Laminar Gas Delivery for Oxidation-Free Laser Welding
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Solution Overview
Problem
Existing welding technologies face challenges in maintaining a controlled atmosphere and preventing interference during laser welding of dissimilar materials, leading to issues like oxidation, hydrolysis, and spatter formation, which affect the quality of the weld joint.
Innovation Solution
A system incorporating a gas delivery device with a high-velocity gas barrier and a shield gas delivery device provides a controlled atmosphere and inhibits interference by directing pressurized gas with laminar flow to prevent oxidation and hydrolysis, while a wire feeder ensures proper welding of dissimilar materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional welding methods are used, then welding process is simple, but oxidation and hydrolysis occur leading to poor weld quality
Solution Approach 1:
The patent employs shield gas (inert atmosphere) delivered through a shield gas delivery device to protect the weld zone from oxidation and hydrolysis. The gas creates a protective environment around the laser welding area, preventing harmful chemical reactions between the molten metal and atmospheric gases.
Solution Approach 2:
The patent introduces a high-velocity gas barrier as an intermediary element between the weld zone and the surrounding atmosphere. This gas barrier acts as a mediator that physically separates the weld area from harmful environmental factors, preventing direct contact between the molten metal and atmospheric contaminants.
2Manufacturing precision
If high-velocity gas barrier is added to prevent oxidation, then weld quality improves, but device complexity increases
Solution Approach 1:
The patent combines the shield gas delivery device and the high-velocity gas barrier into an integrated system. The gas delivery device includes a body with a discharge slot that directs both shield gas and high-velocity gas through a unified structure, reducing the number of separate components and simplifying the overall system while maintaining weld quality.
3Object-affected harmful factors
If pressurized gas is used to create laminar flow, then protection against chemical reactions improves, but gas consumption increases
Solution Approach 1:
The patent applies gas protection locally at the weld zone rather than throughout the entire workspace. The discharge slot is positioned to deliver pressurized gas precisely where needed - at the laser welding area - creating laminar flow only in the critical protection zone. This localized approach minimizes overall gas consumption while maintaining effective protection against chemical reactions.
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 system effectively maintains a controlled atmosphere, reducing unwanted chemical reactions and spatter, resulting in improved weld quality and consistency by stabilizing the shield gas layer and preventing edge effects above the weld zone.
Implementation Method 1
a discharge slot that receives the pressurized gas from the interior cavity and outputs the pressurized gas with substantially laminar flow toward the laser beam
Implementation Method 2
a welding system that projects a laser beam that welds a first part to a second part
Data Source
AI summary
A system for making a welded assembly. The system may include a welding system that projects a laser beam that welds a first part to a second part. The system may further include a gas delivery device defining an interior cavity. The gas delivery device may include an inlet that provides pressurized gas to the interior cavity, and a discharge slot that receives the pressurized gas from the interior cavity and outputs the pressurized gas with substantially laminar flow toward the laser beam.