outlet tube in the through hole
of the vehicle fuel tank cover with the flange of the vehicle fuel
tank cover projecting away from the rim of the inlet/outlet tube;
and d) after step c), resistance welding together the vehicle fuel
tank cover and the inlet/outlet tube so as to create a weld,
wherein after the weld is created, the rim of the inlet/outlet tube
is seated on the vehicle fuel tank cover at the first longitudinal
end of the through hole, and wherein the inlet/outlet tube
longitudinally extends beyond the second longitudinal end of the
through hole.
22. A method for metallurgically attaching together two members
comprising the steps of: a) obtaining a first member including a
through hole having a longitudinal axis and first and second
longitudinal ends and including a longitudinally-projecting flange
surrounding the through hole; b) obtaining a second member; c)
after steps a) and b), at least partially disposing the second
member in the through hole of the first member; and d) after step
c), resistance welding together the first and second members so as
to create a weld.
Description
TECHNICAL FIELD
[0001] The present invention relates generally to metallurgy, and
more particularly to a method for metallurgically attaching
together two members.
BACKGROUND OF THE INVENTION
[0002] Resistance welding (also known as electric-resistance
welding) is a known metallurgical process wherein metal is heated
by its own resistance to a semi-fused or fused state by the passage
of very heavy electric currents for very short lengths of time and
then welded by the application of pressure.
[0003] Conventional methods for metallurgically attaching together
two parts also include a known method for metallurgically attaching
together an inlet/outlet tube to a vehicle fuel tank cover. In the
known method, a sheetmetal plate of low-carbon steel is obtained
for the vehicle fuel tank cover, and a low-carbon steel tube is
obtained for the inlet/outlet tube. A through hole is punched in
the plate creating a flange which surrounds the through hole and
which projects longitudinally away from the plate. Forming
operations on the tube create a transversely-projecting annular rim
on the tube. The tube is sized so that it is insertable in the
through hole so as to longitudinally extend beyond both
longitudinal ends of the through hole. The tube is inserted in the
through hole so that the rim of the tube is seated on the plate and
the flange of the plate projects away from the rim. Then, the tube
and the plate are brazed together near the through hole.
[0004] For the brazing operation, a furnace is required having
specific temperatures and temperature gradients. The furnace must
be kept with a controlled reducing atmosphere to remove the oxides
from the plate and the tube before the brazing is actually
performed. Also, a copper ring must be used for the filler material
to perform the brazing. A ceramic chain pulley mechanism is
required to move the parts through the furnace.
[0005] What is needed is a less expensive method for
metallurgically attaching together two members, such as
metallurgically attaching together an inlet/outlet tube to a
vehicle fuel tank cover.
SUMMARY OF THE INVENTION
[0006] A first method of the invention is for metallurgically
attaching together two members. The method includes steps a)
through d). Step a) includes obtaining a first member having a
through hole with a longitudinal axis and first and second
longitudinal ends and having a longitudinally-projecting flange
surrounding the through hole. Step b) includes obtaining a second
member having a transversely-projecting annular rim. Step c)
includes, after steps a) and b), at least partially disposing the
second member in the through hole of the first member with the
flange of the first member projecting away from the rim of the
second member. Step d) includes, after step c), resistance welding
together the first and second members so as to create a weld,
wherein after the weld is created, the rim of the second member is
seated on the first member at the first longitudinal end of the
through hole.
[0007] In one application of the first method, the first member is
a plate, such as a vehicle fuel tank cover, and the second member
is a tube, such as an inlet/outlet tube. In one implementation,
step d) creates a resistance weld between the flange of the plate
and the tube. In another implementation, step d) creates a
resistance weld between the plate and the rim of the tube. In an
additional implementation, step d) first creates a resistance weld
between the flange of the plate and the tube and then creates a
resistance weld between the plate and the rim of the tube.
[0008] An other method of the invention is for metallurgically
attaching together two members. The other method includes steps a)
through d). Step a) includes obtaining a first member having a
through hole with a longitudinal axis and first and second
longitudinal ends and having a longitudinally-projecting flange
surrounding the through hole. Step b) includes obtaining a second
member. Step c) includes, after steps a) and b), at least partially
disposing the second member in the through hole of the first
member. Step d) includes, after step c), resistance welding
together the first and second members so as to create a weld.
