Beam Weld Seam Recess Layout to Prevent End Craters
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Solution Overview
Problem
In metal welding, particularly with aluminum components, elevations at the start or end of the weld seam can occur, leading to visible imperfections and potential weakening of the joint, necessitating additional machining to remove these elevations.
Innovation Solution
The weld seam is designed with a main section along the joint gap and start/end sections that lead out of the joint gap into a component with local depressions, allowing the weld material to be absorbed and eliminating the need for rework by creating sufficient space for the welding material, thereby avoiding elevations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the weld seam is produced by beam welding process, then the joining strength is improved, but elevations and end craters occur at the start and end sections causing visible imperfections and potential weakening
Solution Approach 1:
The method applies preliminary action by creating a depression in the workpiece surface at the start and/or end sections before welding. This depression is prepared in advance to accommodate the weld metal that would otherwise form elevations, and to prevent end crater formation by providing a gradual transition zone for the weld pool
Solution Approach 2:
The invention applies local quality by creating a depression only at specific locations (start and/or end sections) where elevations and end craters typically occur, rather than modifying the entire weld path. This localized modification allows the weld seam to have different geometries in different sections, optimizing both strength and surface quality where needed
2Reliability
If the weld seam is extended into the component with local depression, then the formation of end craters is reduced, but the weld path becomes more complex
Solution Approach 1:
The depression is created as a preliminary feature in the workpiece before welding begins. This pre-prepared geometry guides the weld pool and accommodates the weld metal flow, reducing end crater formation without requiring complex real-time welding process adjustments
Solution Approach 2:
The depression structure serves multiple functions automatically: it accommodates weld metal to prevent elevations, provides a gradual transition zone to prevent end craters, and defines the weld pool geometry. The workpiece structure itself performs the function of controlling weld morphology without additional active control systems
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 design reduces the formation of end craters and avoids the need for rework, enhancing the strength and appearance of the weld joint by keeping the notch effect outside the joint gap.
Implementation Method 1
a weld produced by means of a beam welding process
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a joining connection comprising a weld seam (4) running between a first metal component (1) and a second metal component (2) and produced by means of a beam welding method. According to the invention, the weld seam (4) has a weld seam main section (4.1) extending along a joining gap (3) formed between the metal components (1, 2), the weld seam (4) has a weld seam starting section (4.2) leading from the direction of the joining gap (3) into the first or second component (1, 2), wherein the first or second component (1, 2) has a recess (2.4) in the region of the weld seam starting section (4.2) that is lowered in relation to the upper edges (1.2, 2.2) of the two components (1, 2) forming the joining gap (3), and/or the weld seam (4) has a weld seam end section (4.3) leading from the direction of the joining gap (3) into the first or second component (1, 2), wherein the first or second component (1, 2) has a recess (2.6) in the region of the weld seam end section (4.3) that is lowered in relation to the upper edges (1.2, 2.2) of the two components (1, 2) forming the joining gap (3). The invention also relates to a method for producing the joining connection according to the invention.