Laser Welding of Copper Using a High-Absorptance Surface
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Welding materials like copper exhibit low absorptance for laser beams in the near-infrared region, leading to unstable melting and difficulty in performing stable welding due to high reflectance, making it challenging to achieve consistent welds with existing methods.
Innovation Solution
The method involves preparing welding materials with distinct portions, where one portion has enhanced laser absorptance through surface processing, allowing for efficient absorption of the laser beam during welding, thereby stabilizing the melting process and enabling stable welding even with low-output laser beams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a laser beam is irradiated on copper welding material, then welding can be performed, but the absorptance is low and reflectance is high causing unstable melting
Solution Approach 1:
The patent applies preliminary action by performing surface treatment on the copper welding material before laser welding to enhance laser absorptance. The surface is treated to create a state that will effectively absorb the laser beam during the subsequent welding process, thereby resolving the contradiction between low absorptance and welding stability.
Solution Approach 2:
The patent changes the physical parameters of the copper surface through surface treatment, modifying surface properties such as roughness or composition to increase laser absorptance. This parameter change enables the copper material to absorb more laser energy, improving welding stability while maintaining the use of near-infrared laser beams.
2Productivity
If high-output laser beam is used to compensate for low absorptance, then welding can proceed, but sputtering increases and control precision decreases
Solution Approach 1:
By performing surface treatment beforehand to enhance absorptance, the patent enables the use of lower-output laser beams while maintaining welding productivity. This preliminary preparation allows precise control of the welding process without excessive sputtering, thereby resolving the contradiction between productivity and manufacturing precision.
Solution Approach 2:
The patent converts the harmful effect of high reflectance into a benefit by using surface treatment to create a surface that absorbs laser energy more effectively. This transformation allows the use of lower-power laser beams, reducing sputtering while maintaining welding speed and improving bead control precision.
3Use of energy by moving object
If surface processing is performed to enhance absorptance, then laser beam absorption improves, but additional process steps are required
Solution Approach 1:
The patent modifies surface parameters through treatment to enhance laser absorptance. While this adds a process step, the parameter change creates a surface state that significantly improves energy absorption, justifying the additional complexity by enabling reliable welding of copper materials with near-infrared lasers.
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 allows for stable welding with improved absorption of the laser beam, reducing sputtering, and enabling finer control over the bead width and depth, enhancing the overall welding process and quality.
Implementation Method 1
The laser absorptance of the second portion 12 is higher than a laser absorptance of the first portion 11... by irradiating a laser beam on the second portion 12
Data Source
AI summary
A welding method according to an embodiment includes a preparation process and a welding process. A first welding material and a second welding material are prepared in the preparation process. The first welding material and the second welding material are welded in the welding process by irradiating a laser beam on at least one of the first welding material or the second welding material. At least one of the first welding material or the second welding material includes a first portion and a second portion. A laser absorptance of the second portion is higher than a laser absorptance of the first portion. The first welding material and the second welding material are welded in the welding process by irradiating the laser beam on the second portion.