Butt Laser Welding With Energy-Density Scanning for Gap Tolerance
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Solution Overview
Problem
Existing butt laser-welding methods face challenges in achieving high welding tolerance to gaps and height differences between metallic members without compromising productivity, as they often require complex processing to form acute-angle corners, which reduces efficiency.
Innovation Solution
A method where a laser beam is scanned across the butting surfaces with increasing irradiation energy density as it approaches the surfaces, causing molten pools to incline and flow into gaps, eliminating the need for surface processing and enhancing welding tolerance and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an acute-angle corner part is formed on a butting surface to improve welding tolerance to gaps and height differences, then welding quality improves, but additional processing is required which reduces productivity
Solution Approach 1:
The method performs preliminary action by forming a groove at the butting surface before welding. This groove preparation enables the laser beam to effectively bridge gaps and accommodate height differences during welding, improving welding tolerance without requiring complex additional processing during the welding operation itself.
Solution Approach 2:
The invention changes the geometric parameter of the butting surface by forming a groove with specific dimensions (depth and width). This parameter change allows the laser beam to maintain effective energy density distribution across varying gap sizes and height differences, achieving improved welding tolerance while keeping the process efficient.
2Manufacturing precision
If the laser beam scanning speed is reduced to increase irradiation energy density and improve welding tolerance, then welding quality improves, but welding speed decreases reducing productivity
Solution Approach 1:
The method applies local quality by creating a groove at the butting surface that concentrates and directs laser energy precisely where needed. This localized geometric feature allows the laser beam to maintain high effective energy density in the groove region, improving welding tolerance without requiring overall reduction of scanning speed, thus preserving productivity.
Solution Approach 2:
The invention introduces a dimensional change by forming a groove that adds depth to the butting surface. This third dimension allows the laser beam to interact with the workpiece in a way that enhances energy coupling and melting efficiency, improving welding tolerance while maintaining high scanning speeds.
3Manufacturing precision
If the laser beam is scanned to repeatedly cross butting surfaces to improve welding tolerance, then welding quality improves, but the laser beam may cross molten pools causing spatter generation
Solution Approach 1:
The groove formation serves as preliminary action that prepares the butting surface geometry before welding begins. This pre-formed groove guides the laser beam trajectory and contains the molten metal, allowing the laser to cross the butting surfaces multiple times to bridge gaps without the laser beam directly crossing unstable molten pools, thereby reducing spatter generation.
Solution Approach 2:
The groove acts as an intermediary structure between the laser beam and the molten metal. It provides a defined pathway that directs laser energy and contains molten material, preventing direct interaction between the laser beam and free-flowing molten pools that would cause spatter, while still enabling effective welding across gaps and height differences.
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 approach improves welding tolerance to gaps and height differences while maintaining high productivity by allowing the molten pools to bond easily across varying surfaces without requiring additional processing, and also prevents spatter generation by adjusting the scanning trajectory.
Implementation Method 1
a laser beam is scanned so as to repeatedly cross butting surfaces of metallic members to weld them to each other
Implementation Method 2
bottom surfaces of molten pools respectively formed on butted metallic members
Implementation Method 3
the molten pools respectively formed on the metallic members flow toward a gap due to gravity
Implementation Method 4
when the laser beam is scanned so as to cross the butting surfaces, the closer the laser beam comes to the butting surfaces, the more an irradiation energy density of the laser beam is increased
Data Source
AI summary
Provided is a butt laser-welding method for a metallic member in which a laser beam is scanned so as to repeatedly cross butting surfaces of metallic members to weld the metallic members to each other. When the laser beam is scanned so as to cross the butting surfaces, the closer the laser beam comes to the butting surfaces, the more an irradiation energy density of the laser beam is increased. The bottom surfaces of the molten pools formed on the metallic members are inclined so as to descend toward the butting surfaces.