Hybrid Arc-Laser Welding for 3D Metallic Structure Accuracy
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Solution Overview
Problem
Current welding processes are limited by welding speed, precision, and material flexibility, making it difficult to produce complex three-dimensional metallic structures with high accuracy and efficiency, especially when dealing with varying geometries and material compositions.
Innovation Solution
The method involves sequentially feeding two different metallic additives to the weld point, where they are melted by arcs generated between electrodes and the base material, with a laser beam providing additional heat input to achieve precise control over the welding process, allowing for flexible material composition and geometry creation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional welding processes (MIG/MAG) are used to produce three-dimensional metallic structures, then material connection and structural integrity are achieved, but welding speed and production efficiency are limited
Solution Approach 1:
The patent combines laser beam and electric arc welding processes into a hybrid welding system. The laser beam provides concentrated heat input to increase welding speed, while the arc maintains material connection and structural integrity. This merging of two welding technologies resolves the contradiction by achieving both high productivity and acceptable precision.
Solution Approach 2:
The patent uses composite welding approach combining laser energy and arc energy. The laser beam delivers high energy density for rapid melting, while the arc provides sustained heating and metal transfer. This composite energy input system enables faster welding speeds without sacrificing weld quality.
2Productivity
If automated welding robots are used to produce three-dimensional structures, then production efficiency increases, but flexibility in material composition and geometry creation is reduced
Solution Approach 1:
The patent implements dynamic control of the hybrid welding system, allowing real-time adjustment of laser power, arc current, wire feed rate, and torch positioning. This dynamic adaptability enables the system to handle varying geometries and material compositions while maintaining high production efficiency through automation.
Solution Approach 2:
The patent utilizes multiple controllable parameters including laser power, arc voltage, wire feed speed, and torch travel speed. By dynamically adjusting these parameters, the system can adapt to different material types and geometric requirements while maintaining automated high-speed production.
3Productivity
If high welding speed is achieved using conventional processes, then productivity improves, but precision and quality of complex geometries deteriorate
Solution Approach 1:
The patent segments the heating process into two distinct components: laser heating for rapid melting and arc heating for sustained material connection. This segmentation allows each energy source to perform its optimal function, achieving high welding speed through laser while maintaining precision through arc control.
Solution Approach 2:
The arc acts as an intermediary between the laser beam and the base material, providing controlled metal transfer and sustained heating. This intermediary role allows the laser to deliver high energy for speed while the arc ensures precise material deposition and weld pool control for dimensional accuracy.
4Adaptability or versatility
If manual welding is used to create complex three-dimensional structures, then material flexibility and geometric freedom are maintained, but production time and costs increase
Solution Approach 1:
The patent replaces manual mechanical welding operations with an automated hybrid welding system. The robotic manipulator provides precise, repeatable positioning and movement, while the hybrid laser-arc process delivers controlled heat input. This substitution maintains geometric flexibility through programmable paths while dramatically reducing production time.
Solution Approach 2:
The patent implements continuous welding operation through automated feeding of consumable wire and continuous laser-arc interaction. This eliminates the interruptions and repositioning delays inherent in manual welding, maintaining geometric flexibility through programmable control while achieving continuous high-speed production.
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 production of complex three-dimensional metallic structures with improved accuracy, efficiency, and material flexibility, reducing production time and costs by allowing for targeted surface hardening and precise dimensional control.
Implementation Method 1
an electric voltage or a resulting electric current ignites an arc between the electrode and the base material, which arc melts the electrode and the area of base material surrounding the electrode
Implementation Method 2
A laser beam is fed to a workpiece using high-performance optics, which melts the workpiece locally by introducing heat
Data Source
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AI summary
In order to provide an improved method for producing metal structures (21, 21a, 21b) which allows a high level of flexibility in respect of process speed of production, material composition of the metal structure (21, 21a, 21b), production accuracy and the quality of the produced metal structure (21, 21a, 21b), according to the invention, a second metal additive (ZSb) is supplied to a welding point (S) on a metal base material (G), which second metal additive is fused at least by means of a second electric arc (11b) produced between a second electrode and the metal base material (G) in order to produce a second weld seam (10b) at the welding point (S), wherein different materials are used as the first metal additive (ZSa) and as the second metal additive (ZSb), and wherein the first metal additive (ZSa) and the second metal additive (ZSb) are supplied to the welding point (S) sequentially in time and are fused in the region of the welding point (S) in whichever of the first and second electric arcs (11a, 11b) is burning, in order to form the three-dimensional metal structure (21, 21a, 21b).