Aluminum Laser Keyhole Welding Geometry to Suppress Sputtering
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Solution Overview
Problem
Laser welding of aluminum materials in electronic components faces issues with sputtering, leading to reduced welding strength and potential short circuits due to dirt accumulation on dirt-proof glasses, which affects the focus and energy delivery during the welding process.
Innovation Solution
A laser keyhole welding method that uses a combination of center and satellite output lights to form a keyhole with a tapered portion spread angle of 45° or less, increasing the molten pool's surface area and ensuring smooth vapor discharge, thereby reducing sputtering and enhancing the mechanical strength of the weld.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser welding is performed on aluminum materials, then electrical connection and mechanical strength are achieved, but sputtering occurs causing dirt accumulation on dirt-proof glass
Solution Approach 1:
The invention changes the key parameter of keyhole geometry by controlling the tapered portion spread angle to 45° or less. This parameter change transforms the keyhole shape to reduce vapor discharge turbulence, thereby suppressing sputtering while maintaining welding quality and electrical connection reliability
Solution Approach 2:
The invention converts the harmful sputtering effect into a beneficial outcome by optimizing the keyhole geometry. The controlled tapered portion angle redirects vapor discharge in a manner that reduces sputtering deposition on surrounding surfaces, including dirt-proof glass, while still achieving effective welding
2Object-affected harmful factors
If dirt-proof glass is used to prevent dirt adhesion, then protection is provided, but welding strength decreases due to focus shift and energy absorption
Solution Approach 1:
The invention extracts the root cause of sputtering (uncontrolled vapor discharge from poorly shaped keyholes) and eliminates it through geometric optimization. By removing the sputtering source, the dirt-proof glass remains clean and transparent, allowing full laser energy transmission and maintaining welding strength
Solution Approach 2:
The invention takes preliminary action by optimizing keyhole geometry before sputtering can occur. The controlled tapered portion angle prevents vapor discharge patterns that would cause sputtering, thereby proactively protecting the dirt-proof glass from contamination before it can affect welding quality
3Productivity
If mass production welding is performed, then productivity increases, but sputtering accumulation leads to defective phenomena
Solution Approach 1:
The invention establishes a stable parameter (tapered portion spread angle ≤45°) that ensures consistent welding quality across mass production. This parameter control prevents sputtering variation between welds, maintaining reliability and preventing defective phenomena even during high-volume production
Solution Approach 2:
The invention ensures continuous clean welding by preventing sputtering accumulation throughout the production process. The optimized keyhole geometry maintains stable vapor discharge patterns, allowing uninterrupted welding operations without quality degradation or defective phenomena
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 stabilizes the welding process by minimizing sputtering, ensuring reliable electrical connections and mechanically strong welds, even in mass production settings.
Implementation Method 1
laser keyhole welding structure of an aluminum material formed by irradiating a laser beam to the electronic component and welding an aluminum material element constituting an electronic component
Implementation Method 2
smooth vapor discharge
Implementation Method 3
stably suppress the generation of sputtering
Data Source
AI summary
Disclosed is a laser keyhole welding structure and a keyhole welding method of an aluminum material which stably suppress the generation of sputtering to ensure a reliable electrical connection and obtain a mechanically strong connection. To achieve this, a laser keyhole welding structure of an aluminum material is formed by welding an aluminum material element constituting an electronic component by irradiating a laser beam to the electronic component, in which a tapered portion spread angle (θ) of an upper portion of a welding nugget to be formed is 45° or less. Also disclosed is a laser keyhole welding structure of an aluminum material.