Laser Brazing Wire Feed Line with Integrated Gas Shielding
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Solution Overview
Problem
Existing laser brazing methods with external solder supply and process gas often result in unsatisfactory surface quality and strength of the soldered seams, requiring rework and frequent cleaning.
Innovation Solution
Integrating the process gas with the soldering material by providing transfer openings on the circumference of the wire feed line, ensuring the gas encases the solder at the joint, preventing smoke and pore formation, and distributing evenly around the wire feed line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If process gas is supplied separately via external feed line, then gas can reach the joint, but surface quality deteriorates and pores form
Solution Approach 1:
The patent combines the process gas supply line with the solder wire feed line into a single integrated conduit. The gas is introduced through transfer openings in the feed line wall, allowing it to flow coaxially with the solder wire to the joint. This merging eliminates separate gas feed equipment and ensures the gas reaches the solder pool effectively, preventing pores and improving surface quality while maintaining reliable soldering.
2Reliability
If process gas is fed together with laser beam, then joint protection is improved, but device complexity increases
Solution Approach 1:
The patent merges the gas supply function with the existing solder wire feed device. The feed line serves dual purposes: guiding the solder wire and transporting the process gas to the joint. This eliminates the need for separate gas supply equipment and complex positioning systems, reducing device complexity while ensuring adequate joint protection through the integrated gas flow.
Solution Approach 2:
The solder wire feed line is given multi-functionality by incorporating process gas transport capability. The same conduit that delivers the solder wire also serves as the gas supply channel, with transfer openings enabling gas introduction. This universal use of the feed line simplifies the overall system while maintaining effective joint protection.
3Quantity of substance
If solder is supplied in wire form, then continuous supply is achieved, but heat input control becomes difficult
Solution Approach 1:
The patent introduces process gas as an intermediary between the laser beam and the solder wire. The gas flows around the solder wire in the feed line and creates a protective atmosphere at the joint. This intermediary gas layer helps control the thermal environment, preventing excessive heat input to the solder wire while maintaining continuous supply, and ensures proper heating conditions at the joint for quality soldering.
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 achieves a seamless, high-quality soldered surface with enhanced strength and reduced rework, eliminating pores and smoke traces, thereby improving the overall brazing process.
Implementation Method 1
the laser beam of which emerges via processing optics 2 onto a joint 3, at which two metal sheets 4 and 5 are to be connected by means of a brazing material
Implementation Method 2
the solder melted at the joint is shielded in the joint
Implementation Method 3
the process gas is supplied to the joint 3 via part of the wire feed line 8 and through the wire outlet nozzle 9, the process gas being fed to the outlet nozzle via transfer openings provided on the circumference of the feed line in front of the outlet nozzle. As a result, the solder melted at the joint is shielded in the joint. Furthermore, there are no traces of smoke and the result is a bare soldered seam surface
Data Source
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AI summary
The method for laser-hard soldering with an external supply of a soldering material (6) such as soldering wire without flux, comprises guiding the external supply of the soldering material such as soldering wire from a storage of soldering material up to in the area of a joint (3) through a supply line over a transport direction, and externally supplying the process gas to the joint using an apparatus, where the process gas is conducted with a distance from the joint to the supply line of the soldering wire and the soldering wire covers from outside. The method for laser-hard soldering with an external supply of a soldering material (6) such as soldering wire without flux, comprises guiding the external supply of the soldering material such as soldering wire from a storage of soldering material up to in the area of a joint (3) through a supply line over a transport direction, and externally supplying the process gas to the joint using an apparatus, where the process gas is conducted with a distance from the joint to the supply line of the soldering wire and the soldering wire covers from outside to conduct directly to the soldering material just before the exit of the soldering material from the supply line, so that the soldering material discharges together with the process gas from the supply line to the joint. An independent claim is included for a device for laser-hard soldering with an external supply of a soldering material such as soldering wire without flux.