Copper Laser Welding with Main-Sub Beam Layout for Blowhole Control
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Solution Overview
Problem
Laser welding of copper workpieces often results in welding defects such as blowholes, particularly when attempting to increase weld depth, due to the difficulty in bonding copper materials which have high thermal conductivity.
Innovation Solution
A laser welding method and apparatus that utilize a beam configuration of a main beam and multiple sub-beams, with a power ratio of 72:1 to 3:7, where the sub-beams are arranged to surround the main beam, preventing defects by ensuring adequate weld depth and strength while reducing power consumption and increasing processing speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser welding is performed on copper workpiece with conventional single beam configuration, then processing speed can be maintained, but welding defects such as blowholes occur and weld depth is insufficient
Solution Approach 1:
The laser beam is segmented into a main beam and multiple sub-beams arranged in a matrix pattern. The main beam provides concentrated energy for deep penetration welding, while the sub-beams distribute energy to prevent blowholes and improve weld quality. This segmentation allows simultaneous achievement of high processing speed and high weld quality without compromising either parameter.
2Length of stationary object
If laser power is increased to increase weld depth in copper workpiece, then weld depth improves, but power consumption increases and processing speed decreases
Solution Approach 1:
Different regions of the workpiece receive different energy densities through the main beam and sub-beams configuration. The main beam delivers high energy density for deep penetration where needed, while sub-beams provide lower energy density to surrounding areas to prevent excessive heat input and blowhole formation. This local quality differentiation achieves adequate weld depth without requiring overall power increase, thus maintaining processing speed and reducing power consumption.
3Manufacturing precision
If laser power is increased to prevent blowholes, then weld quality improves, but processing speed decreases
Solution Approach 1:
The segmented beam structure with main beam and sub-beams allows simultaneous optimization of weld quality and processing speed. The sub-beams prevent blowholes by distributing energy to eliminate gas pockets, while the main beam maintains high energy concentration for rapid melting and welding. This segmentation enables high processing speed to be maintained without sacrificing weld quality or increasing overall power consumption.
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 described method effectively prevents the occurrence of welding defects like blowholes, even at reduced processing speeds, by optimizing the beam configuration to ensure strong bonding and efficient energy use in copper welding.
Implementation Method 1
irradiating a workpiece with laser light to melt and weld an irradiated portion of the workpiece
Implementation Method 2
Laser welding is a welding method including irradiating a portion to be welded in a workpiece with laser light and melting the portion by energy of the laser light
Data Source
AI summary
A welding method includes: arranging a workpiece containing copper in a region to be irradiated with laser light; and irradiating the workpiece with the laser light to melt and weld an irradiated portion of the workpiece. Further, the laser light is formed of a main beam and a plurality of sub beams, and a ratio of power of the main beam to total power of the plurality of sub beams is 72:1 to 3:7.