Internal Laser Welding of Composite Laminate Pipes
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Solution Overview
Problem
The high cost and weight of tubular structures made from solid metal alloys for high-speed transportation systems, particularly those requiring near-vacuum environments, necessitate the development of more efficient methods for forming tubular structures that can maintain strength and reduce material thickness.
Innovation Solution
The use of a laminate pipe structure with two thicker outer walls and a corrugated interior layer, where laser beam welds are formed internally between the corrugated layer and the outer or inner walls, avoiding the need to penetrate the thicker outer walls and thus reducing the risk of damaging the thinner interior layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid metal alloy tubular structures are used for high-speed transportation systems, then strength and structural integrity are maintained, but weight and manufacturing cost increase significantly
Solution Approach 1:
The patent applies composite materials by combining metal outer layers with a corrugated plastic or composite interior layer. This hybrid structure maintains the strength and structural integrity of metal while reducing overall weight compared to solid metal alloy tubular structures. The composite construction allows the structure to meet mechanical requirements with lower material density.
Solution Approach 2:
The tubular structure is segmented into distinct functional layers: outer metal layers for structural strength and an inner corrugated layer for lightweight reinforcement. This segmentation allows each layer to contribute its specific properties, achieving optimal strength-to-weight ratio without requiring solid metal construction throughout.
2Ease of manufacture
If laser beam welding is performed from the external surface through thick outer walls, then weld joints can be formed, but the thinner interior corrugated layer may be damaged due to excessive heat or beam penetration
Solution Approach 1:
The patent inverts the conventional welding approach by performing laser beam welding from the interior surface rather than from the external surface. This reversal allows the laser to weld the metal outer layers to the corrugated interior layer without excessive heat affecting the interior layer, as the welding origin is now on the interior side where the corrugated structure provides immediate structural support.
Solution Approach 2:
The corrugated interior layer acts as an intermediary that facilitates welding by providing a textured surface that enhances laser beam interaction and weld penetration control. The corrugations create multiple reflection points and increase surface area, allowing for better weld distribution and reduced localized heat concentration that could damage the interior layer.
3Weight of moving object
If material thickness is reduced to lower cost and weight, then manufacturing cost and weight decrease, but structural strength and weldability may be compromised
Solution Approach 1:
The composite structure combines thin metal outer layers with a corrugated plastic or composite interior layer, creating a hybrid material system that achieves required structural strength with reduced overall material thickness. The corrugated interior provides reinforcement through its geometric structure, compensating for the reduced metal thickness.
Solution Approach 2:
The corrugated interior layer introduces curvature and geometric complexity to the structure. The undulating corrugations provide structural reinforcement through their three-dimensional form, allowing the walls to be thinner while maintaining strength. The curved geometry of corrugations distributes stresses more effectively than flat surfaces.
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 reduces the material thickness and weight of the tubular structure while maintaining strength, lowers manufacturing costs, and allows for the use of laser beam welding without damaging the internal layers, enhancing the efficiency and cost-effectiveness of the tubular structure.
Implementation Method 1
emitting a laser beam from the welding apparatus to form the internally-arranged laser-beam weld between layers of the composite structure
Data Source
AI summary
A method of forming an internally-arranged laser-beam weld from within a composite structure. The method includes arranging a welding apparatus within an internal passage of the composite structure, and emitting a laser beam from the welding apparatus to form the internally-arranged laser-beam weld between layers of the composite structure.