Laser Weld Irradiation Pattern for Gap Sealing and Hole Prevention
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Solution Overview
Problem
Existing methods for welding metal plates together may result in gaps between the end surfaces, leading to holes in the finished welded member due to insufficient sealing by laser beams.
Innovation Solution
A method involving a laser beam irradiation strategy with distinct power densities and spatial configurations, including a first area, a second area surrounding the first, and a third area outside the second, where the power densities satisfy q1>q2, q3, and the third area is spaced, to ensure complete sealing and stable molten pool formation despite gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a laser beam is applied to weld metal plates with abutted end surfaces, then welding is achieved, but gaps between end surfaces may remain unsealed creating holes in the finished welded member
Solution Approach 1:
The laser beam is divided into three distinct areas (first, second, and third areas) with different power densities. The first area provides high power density for deep penetration welding, the second area provides moderate power density for sealing gaps, and the third area provides low power density for preventing hole formation. This segmentation of the laser beam into functional zones resolves the contradiction by addressing both deep welding and gap sealing simultaneously.
Solution Approach 2:
Different regions of the laser beam are assigned different power densities tailored to specific local requirements. The high power density first area targets the weld joint for strong bonding, the moderate power density second area targets gap regions for sealing, and the low power density third area targets potential hole formation zones for prevention. This local differentiation of beam quality resolves the contradiction between achieving reliable welding and maintaining precision gap sealing.
2Manufacturing precision
If high power density is used to seal gaps, then gap sealing improves, but molten pool stability decreases and spatter increases
Solution Approach 1:
The laser beam is structured with the second area providing moderate power density specifically for gap sealing, while the first area provides high power density for deep penetration. This local quality differentiation allows gap sealing without subjecting the entire molten pool to high power density, thereby maintaining molten pool stability while achieving precise gap sealing.
Solution Approach 2:
The laser beam is segmented into three power density zones, with the second area specifically dedicated to gap sealing at moderate power density. This segmentation prevents the entire welding zone from experiencing high power density fluctuations, thereby maintaining overall molten pool stability while achieving effective gap sealing in the second area.
3Strength
If laser beam parameters are optimized for deep penetration welding, then welding strength improves, but gap sealing capability decreases
Solution Approach 1:
The laser beam is segmented into three functional areas: the first area with high power density for deep penetration welding that ensures welding strength, the second area with moderate power density for gap sealing that ensures precision, and the third area with low power density for hole prevention. This segmentation allows each area to optimize for its specific function, resolving the contradiction between welding strength and gap sealing precision.
Solution Approach 2:
Different regions of the laser beam are assigned different power densities: high power density in the first area for strong weld penetration, moderate power density in the second area for precise gap sealing, and low power density in the third area for hole prevention. This local quality optimization allows the system to achieve both high welding strength and precise gap sealing simultaneously.
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 prevents hole formation in the welded member, enhances molten pool stability, reduces spatter, and lowers power consumption by efficiently sealing gaps between metal plates.
Implementation Method 1
applying a laser beam along an end surface of the first metal plate and an end surface of the second metal plate
Implementation Method 2
forming a welded member by welding a first metal plate and a second metal plate together
Data Source
AI summary
In a method for manufacturing a welded member, an irradiation area that is irradiated by a laser beam relatively moves along end surfaces. The irradiation area includes a first area, a second area, and a third area. The second area surrounds an outer circumference of the first area. The third area is located outside of the second area and at least forward of the second area in a moving direction. The moving direction is a direction in which the irradiation area relatively moves. A rear end of the third area is located in front of a rear end of the second area in the moving direction. A first power density q1, a second power density q2, and a third power density q3 of the laser beam with which the first area, the second area, and the third areas are respectively irradiated satisfy a relationship q1>q2, q3.