Laser-Welded Metal Foil Coating for Mixed Connection Surfaces
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Solution Overview
Problem
Existing methods for coating metal parts to prepare them for different types of connections, such as welded and force connections, often result in imperfect surface cleaning and increased production costs due to complex removal processes of previous coatings, leading to residual coating materials and uneven surfaces.
Innovation Solution
A method involving the selective laser welding of a metal foil onto a metal part to create a local coating, allowing for precise adjustment of surface properties without altering uncoated areas, using a metal foil that can be ductile or chemically adapted to match the requirements of the connection type, and welded or evaporated as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coating is applied to prepare the surface for force connections, then the mechanical contact quality is improved, but the surface must be locally removed for welded connections, resulting in residual coating materials and uneven surfaces
Solution Approach 1:
The contact part is divided into multiple regions with different surface properties: a first region with a ductile coating for force connections and a second region with pure base material for welded connections. This segmentation allows each region to be optimized for its specific connection type without compromising the other.
Solution Approach 2:
Different surface qualities are applied to different regions of the contact part. The first region receives a ductile coating to compensate for surface unevenness in force connections, while the second region maintains pure base material for clean welded connections, eliminating the need for coating removal.
2Reliability
If the entire contact part is coated with a second metal, then the surface is prepared for force connections with improved contact area, but the base material is no longer accessible for welded connections
Solution Approach 1:
The coating is applied selectively only to the first region intended for force connections, while the second region for welded connections remains uncoated. This eliminates the need for subsequent coating removal steps and simplifies the manufacturing process.
Solution Approach 2:
The coating is applied in advance only to the specific region where it is needed for force connections, rather than coating the entire part and then removing it later. This preliminary selective coating reduces manufacturing steps and improves efficiency.
3Reliability
If coating removal is performed to expose base material for welded joints, then access to pure material is restored, but the surface is not perfectly clean and production costs increase
Solution Approach 1:
Instead of coating the entire surface and then removing the coating where welding is needed, the approach is inverted: the coating is applied only where it is needed for force connections from the beginning, so no removal is necessary. This eliminates complex removal processes and their associated costs.
Solution Approach 2:
The coating application process is extracted and limited to only the first region where it is needed for force connections, rather than applying it to the entire contact part. This eliminates the need for subsequent removal operations.
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 method enables a seamless, cohesive connection with reduced electrical resistance and mechanical deformation, maintaining the smoothness of uncoated areas while adapting the surface for optimal contact and corrosion prevention, thus enhancing the quality of connections and simplifying the production process.
Implementation Method 1
the laser beam 32 is moved along a welding pattern over the welding surface, wherein the laser beam heats and melts the foil as well as the material of the metal part underlying the foil
Implementation Method 2
the laser beam heats and melts the foil as well as the material of the metal part underlying the foil
Implementation Method 3
the laser beam evaporates the foil in those areas where the foil does not rest directly on the metal part
Data Source
Figure 1a~1c
Figure 2~3c
Figure 4a~4c
AI summary
The invention relates to a method for coating metal parts, comprising the provision of a metal part made from a first metal material, applying a film made from a second metal material onto the metal part in a support region, and irradiating the film resting on the metal part in at least a part of the support region using a laser.