Laminated Metal Foil Welding via Crimping and Laser Feedback
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Solution Overview
Problem
Existing methods of welding laminated metal foils often result in microscopic gaps leading to blowholes and spatter, which adversely affect the fatigue strength and electrical resistance of the welded part, and are not adequately prevented by simply sandwiching the foils between metal plates.
Innovation Solution
The method involves locally pressing and crimping the laminated metal foils between a pair of metal plates at the welding point to reduce microscopic gaps, followed by laser welding, with feedback-controlled irradiation conditions based on thermal radiation light intensity to prevent burn-through and improve the quality of the weld.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laminated metal foils are directly irradiated with laser beam for welding, then welding efficiency is improved, but temperature of metal foil sharply increases causing spatter
Solution Approach 1:
A pair of metal plates are introduced as intermediary elements to sandwich the laminated metal foils during welding. These metal plates act as mediators that absorb and distribute the laser beam energy, preventing direct concentration of heat on the metal foils thereby reducing temperature spikes and spatter while maintaining welding efficiency
2Manufacturing precision
If laminated metal foils are pressed against projection with annular pressing member, then contact between foils and metal plate is improved, but microscopic gaps still form between foils
Solution Approach 1:
The metal foils are pre-pressed and crimped between the metal plates before laser welding begins. This preliminary action of crimping creates intimate contact and eliminates microscopic gaps at the welding interface, ensuring that when the laser beam is applied, there are no gaps to form blowholes, thereby improving manufacturing precision and preventing defects
3Manufacturing precision
If laser intensity is increased to prevent blowholes, then welding quality improves, but spatter occurs when blowholes burst
Solution Approach 1:
The metal foils are pre-pressed and crimped between the metal plates before laser welding begins. This preliminary action eliminates microscopic gaps that would otherwise form blowholes during welding, allowing for controlled laser intensity without the risk of blowhole formation and subsequent spatter
Solution Approach 2:
Metal plates sandwiching the foils serve as intermediaries that distribute heat evenly and prevent localized overheating that causes blowholes. This mediator approach allows for optimized laser intensity settings that improve welding quality without causing the blowhole-burst-spatter cycle
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 effectively reduces the formation of blowholes and spatter, enhances the fatigue strength, and minimizes electrical resistance of the welded part by ensuring better contact and heat control during the welding process.
Implementation Method 1
a laser welding machine, a galvanometer scanner for irradiating laser light from the laser welding machine to the workpiece
Implementation Method 2
the intensity of the laser light is increased when the intensity of the reflected light decreases and the degree of the increase in the intensity of the thermal radiation light decreases
Data Source
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AI summary
Provided is a method of welding laminated metal foils that can prevent blowholes and spatter from being formed. It is a method of welding laminated metal foils sandwiched between a pair of metal plates to the pair of metal plates. The method of welding laminated metal foils sandwiched between a pair of metal plates to the pair of metal plates includes locally pressing and crimping the laminated metal foils sandwiched between the pair of metal plates at a welding point in a laminating direction, and welding the crimped pair of metal plates and laminated metal foils at the welding point.