[0009] In one application of the other method, the first member is
a plate, such as a vehicle fuel tank cover, and the second member
is a tube, such as an inlet/outlet tube. The other method is useful
when it is desired only to create a resistance weld between the
flange of the plate and the tube, and for this weld, as can be
appreciated by the artisan, the tube does not require a rim.
[0010] Several benefits and advantages are derived from the
invention. Resistance welding is less expensive than brazing. In
the application for metallurgically attaching together a vehicle
fuel tank cover and an inlet/outlet tube, instead of costing about
one dollar per attachment it is expected to cost only a few cents
per attachment.
SUMMARY OF THE DRAWINGS
[0011] FIG. 1 is a schematic, side cross-sectional view of an
unattached first member in the form of a plate, having a through
hole, and of an unattached second member in the form of a tube;
[0012] FIG. 2 is a schematic, side cross-sectional view of the
first and second members of FIG. 1 metallurgically attached
together by one method of the invention;
[0013] FIG. 3 is a schematic, side cross-sectional view of the
plate and tube of FIG. 1, wherein the tube has a non-interference
fit with the through hole, and also including first and second
electrodes with the first electrode shaped and positioned for
creating an interference fit with the flange of the plate and a
resistance weld between the flange of the plate and the tube;
[0014] FIG. 4 is a view, as in FIG. 3, but with different first and
second electrodes, wherein the tube has a non-interference fit with
the through hole, and wherein the first electrode has a
non-interference fit with the flange and is seated on the surface
of the plate for creating a resistance weld between the plate and
the rim of the tube; and
[0015] FIG. 5 is a view, as in FIG. 3, but with different first and
second electrodes and a different tube, wherein the tube has an
interference fit with the through hole, and wherein the first
electrode is shaped and positioned to longitudinally engage the
flange of the plate for creating a resistance weld between the
flange of the plate and the tube.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Referring to FIGS. 1-2, wherein like numerals represent like
elements throughout, a first method of the invention is for
metallurgically attaching together two members comprising steps a)
through d). Step a) includes obtaining a first member 10 including
a through hole 12 having a longitudinal axis 14 and first and
second longitudinal ends 16 and 18 and including a
longitudinally-projecting flange 20 surrounding the through hole
12. Step b) includes obtaining a second member 22 including a
transversely-projecting annular rim 24. Step c) includes, after
steps a) and b), at least partially disposing the second member 22
in the through hole 12 of the first member 10 with the flange 20 of
the first member 10 projecting away from the rim 24 of the second
member 22. Step d) includes, after step c), resistance welding
together the first and second members 10 and 22 so as to create a
weld (two annular welds 26 and 28 are shown in FIG. 2), wherein
after the weld 26 and 28 is created, the rim 24 of the second
member 22 is seated on the first member 10 at the first
longitudinal end 16 of the through hole 12. It is noted that
resistance welding is also known as electric-resistance
welding.
[0017] In one example, the first member 10 is a plate 30, and the
through hole 12 is a substantially circular through hole. In one
construction, the plate 30 is a sheet metal plate and comprises low
carbon steel such as AISI 1008 to 1010. In the same or different
example, the second member 22 is a tube 32. In one construction,
the tube 32 comprises low carbon steel such as AISI 1008 to 1010.
In one application, the plate 30 is a vehicle fuel tank cover
having a thickness of generally 2 millimeters, the through hole 12
has a diameter of generally 6 to 7 millimeters, and the flange 20
projects generally at least 4 millimeters from the plate 30. In
this application, the tube 32 is an inlet/outlet tube having a wall
thickness of generally 2 millimeters and an outside diameter equal
to the diameter of the through hole 12 plus or minus one
millimeter. The rim 24 of the tube 32 projects generally 2
millimeters. After the weld 26 and 28 is created, the tube 32
longitudinally extends beyond the second longitudinal end 18 of the
through hole 12. Other examples of the first and second members,
their purposes, shapes, compositions, and dimensions, etc. are left
to the artisan. Although the following discussion is presented in
terms of a plate and tube, it is understood to apply to any first
and second member.
[0018] In one implementation of the first method, as seen in FIGS.
3 and 4, the tube 32 and the through hole 12 do not have an
interference fit. Here, step c) fully disposes the tube 32 in the
through hole 12 of the plate 30 with the rim 24 of the tube 32
seated on the plate 30 at the first longitudinal end 16 of the
through hole 12.
