Laser Beam Power Splitting for Stronger Low-Spatter Welding
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Solution Overview
Problem
Laser welding methods face challenges in achieving required weld strength while minimizing spatter generation, which can lead to insufficient metal material and potential electrical circuit abnormalities due to spatter adherence.
Innovation Solution
A welding method and apparatus that emit a laser beam with a main power region and at least one auxiliary power region, where the power ratio of the main to auxiliary regions is within 144:1 to 1:1, utilizing a diffractive optical element to split the beam into a main beam and auxiliary beams, with the auxiliary beams positioned in front of the main beam to stabilize the molten pool and reduce spatter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a laser beam is emitted to weld a workpiece, then weld strength is achieved, but spatter is generated causing processing defects and potential electrical circuit abnormalities
Solution Approach 1:
The laser beam is divided into multiple beams (main beam and auxiliary beams) with different power levels. The main beam provides high power for welding, while auxiliary beams with lower power are positioned at specific locations to suppress spatter generation without compromising weld strength
Solution Approach 2:
Different regions of the laser beam are assigned different power characteristics. The main beam region delivers high power for effective welding, while auxiliary beam regions deliver lower power specifically targeted at spatter-prone areas, creating localized quality control to suppress spatter where needed
2Productivity
If high power laser beam is used to achieve weld strength, then welding efficiency is improved, but spatter occurrence increases leading to material loss
Solution Approach 1:
The high power laser beam is segmented into a main beam and multiple auxiliary beams. The main beam maintains high power for welding efficiency, while auxiliary beams are configured with lower power to reduce spatter and material loss without significantly impacting overall welding productivity
Solution Approach 2:
The power parameters of the laser beam are changed by introducing auxiliary beams with different power levels. This allows optimization of the power distribution to maintain welding efficiency while reducing the power concentration that causes excessive spatter and material loss
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 configuration effectively suppresses spatter generation and achieves higher weld strength by maintaining a suitable aspect ratio of the weld, ensuring strong and defect-free welds.
Implementation Method 1
utilizing a diffractive optical element to split the beam into a main beam and auxiliary beams
Implementation Method 2
a laser beam is emitted to a portion to be welded of a workpiece to melt the portion with the energy of the laser beam
Implementation Method 3
melt the portion with the energy of the laser beam
Data Source
AI summary
A welding method includes: emitting a laser beam to a workpiece including a metal; and welding a portion of the workpiece to which the laser beam is emitted by melting. The laser beam includes a main power region and at least one auxiliary power region, power in the main power region is equal to or higher than power in each of the at least one auxiliary power region, and a power ratio of the power in the main power region and a total of the power in the at least one auxiliary power region is within a range of 144:1 to 1:1.