Clad Slab Assembly with Laser Weld Geometry for Stable Rolling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for manufacturing clad steel plates face issues with electron beam deflection and laser beam penetration, leading to poor bonding and instability in the slab assembly process, resulting in inadequate penetration depth and thermal stress during rolling.
Innovation Solution
The method involves forming deep, long, and narrow metal welds using laser beam welding in a vacuum atmosphere, with controlled dimensions and angles to ensure the deepest portions of the welds are within the base metal plates, and using a spacer to prevent laser beam penetration through, thereby achieving stable and efficient clad steel plate production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electron beam welding is used to join base metal plate and cladding plate, then welding can be performed in vacuum atmosphere, but electron beam deflects due to thermoelectromotive force and magnetic property differences, causing insufficient penetration depth
Solution Approach 1:
The patent replaces electron beam welding with laser beam welding. Laser beams are not deflected by magnetic fields or thermoelectromotive forces, eliminating the beam deviation problem that causes insufficient penetration depth. The laser beam maintains precise targeting while welding the base metal plate and cladding plate in vacuum atmosphere.
Solution Approach 2:
The patent changes the welding method from electron beam to laser beam, fundamentally altering the energy delivery parameters. This parameter change eliminates susceptibility to magnetic field interference and thermoelectromotive force effects, ensuring consistent penetration depth and welding reliability.
2Manufacturing precision
If laser beam welding is used to join base metal plate and spacer, then welding precision is improved, but laser beam may penetrate through the spacer and reach the cladding plate, causing poor bonding
Solution Approach 1:
The patent specifies that the laser beam welding parameters are controlled in advance to ensure the weld depth reaches the cladding plate but does not penetrate through it. The welding is performed with predetermined parameters that achieve sufficient bonding without excessive penetration that would compromise the cladding plate integrity.
Solution Approach 2:
The patent carefully controls laser beam parameters (power, speed, focal position) to achieve the optimal penetration depth. By adjusting these parameters, the weld reaches sufficient depth to bond the base metal plate to the cladding plate while preventing penetration through the cladding plate that would cause poor bonding quality.
3Productivity
If clad steel plate is heated and rolled, then productivity and dimensional accuracy are improved, but thermal stress occurs during heating and flow stress during rolling, destroying small penetration depth portions
Solution Approach 1:
The patent ensures that laser beam welding creates sufficient penetration depth in advance, forming strong bonds between the base metal plate and cladding plate before heating and rolling. This preliminary strong bonding prevents destruction of the contact surface during subsequent thermal and mechanical processing.
Solution Approach 2:
The patent creates an excess of penetration depth during laser beam welding to provide a buffer against the thermal stress during heating and flow stress during rolling. This beforehand cushioning ensures that even with some degradation from subsequent processing, sufficient bonding strength remains to prevent contact surface destruction.
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 ensures tight contact between base metal and cladding plates, preventing thermal stress and improving bonding, allowing for efficient and stable manufacturing of clad steel plates with enhanced yield and adhesion.
Implementation Method 1
performing laser beam welding in a vacuum atmosphere to join the base metal plates and the spacer together
Implementation Method 2
performing laser beam welding in a vacuum atmosphere
Data Source
Figure 1~2
Figure 3~4
AI summary
Provided is a slab assembly that is composed of clad raw workpieces each including a base metal plate and a cladding plate stacked together. When the slab assembly is rolled to manufacture clad steel plates, the base metal plates and the respective cladding plate can be bought into sufficiently tight contact with each other, and clad steel plates can be manufactured efficiently and stably. Two clad raw workpieces are disposed such that their cladding plates face each other, and a release material is interposed between the cladding plates. A spacer is disposed along four sides of cladding plates. Welding is performed along abutting surfaces between each spacer and the base metal plates such that metal welds having respective deepest portions located inside the respective base metal plates are formed. Each abutting surface has a portion in which a corresponding metal weld forms a joint located in a region extending from a surface of the spacer to a position located at 50% or more and less than 100% of the thickness T5 of the spacer. A width W (mm) of each metal weld along the surface of a corresponding base metal plate, a length D (mm) of a straight line M connecting a center of the width W of the metal weld and its deepest portion, and an angle A(°) between the straight line M and a corresponding abutting surface satisfy D/W ≥ 5 and 1 ≤ A ≤ 15.