[0019] Referring to FIG. 3, in one modification of this
implementation step d) includes longitudinally engaging the flange
20 of the plate 30 with a first electrode 34 shaped (such as with
an angled surface as seen in FIG. 3) to create interference between
the flange 20 and the tube 32, longitudinally engaging the rim 24
of the tube 32 with a second electrode 36, passing electric current
between the first and second electrodes 34 and 36 through the plate
30 and the tube 32, and relatively moving the first and second
electrodes 34 and 36 longitudinally toward each other. Unnumbered
arrows in the figures indicate the direction for relatively moving
together, and applying pressure to, the electrodes. In one
variation, step d) creates a resistance weld 26 between the flange
20 of the plate 30 and the tube 32. When annular electrodes 34 and
36 are used, the resistance weld 26 is an annular weld. In one
example (the vehicle fuel tank cover and inlet/outlet tube
example), pulses (totaling generally 1/3 of a second) of electric
current of generally 5,000 amperes are applied while applying a
force of generally 300 to 800 pounds to the electrodes 34 and 36.
This softens and deforms the flange 20 into an interference fit
against the tube 32 as the first electrode 34 moves down the flange
20 to the surface of the plate 30. In another variation, step d)
also creates a resistance weld 28 between the plate 30 and the rim
24 of the tube 32 after creating the resistance weld 26 between the
flange 20 of the plate 30 and the tube 32. In one example, after
weld 26 is created and the first electrode 34 is forcibly seated
(with generally 300 to 800 pounds of force) against the surface of
the plate 30, more electric current is applied for generally 1/3 of
a second at generally 15,000 to 20,000 amperes to create weld 28.
In the same or another example, during welding an
electrically-insulating support (not shown) is disposed between the
second electrode 36 and the plate 30 radially outward from the rim
24.
[0020] Referring to FIG. 4, in another modification of this
implementation, step d) includes longitudinally engaging the plate
30 with a first electrode 38, longitudinally engaging the rim 24 of
the tube 32 with a second electrode 40, and passing electric
current between the first and second electrodes 38 and 40 through
the plate 30 and the tube 32, wherein the first electrode 38 does
not longitudinally engage the flange 20 of the plate 30. In one
variation, step d) creates a resistance weld 28 between the plate
30 and the rim 24 of the tube 32. In one example (the vehicle fuel
tank cover and inlet/outlet tube example), the first electrode 34
is forcibly seated (with generally 300 to 800 pounds of force)
against the surface of the plate 30, and electric current is
applied for generally 1/3 of a second at generally 15,000 to 20,000
amperes to create weld 28. In the same or another example, during
welding an electrically-insulating support (not shown) is disposed
between the second electrode 40 and the plate 30 radially outward
from the rim 24. It is noted that the gap between the tube 32 and
the flange 20 may be less than that shown in FIG. 4 and adjusted to
promote a suitable weld current path.
[0021] In another implementation of the first method, as seen in
FIG. 5, a different tube 42 and the through hole 12 do have an
interference fit. Here, step c) only partially disposes the tube 42
in the through hole 12 of the plate 30 (such as through a lead-in
chamfer). Step d) includes longitudinally engaging the flange 20 of
the plate 30 with a first electrode 44, longitudinally engaging the
rim 24 of the tube 42 with a second electrode 46, passing electric
current between the first and second electrodes 44 and 46 through
the plate 30 and the tube 42, and relatively moving the first and
second electrodes 44 and 46 longitudinally toward each other until
the rim 24 of the tube 42 is seated on the plate 30 at the first
longitudinal end 16 of the through hole 12. In one variation, step
d) creates a resistance weld between the flange 20 of the plate 30
and the tube 42 (in a similar manner to the previously-described
creation of weld 26 for tube 32). In another variation, step d)
also creates a resistance weld between the plate 30 and the rim 24
of the tube 42 (in a similar manner to the previously-described
creation of weld 28 for tube 32) after creating the resistance weld
between the flange 20 of the plate 30 and the tube 42.
