Laser Weld Focal-Point Scanning for Low-Distortion Wire Feed
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Solution Overview
Problem
Conventional laser-based welding systems cause intense, localized heat damage and require high laser power for large weld puddles, leading to thermal distortion and residual stress.
Innovation Solution
A laser welding system that uses a continuously fed electrode wire preheated by a wire heater and a laser scanner to move the focal point in multiple dimensions, creating a controlled heat distribution and reducing thermal input, thereby minimizing heat affected zones and improving puddle convection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional fixed beam laser welding is used, then welding speed and precision are improved, but intense localized heat causes thermal distortion and residual stress
Solution Approach 1:
The patent applies dynamics by transitioning from a fixed laser beam to a moving focal point that oscillates in multiple dimensions. The laser focal point is continuously moved along a predetermined path during welding, creating dynamic heat distribution that reduces localized thermal accumulation and minimizes thermal distortion while maintaining welding speed
Solution Approach 2:
The patent implements another dimension by moving the laser focal point not only along the weld path but also in lateral dimensions through oscillation. This multi-dimensional movement distributes heat over a larger area and reduces peak temperature concentration, thereby reducing residual stress and thermal distortion while preserving welding efficiency
2Quantity of substance
If high laser power is used to create large weld puddles, then weld size and penetration are improved, but thermal input increases causing heat damage
Solution Approach 1:
The patent uses dynamics to maintain large weld puddle size with lower laser power by continuously moving the focal point. The motion prevents heat concentration in any single location, allowing the weld pool to maintain adequate size and penetration while reducing peak power requirements and overall thermal input to the workpiece
Solution Approach 2:
The patent applies periodic action through oscillating the laser focal point in a predetermined pattern. This periodic movement creates cycles of heating and cooling that prevent excessive heat buildup, enabling large weld puddles to be formed with reduced laser power and minimized thermal damage to surrounding material
3Power
If preheating the electrode wire is implemented, then filler metal melting efficiency is improved, but system complexity increases
Solution Approach 1:
The patent applies preliminary action by preheating the electrode wire before it reaches the weld zone. This preheating reduces the thermal load on the laser system and improves melting efficiency of the filler metal. The wire is heated in advance through contact with the laser beam or induction heating, reducing the energy required for melting and improving overall process efficiency
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 thermal distortion and residual stress, maintains high laser intensity with low power levels, and prevents crowning and drooping issues, enhancing the stability and uniformity of welds in additive manufacturing.
Implementation Method 1
A laser welding system is disclosed that uses a continuously fed electrode wire preheated by a wire heater
Implementation Method 2
a laser scanner to move the focal point in multiple dimensions, creating a controlled heat distribution and reducing thermal input
Implementation Method 3
The beam provides a concentrated heat source, enabling a precise control of the heat input and high welding speed
Data Source
AI summary
Systems and methods of a laser welding device are disclosed. The laser welding device includes a laser generator configured to generate welding-type lasing power. A lens focuses the welding-type lasing power at a focal point on a workpiece to generate a puddle during a welding-type operation. A wire feeder is configured to feed wire to the puddle generated by the laser generator. A laser scanner controls the lens to move the focal point of the welding-type lasing power in multiple dimensions over the workpiece during the welding-type operation. In some examples, the feed wire is used in an additive manufacturing process.