Dissimilar Metal Plate Joining With Alternating Sine-Wave Laser Loci
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Solution Overview
Problem
Existing methods for joining dissimilar metal plates, such as copper and aluminum, face challenges in maintaining consistent welding quality due to varying moving speeds of the laser beam along nonlinear paths, leading to reduced joint strength.
Innovation Solution
A method and apparatus that utilize a laser beam to form a sine-wave shaped welded part by reciprocating the irradiation point in a perpendicular direction, with specific amplitude and pitch ratios, and alternating irradiation loci to enhance joint strength by reinforcing weaker sections with stronger ones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a nonlinear irradiation locus (sine-wave shape) is used for laser beam welding, then the welding coverage and heat distribution are improved, but the moving speed of the irradiation point varies causing inconsistent welding quality and reduced joint strength
Solution Approach 1:
The patent applies periodic action by using multiple irradiation loci with sine-wave shapes that are separated in the perpendicular direction. Each locus follows a periodic sine-wave pattern, and by alternating between multiple loci, the system maintains consistent welding quality while distributing the heat input periodically across different paths.
Solution Approach 2:
The patent resolves the speed inconsistency by adding another dimension - separating irradiation loci in the perpendicular direction (width direction) rather than attempting to maintain constant speed along a single nonlinear path. This dimensional separation allows each locus to be simpler while collectively achieving better welding coverage and consistency.
2Area of stationary object
If multiple irradiation loci are drawn separated in the perpendicular direction, then the welding coverage is improved, but the complexity of the irradiation path control increases
Solution Approach 1:
The patent segments the welding path into multiple separate irradiation loci that are distributed in the perpendicular direction. Each locus is a simpler sine-wave pattern, and by dividing the overall welding task into these segmented paths, the system achieves broader coverage while keeping individual path control relatively simple.
3Strength
If the amplitude to pitch ratio is optimized, then the joint strength is improved, but the parameter optimization range becomes more constrained
Solution Approach 1:
The patent applies parameter changes by optimizing the amplitude to pitch ratio within a specific range (1.3 to 3.3) to achieve maximum joint strength. This controlled parameter optimization ensures consistent welding quality and strong joints, while the defined range provides sufficient adaptability for different material thicknesses and welding conditions.
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
The method and apparatus increase the joint strength of dissimilar metal plates by ensuring consistent welding volume and reducing heat-induced distortions, thereby enhancing the overall structural integrity.
Implementation Method 1
irradiating a laser beam onto the overlapping area to form a welded part in the overlapping area by heat caused by the irradiation of the laser beam
Data Source
AI summary
A method of joining a first metal plate and a second metal plate made of different materials, includes, a placement step of forming an overlapping area where the first and second metal plates are overlapped with each other, and a laser welding step of irradiating a laser beam onto the overlapping area and reciprocating the laser irradiation point in a first direction, while moving the irradiation point in a second direction perpendicular to the first direction to form a welded part along a sine-wave-shaped irradiation locus having an amplitude. In the welding step, a plurality of irradiation loci are drawn so as to be separated from each other in the first direction, and when seen in the second direction, one of the irradiation loci adjacent in the first direction to another irradiation locus is overlapped within a range of the amplitude of the other irradiation locus.