[0022] A second method of the invention is for metallurgically
attaching together a first member 10 and a second member 22. The
second method includes steps a) through d). Step a) includes
creating a through hole 12 in the first member 10 so as to produce
an annular flange 20 surrounding the through hole 12, wherein the
through hole 12 has a longitudinal axis 14, first and second
longitudinal ends 16 and 18, and substantially matches a first
portion 48 of the second member 22, and wherein the flange 20
projects longitudinally away from the first member 10. Step b)
includes creating an annular rim 24 in the second member 22
proximate the first portion, wherein the rim 24 projects
transversely away from the first portion 48. Step c) includes,
after steps a) and b), at least partially disposing the second
member 22 in the through hole 12 of the first member 10 with the
flange 20 of the first member 10 projecting away from the rim 24 of
the second member 22. Step d) includes, after step c), resistance
welding together the first and second members 10 and 22 so as to
create a weld (two welds 26 and 28 are shown in FIG. 2), wherein
after the weld 26 and 28 is created, the rim 24 of the second
member 22 is seated on the first member 10 at the first
longitudinal end 16 of the through hole 12.
[0023] In one example of the second method, the first member 10 is
a plate 30, the through hole 12 is a substantially circular through
hole, the second member 22 is a tube 32, and the first portion 48
of the tube 32 has a substantially circular outside diameter. In
one implementation, step d) creates a resistance weld 26 between
the flange 20 of the plate 30 and the tube 32. In another
implementation, step d) creates a resistance weld 28 between the
plate 30 and the rim 24 of the tube 32.
[0024] A third method of the invention is for metallurgically
attaching together an inlet/outlet tube to a vehicle fuel tank
cover. The third method includes steps a) through d). Step a)
includes obtaining a vehicle fuel tank cover including a through
hole having a longitudinal axis and first and second longitudinal
ends and including a longitudinally-projecting flange surrounding
the through hole. Step b) includes obtaining an inlet/outlet tube
including a transversely-projecting annular rim. Step c) includes,
after steps a) and b), at least partially disposing the
inlet/outlet tube in the through hole of the vehicle fuel tank
cover with the flange of the vehicle fuel tank cover projecting
away from the rim of the inlet/outlet tube. Step d) includes, after
step c), resistance welding together the vehicle fuel tank cover
and the inlet/outlet tube so as to create a weld, wherein after the
weld is created, the rim of the inlet/outlet tube is seated on the
vehicle fuel tank cover at the first longitudinal end of the
through hole, and wherein the inlet/outlet tube longitudinally
extends beyond the second longitudinal end of the through hole.
[0025] In one embodiment, the previously-discussed electrodes are
installed in "T"-shaped electrode holders of a resistance welding
machine (not shown). In one example, not shown, each electrode is
formed from two sections which are brought together around the
corresponding one of the first and second members and engage that
member. The electrode sections have surfaces generally
corresponding to the shape of the engaged portion of that member.
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.
[0026] An other method of the invention is for metallurgically
attaching together two members. The other method includes steps a)
through d). Step a) includes obtaining a first member 10 having a
through hole 12 with a longitudinal axis 14 and first and second
longitudinal ends 16 and 18 and having a longituclinally-projecting
flange 20 surrounding the through hole 12. Step b) includes
obtaining a second member 22. Step c) includes, after steps a) and
b), at least partially disposing the second member 22 in the
through hole 12 of the first member 10. Step d) includes, after
step c), resistance welding together the first and second members
10 and 22 so as to create a weld 28.
[0027] In one application of the other method, the first member 10
is a plate 30, such as a vehicle fuel tank cover, and the second
member 22 is a tube 32, such as an inlet/outlet tube. The other
method is useful when it is desired only to create a resistance
weld 28 between the flange 20 of the plate 30 and the tube 32, and
for this weld 28, as can be appreciated by the artisan, the tube 32
does not require a rim 24. The actual welding can be visualized by
mentally replacing the rim 24 of the tube 32 in the figures and in
the previous discussion of the first, second, and third methods
with an electrical insulation portion of the resistance welding
apparatus, as can be understood by the artisan.
[0028] Several benefits and advantages are derived from the
invention. Resistance welding is less expensive than brazing. In
the application for metallurgically attaching together a vehicle
fuel tank cover and an inlet/outlet tube, instead of costing about
one dollar per attachment it is expected to cost only a few cents
per attachment.
[0029] The foregoing description of a several methods of the
invention has been presented for purposes of illustration. It is
not intended to be exhaustive or to limit the invention to the
precise procedure or precise form disclosed, and obviously many
modifications and variations are possible in light of the above
teaching. It is intended that the scope of the invention be defined
by the claims appended hereto.
* * * * *