Laser Seam Between Thin-Walled Sheet-Metal Parts
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Solution Overview
Problem
Laser weld seams in thin-walled sheet-metal parts often result in sink marks and cracks, leading to costly and time-consuming refinishing processes, especially in visible areas of vehicle bodies.
Innovation Solution
A connecting seam is formed with a thermal bead in the joining zone, surrounded by solidified melt, which temporarily compensates for shear stress during production, reducing or eliminating sink marks and preventing cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laser weld seam or laser soldered seam is produced between thin-walled sheet-metal parts, then connecting strength is achieved, but sink marks and cracks occur in the flange region
Solution Approach 1:
A bead is introduced into the flange portion before the laser welding or soldering process. This preliminary structural modification allows the flange to better withstand thermal stresses during joining, preventing sink marks and cracks while maintaining surface quality in visible areas.
Solution Approach 2:
The bead is specifically positioned in the flange region where thermal stresses concentrate during laser joining. This localized reinforcement provides additional material and structural support precisely where needed to prevent defects, without affecting other areas of the sheet-metal parts.
2Manufacturing precision
If manual refinishing work is performed to remove sink marks, then surface quality is improved, but production time and costs increase
Solution Approach 1:
The bead is introduced before laser joining to prevent sink marks from forming in the first place. This proactive measure eliminates the need for subsequent manual refinishing operations, significantly reducing production time and costs while ensuring consistent surface quality.
3Reliability
If thermal bead is introduced in the flange portion, then sink marks and cracks are prevented, but device complexity increases
Solution Approach 1:
The bead can be introduced using existing manufacturing equipment and processes before laser joining. This approach integrates seamlessly into current production workflows without requiring additional complex devices or processes, thereby maintaining simplicity while significantly improving reliability by preventing defects.
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
The solution significantly reduces or eliminates sink marks and cracks, minimizing refinishing work and ensuring a flawless surface, thereby enhancing the visual appearance and durability of vehicle bodies.
Implementation Method 1
A connecting seam is formed between two thin-walled sheet-metal parts as a laser weld seam or as a laser soldered seam
Implementation Method 2
solidified melt of seam material after the connecting seam has been produced
Implementation Method 3
the bead is at least partially surrounded, in particular completely filled, by solidified melt of seam material
Data Source
AI summary
A connecting seam is formed between two thin-walled sheet-metal parts as a laser weld seam or laser soldered seam as additional material is supplied, respectively. The sheet-metal parts have flange portions for formation of a connecting region. At least one flange portion includes in the region of a joining zone a bead which is at least partially surrounded or filled by solidified melt from seam material after the production of the connecting seam.