Angled Single Laser Weld Geometry for Lower Heat-Affected Zones
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Laser welding processes often result in defects such as blowouts and residual stresses due to heat-affected zones, which can lead to material property degradation and cracking, especially when multiple welds are applied, increasing the risk of part failure.
Innovation Solution
A method of forming a single, angled hourglass-shaped weld by adjusting the laser's angle and focal point to create a junction with specific surface and root length ratios, using a laser power range of 2 kW to 6 kW and a spot size of 200 to 600 micrometers, and optionally preheating the components to reduce heat-affected zones and enhance weld strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If double welds are applied to reduce defects, then weld strength is improved, but heat-affected zones increase causing more microstructure disruption and residual stresses
Solution Approach 1:
The patent combines two weld passes into a single continuous laser welding operation by positioning the laser beam at a specific angle (5-35 degrees from perpendicular) to the faying surface. This merging approach creates an hourglass-shaped weld that achieves the strength benefits of double welds while eliminating the need for separate heating and cooling cycles, thereby reducing heat-affected zone disruption and residual stress accumulation.
Solution Approach 2:
The patent introduces a new dimension by tilting the laser beam angle away from the conventional perpendicular position. This angular deviation creates a three-dimensional hourglass-shaped weld profile with controlled surface and root dimensions, allowing the weld to achieve adequate strength while minimizing the volume of heat-affected material through optimized geometric configuration.
2Productivity
If laser welding is applied to join components, then productivity is improved, but blowouts and weld root notches occur causing defects
Solution Approach 1:
The patent changes critical welding parameters by optimizing the laser beam angle (5-35 degrees from perpendicular) and controlling the welding speed (1.00-3.00 meters per minute). These parameter adjustments transform the conventional weld profile into an hourglass shape with controlled surface and root dimensions, preventing blowouts and root notches while maintaining high welding productivity through continuous single-pass operation.
3Strength
If more heat cycles are applied, then weld penetration is improved, but cracking incidence increases in the heat affected zone
Solution Approach 1:
The patent implements continuous useful action by performing the entire weld in a single continuous laser pass rather than multiple discrete heat cycles. The tilted laser beam creates an hourglass-shaped melt pool that continuously progresses through the material, achieving adequate penetration while avoiding the repeated heating and cooling cycles that cause thermal fatigue and cracking in conventional multi-pass welding.
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 achieves a smooth weld finish, reduces heat-affected areas, and increases weld strength by forming a single hourglass-shaped weld that minimizes cracking and enhances loading conditions, while allowing for precise control over fusion properties.
Implementation Method 1
irradiating at least one of a) the first front surface of the first component and b) the second front surface of the second component at the interface with a laser
Implementation Method 2
melting the first faying surface and second faying surface and forming a melt pool at the interface
Implementation Method 3
focusing the laser at a focal point between the first front surface and the first back surface at a distance in the range of 35 percent to 65 percent of a thickness of the first component
Data Source
AI summary
Angled, single laser weld and a method of forming an angled, single laser weld including arranging a first and second faying surfaces of a first and second component adjacently to form an interface between the components; irradiating at least one of the first and second components at the interface with a laser, wherein the first faying surface defines a plane formed at an angle alpha in the range of +/â5 degrees to 60 degrees from an axis A perpendicular to the first front surface and the second faying surface matches the first faying surface; and forming a junction at the interface with an hourglass shaped weld.