Additive Edge Layer for AlSi-Coated Boron Steel Laser Welding
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Solution Overview
Problem
The presence of aluminum from AlSi-coated boron steel coatings in the molten weld pool during laser welding of tailor welded blanks impedes the complete thermal transformation of the weld into an ultra-high strength material, resulting in a weaker weld compared to the blanks.
Innovation Solution
A method involving the formation of an additive layer on the side surfaces of the blanks devoid of the coating, using a powder laser deposition process, where the additive layer is formed of the same or different material as the blanks, allowing laser welding without irradiating the coating, thus preventing aluminum from the coating from entering the weld pool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If AlSi-coated boron steel blanks are laser welded directly, then the welding process is simple and fast, but aluminum from the coating enters the weld pool and impedes thermal transformation, resulting in weaker weld strength
Solution Approach 1:
An additive layer is deposited on the blank surface before welding to create a barrier that prevents aluminum from the AlSi coating from entering the weld pool. This preliminary action ensures that when laser welding occurs, the weld pool remains free of aluminum contamination, enabling complete thermal transformation and achieving weld strength comparable to the base material while maintaining welding efficiency
2Strength
If an additive layer is formed on the blank surface before welding, then aluminum is prevented from entering the weld pool and weld strength is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The additive layer serves as an intermediary barrier between the AlSi coating and the weld pool. This intermediate layer prevents direct contact and aluminum transfer during welding, ensuring weld strength comparable to the base material. The process integrates the additive layer formation and welding in a streamlined sequence, managing complexity through systematic process integration
3Quantity of substance
If the additive layer thickness is increased to ensure complete aluminum prevention, then weld pool purity is improved, but the material usage and processing time increase
Solution Approach 1:
The thickness of the additive layer is optimized to a specific range that provides sufficient barrier function to prevent aluminum from the AlSi coating from reaching the weld pool, while avoiding excessive material deposition. This parameter optimization ensures complete aluminum prevention in the weld pool and enables efficient thermal transformation, achieving ultra-high strength properties without unnecessary material usage or processing time extension
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method ensures the formation of a weld pool devoid of aluminum, enabling complete and consistent thermal transformation into an ultra-high strength material during thermal-hardening, resulting in a weld strength comparable to the blanks.
Implementation Method 1
the laser irradiates a material of the additive layer without irradiating the coating to form a weld pool
Implementation Method 2
forming an additive layer on at least one of the side surfaces that is devoid of the coating, and includes laser welding the first blank including the additive layer
Data Source
AI summary
The present disclosure provides a method that includes providing a first blank including an upper major surface, a lower major surface, and a plurality of side surfaces that connect the lower major surface to the upper major surface. The upper and lower major surfaces each includes a coating that includes aluminum, and the side surfaces are devoid of the coating. The method also includes forming an additive layer on at least one of the side surfaces that is devoid of the coating, and includes laser welding the first blank including the additive layer to a second blank, wherein a thickness of the additive layer is such that during the laser welding, the laser irradiates a material of the additive layer without irradiating the coating to form a weld pool that includes the material of the additive layer and does not include the aluminum of the coating.