Laser-Mechanical Joining of Dissimilar Metals with Localized Melting
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Solution Overview
Problem
Existing methods for connecting two metal parts using laser radiation often require high energy input, leading to potential damage or deformation of non-joining areas due to excessive heating, especially when joining materials with different melting points.
Innovation Solution
A method where only the areas necessary for joining are thermally stressed using laser radiation, with the first part being partially melted to serve as a stop for precise alignment and positioning, while minimizing thermal stress on the rest of the first part, allowing for efficient connection of materials like aluminum and copper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire joining zone is heated or melted by laser radiation, then reliable connection between the two metal sheets is achieved, but excessive thermal stress causes damage or deformation to non-joining areas
Solution Approach 1:
The laser beam is directed to melt only the peripheral surface area of the first joining partner that will be in contact with the second joining partner, while leaving the end face area (except for a small margin) unmelted. This localized melting approach ensures reliable connection at the joining zone while preventing thermal damage to the bulk material and non-joining areas.
Solution Approach 2:
The joining zone is segmented into different functional areas: a peripheral surface area that is melted for connection, and an end face area that remains unmelted to serve as a stop and prevent over-penetration. This segmentation allows each area to fulfill its specific function without unnecessary thermal stress.
2Strength
If high energy input is applied to melt the joining zone, then complete melting and strong bonding are achieved, but the risk of overheating and deforming non-joining areas increases
Solution Approach 1:
The laser energy is concentrated only on the peripheral surface area where melting is required for bonding, rather than applying high energy input across the entire end face. This localized energy application achieves strong bonding at the joining zone while keeping the temperature of non-joining areas within safe limits.
Solution Approach 2:
Instead of melting the entire end face (excessive action), only the necessary peripheral surface area is melted (partial action). This partial melting provides sufficient bonding strength while avoiding the harmful effects of overheating the entire component.
3Manufacturing precision
If the laser beam is directed at the end face for complete melting, then uniform connection is achieved, but alignment precision is compromised due to material flow
Solution Approach 1:
The laser beam targets only the peripheral surface area for melting, leaving the majority of the end face intact. This creates a precise unmelted stop area that maintains geometric fidelity and serves as an accurate positioning reference, thereby improving alignment precision while still achieving uniform connection through the melted peripheral region.
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 reduces the risk of damage and deformation, enabling easier alignment and positioning of parts during connection, while maintaining the structural integrity of non-melted areas, particularly suitable for electrical connections like those in lithium-ion batteries.
Implementation Method 1
heating one metal sheet in the area of the joining zone by means of a laser beam device
Implementation Method 2
The material of the first joining partner is partially heated or melted in the connection area by means of a laser beam device
Implementation Method 3
the two metal sheets are then passed between two press rollers, so that the two metal sheets are pressed against one another in the joining zone with high pressure pressed and thus connected
Implementation Method 4
After the material of the first joining partner has melted, a pneumatic device exerts an axial force on the first joining partner, which thereby presses the first joining partner with the material melted over the entire face of the first joining partner against the second joining partner
Implementation Method 5
The joining partner, which consists of the material with the lower melting temperature, is partially heated or liquefied, so that after it has solidified, the melted area forms a positive connection with the joining partner with a higher melting temperature
Data Source
AI summary
The invention relates to a method for connecting two joining partners (10) by means of laser radiation (1), wherein the material of a first joining partner (10) is melted in the region of connection to a second joining partner (11) and the two joining partners (10) are then pressed against each other under mechanical pressure. The material of the first joining partner (10) is melted in the connection region only over a portion of the surface of the connection region.