Laser Fillet Welded Component Arrangement for Zero-Clearance Sealing
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Solution Overview
Problem
Laser-beam welding in vehicle bodywork manufacturing faces limitations due to low gap bridging capacity and the need for precise technical zero clearance, which results in seam defects and increased costs, especially when dealing with components having anticorrosion coatings that evaporate during welding, leading to limited adoption in comparison to resistance spot welding.
Innovation Solution
A component arrangement featuring a first and second component in an overlapping configuration with a laser fillet weld and laterally offset fixing positions, where a protrusion on one component is designed to create a flange section that presses obliquely onto the other component, forming a continuous adhesive bonding region and a degassing cavity, allowing for controlled zero clearance and improved sealing during laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If remote laser-beam welding is carried out with a large working distance without auxiliary material, then welding speed and flexibility are increased, but gap bridging capacity is reduced and technical zero clearance is required
Solution Approach 1:
A protrusion is provided on one of the components, which protrudes in the direction of the other component and is arranged and configured in such a way that with accurate positioning of the components with respect to one another and by pressing together at the fixing positions, a flange section of the first component is pressed, while being obliquely set in the region of the laser fillet weld to be formed, with a component edge onto the second component. This preliminary geometric configuration ensures forced zero clearance at the welding position before welding begins.
2Productivity
If laser-beam welding is used on components with anticorrosion coating, then high welding speed and flexibility are achieved, but evaporation of coating material causes splashes and seam defects
Solution Approach 1:
The protrusion is configured to create a degassing cavity when components are pressed together. This cavity provides a controlled path for zinc vapor to escape during laser welding, converting the harmful effect of coating evaporation into a controlled degassing process that prevents splashes and seam defects.
3Productivity
If technical zero clearance is required for remote laser welding, then welding speed is maintained, but elaborate clamping systems are needed to press components together
Solution Approach 1:
The protrusion on one component serves a dual function: it guides the positioning of components and automatically creates the forced zero clearance at the welding position when components are pressed together at the fixing positions. This self-positioning and self-clamping mechanism eliminates the need for elaborate external clamping systems.
4Force
If fixing positions are arranged at the edge of components, then clamping force is maximized, but sealing at the joint is compromised
Solution Approach 1:
The protrusion creates a three-dimensional geometric configuration with an obliquely set flange section that generates forced zero clearance at the welding position. This spatial arrangement allows fixing positions to be arranged set-back from the edge while maintaining both clamping force through the protrusion mechanism and sealing at the joint through the created zero clearance condition.
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 solution enhances the sealing and strength of the component arrangement while minimizing installation space, enabling efficient and reliable laser welding with reduced seam defects and the ability to handle components with anticorrosion coatings, thus improving the economic use of laser welding in vehicle bodywork manufacturing.
Implementation Method 1
a focused laser beam with a high power density is directed onto a joint, so that the irradiated material melts
Implementation Method 2
Because of the low boiling temperature of the coating, evaporation of the coating material takes place during the welding
Data Source
AI summary
A component arrangement and a method for producing the component arrangement are provided. The component arrangement includes a first component and a second component, which are arranged in an overlapping arrangement and are connected by a laser fillet weld and at two fixing points arranged laterally offset from the laser fillet weld, one of the components is provided with at least one projection, which projects in the direction of the other component and which is arranged and formed such that, when the components are positioned correctly in relation to one another and are pressed together at the fixing points, a flange portion of the first component, set at an angle in the region of the laser fillet weld to be formed, is pressed onto the second component by way of the component edge. For sealing the component arrangement, the fixing points are arranged set back into the overlapping region with respect to the laser fillet weld, and at least between the fixing points there is formed a continuous bonding region, in which the first and second components are bonded to one another.