IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0386202
(2006-03-22)
|
등록번호 |
US-7498543
(2009-03-03)
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발명자
/ 주소 |
- Ruokolainen,Robert B.
- Hanna,Michael D.
|
출원인 / 주소 |
- GM Global Technology Operations, Inc.
|
인용정보 |
피인용 횟수 :
4 인용 특허 :
10 |
초록
▼
A method of joining or repairing metal surface structures. Joinder and/or repair of metal or metal-polymer laminate panels may be carried out using so-called "cold metal transfer" gas metal arc welding techniques. Moreover, suitable zinc-copper-aluminum alloys may improve weldability, durability an
A method of joining or repairing metal surface structures. Joinder and/or repair of metal or metal-polymer laminate panels may be carried out using so-called "cold metal transfer" gas metal arc welding techniques. Moreover, suitable zinc-copper-aluminum alloys may improve weldability, durability and strength. The reduced thermal input permits effective weld formation at the metal sheet layers without giving rise to temperature gradient sufficient to significantly damage the interior elements.
대표청구항
▼
The invention claimed is: 1. A method of joining or repair of a metal surface laminate construction, the laminate construction comprising a metal sheet with an outer metal surface layer and an opposing surface layer to which a polymer layer is bonded, the polymer layer being coextensive with the op
The invention claimed is: 1. A method of joining or repair of a metal surface laminate construction, the laminate construction comprising a metal sheet with an outer metal surface layer and an opposing surface layer to which a polymer layer is bonded, the polymer layer being coextensive with the opposing surface layer, the metal sheet having a thickness up to about one-half millimeter and the polymer layer being no thicker than the metal sheet, the method comprising the steps of: (a) providing at least a first laminate construction comprising at least a first outer metal surface layer with at least one polymer layer disposed on an opposing sheet surface layer below the first metal outer surface layer; (b) defining a desired weld line along said the first outer metal surface layer in which weld filler metal is deposited in contact with polymer material of the polymer layer; and (c) applying a substantially continuous weld along the defined weld line, by use of cold metal transfer gas metal arc welding, wherein a weld wire of filler metal comprising a zinc based alloy is cyclically inserted and withdrawn from a weld pool during weld application in coordination with activation and deactivation of arc heating, such that arc heating is terminated when the weld wire contacts the weld pool and arc heating is reactivated when the weld wire is withdrawn from with the weld pool, such that heat input to the laminate construction is limited for the purpose of minimizing thermal damage to the polymer material in the vicinity of the weld. 2. The invention as recited in claim 1, wherein said first metal surface layer comprises a steel alloy. 3. The invention as recited in claim 1, wherein the zinc based alloy consists essentially of, by weight, about 4 to 12 percent copper, about 2 to 8 percent aluminum, optionally up to 0.05 percent magnesium and the balance zinc and impurities. 4. The invention as recited in claim 1, wherein the zinc based alloy consists essentially of, by weight, about 3.5 to 4.5 percent copper, about 6.3 to 8 percent aluminum, optionally up to 0.05 percent magnesium and the balance zinc and impurities. 5. The invention as recited in claim 1, wherein the zinc based alloy consists essentially of, by weight, about 10 to 11 percent copper, about 2 to 4 percent aluminum, optionally up to 0.05 percent magnesium and the balance zinc and impurities. 6. A method of joining a pair of metal surface laminate constructions, the method comprising the steps of: (a) providing at least a first laminate construction and a second laminate construction, each of the laminate constructions comprising a first metal surface layer and second metal surface layer with at least one polymer layer disposed at a position between the surface layers, each of the metal surface layers of the laminate constructions having a thickness of up to about one-half millimeter and each of the polymer layers having a thickness of no more than about sixty percent of the thickness of its laminate; (b) positioning the first laminate construction in adjacent or overlapping contacting relation with the second laminate construction to define an interface between the first and second laminate constructions for a weld line to be formed in which weld filler metal is deposited in contact with a portion of at least one of the first and second laminate constructions such that the weld filler material extends at least entirely across the thickness of one of the metal surface layers and the thickness of the polymer layer of the at least one of the first and second laminate constructions; and (c) applying a substantially continuous weld along the weld line at the interface between the first and second laminate constructions by use of cold metal transfer gas metal arc welding, wherein a weld wire of filler metal comprising a zinc based alloy is cyclically inserted and withdrawn from a weld pool during weld application in coordination with activation and deactivation of arc heating, such that arc heating is terminated when the weld wire contacts the weld pool and arc heating is reactivated when the weld wire is withdrawn from with the weld pool, such that heat input to the interface is limited for the purpose of minimizing thermal damage to the polymer material in the vicinity of the weld. 7. The invention as recited in claim 6, wherein said first and second metal surface layers each comprises a steel alloy. 8. The invention as recited in claim 6, wherein the zinc based alloy consists essentially of, by weight, about 4 to 12 percent copper, about 2 to 8 percent aluminum, optionally up to 0.05 percent magnesium and the balance zinc and impurities. 9. The invention as recited in claim 6, wherein the zinc based alloy consists essentially of by weight, about 3.5 to 4.5 percent copper, about 6.3 to 8 percent aluminum, optionally up to 0.05 percent magnesium and the balance zinc and impurities. 10. The invention as recited in claim 6, wherein the zinc based alloy consists essentially of, by weight, about 10 to 11 percent copper, about 2 to 4 percent aluminum, optionally up to 0.05 percent magnesium and the balance zinc and impurities. 11. The invention as recited in claim 6, wherein at least one of the first laminate construction and the second laminate construction further comprises at least one interior metal layer disposed between the first metal surface layer and second metal surface layer. 12. The invention as recited in claim 6, wherein each of the first laminate construction and the second laminate construction further comprises at least one interior metal layer disposed between the first metal surface layer and second metal surface layer. 13. A method of forming a welded joint between two metal surface elements where at least one of the metal surface elements comprises a metal sheet having a thickness up to about one-half millimeter and the metal sheet has a polymer layer bonded to at least one side of the sheet, the polymer layer being no thicker than the sheet and lying in the vicinity of the welded joint, the method comprising the steps of: (a) providing a first metal surface element and a second metal surface element; (b) positioning the metal surface elements in contacting relation for a weld line to be formed along a surface element in which weld filler metal is deposited in contact with polymer material of the polymer layer; and (c) applying a weld along the weld line between the metal surface elements by use of cold metal transfer gas metal arc welding, wherein a weld wire of filler metal consisting essentially of, by weight, about 4 to 12 percent copper, about 2 to 8 percent aluminum, optionally up to 0.05 percent magnesium and the balance zinc and impurities is cyclically inserted and withdrawn from a weld pool during weld application in coordination with activation and deactivation of arc heating, such that arc heating is terminated when the weld wire contacts the weld pool and arc heating is reactivated when the weld wire is withdrawn from with the weld pool, such that heat input to the interface is limited for the purpose of minimizing thermal damage to the polymer material in the vicinity of the weld. 14. The invention as recited in claim 13, wherein the filler metal consists essentially of, by weight, about 4 percent copper, about 7.6 percent aluminum, optionally up to 0.05 percent magnesium and the balance zinc and impurities. 15. The invention as recited in claim 13, wherein the metal surface elements are disposed in overlapping relation at the interface. 16. The invention as recited in claim 13, wherein the metal surface elements are disposed in abutting relation at the interface.
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