Sacrificial Edge-Tab Laser Welding for Modular Mandrel Assembly

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Solution Overview

Problem

Conventional methods for forming layup mandrels are labor-intensive and challenging due to the need for large, specialized tools and the difficulty in manufacturing complex, distortion-prone components, especially when transporting and handling large, unitary mandrels.

Innovation Solution

A method involving laser welding of modular components with sacrificial edge-tabs, where the edge-tabs are melted to form a melt-pool that solidifies into a weld, joining the components together, allowing for the fabrication of modular, complex layup mandrels with reduced warping and manufacturing time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the entire mandrel is fabricated and transported as one piece, then the structural integrity and precision are maintained, but the transportation and handling become time-consuming and labor-intensive

Engineering Contradiction:

Improvemandrel precisionVSAvoidtransportation time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The mandrel is divided into multiple modular components that can be fabricated separately and transported independently. These components are then joined using laser welding technology to form the complete mandrel structure, reducing transportation time and handling requirements while maintaining structural integrity through precise welding joints.

Inventive Principle:

Principle #1Segmentation

2Strength

If the entire mandrel is fabricated as one piece, then the structural integrity is maintained, but the fabrication process becomes labor-intensive and requires specialized tools

Engineering Contradiction:

Improvemandrel strengthVSAvoidfabrication ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The mandrel structure is segmented into multiple components that can be manufactured using standard fabrication processes rather than requiring specialized tools for entire-large-component fabrication. The modular approach allows each component to be fabricated more easily while laser welding joins them to achieve the required overall strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Traditional mechanical joining methods (such as bolting or riveting) are replaced with laser welding technology, which provides stronger, more precise joints without requiring extensive mechanical assembly operations. This substitution reduces labor intensity while maintaining or improving structural strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If conventional welding methods are used on large surface areas, then the components are joined together, but excessive heating causes warping and distortion

Engineering Contradiction:

Improveweld strengthVSAvoidweld tolerance

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

Conventional arc welding or resistance welding methods are replaced with laser welding technology. The laser provides highly concentrated energy that creates precise welds with minimal heat input to the surrounding material, preventing thermal distortion and maintaining tight tolerances on large surface areas.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser welding process applies heat locally and precisely to the weld zone rather than heating large surface areas. This localized energy application creates strong welds while minimizing thermal affect on surrounding materials, preventing warping and maintaining manufacturing precision.

Inventive Principle:

Principle #3Local quality

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 enables the efficient fabrication of large, complex layup mandrels with reduced warping and labor costs, as modular components can be easily assembled and transported, and the laser welding process minimizes heating of large surface areas, maintaining tight tolerances.

Implementation Method 1

exposing the sacrificial edge-tab to laser energy, the laser energy being sufficient to melt at least a portion of the sacrificial edge-tab

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

the laser energy being sufficient to melt at least a portion of the sacrificial edge-tab; forming a melt-pool in the gap between the first component and the second component, the melt-pool comprising material from the melted portion of the sacrificial edge-tab

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentEP3165322B1Edge preparation for laser welding

Publication Date: 2023.11.29 THE BOEING CO

Figure 1A~1B
Figure 2~3A
Figure 3B

AI summary

Provided is a laser-weld manufacturing method. The method includes: providing a first component and a second component that are separated from one another by a gap, the gap having a depth and a width and at least one of the first component and the second component having a sacrificial edge-tab; exposing the sacrificial edge-tab to laser energy, the laser energy being sufficient to melt at least a portion of the sacrificial edge-tab; forming a melt-pool in the gap between the first component and the second component, the melt-pool including material from the melted portion of the sacrificial edge-tab; and solidifying the melt-pool to form a weld that joins the first component and the second component together.