Laser Beam Scanning Patterns for Asymmetric Weld Heat Control
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Solution Overview
Problem
Existing laser welding techniques, such as those described in WO-2016/118555-A1, do not fully utilize the capabilities of current laser scanning systems, particularly in achieving asymmetric two-dimensional energy distributions which can enhance weld quality for parts with varying thicknesses, materials, or curved surfaces.
Innovation Solution
A method and system for laser welding that employs two-dimensional scanning with an asymmetric energy distribution, where the energy density can be dynamically adapted along a track with varying power levels and patterns, including a 'hot leading' and 'cooler trailing' design, to optimize heating and cooling curves, and adapt to specific conditions like material differences and surface geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional one-dimensional laser beam displacement is used, then the welding process is simple, but the weld quality cannot be optimized for parts with varying thicknesses, materials, or curved surfaces
Solution Approach 1:
The patent transitions from conventional one-dimensional laser beam displacement to two-dimensional scanning patterns, enabling the laser beam to oscillate in both transverse and longitudinal directions. This dimensional expansion allows asymmetric energy distribution and optimized heating/cooling curves for complex geometries, directly improving weld quality while utilizing advanced scanning capabilities
Solution Approach 2:
The patent implements asymmetric two-dimensional scanning patterns where the laser beam spends more time in certain regions or applies different energy densities in different directions. This asymmetry enables tailored energy distribution that accommodates varying material thicknesses, different materials, and curved surfaces, optimizing weld quality for complex parts
2Adaptability or versatility
If symmetric energy distribution is used, then the welding process is straightforward, but it cannot provide optimized heating and cooling curves for different material conditions
Solution Approach 1:
The patent employs asymmetric energy distribution through non-uniform scanning patterns, where the laser beam applies different power levels in different regions or directions. This enables tailored heating and cooling curves that adapt to varying material thicknesses, thermal conductivities, and geometric features, significantly improving adaptability to different material conditions
Solution Approach 2:
The patent applies different scanning parameters and energy densities to different local regions of the workpiece. By adjusting scanning speed, amplitude, and frequency locally, the system optimizes the energy distribution for specific material conditions, part geometries, and joint configurations, enhancing versatility
3Productivity
If high welding speed is used, then productivity increases, but weld quality may deteriorate due to insufficient heating and cooling control
Solution Approach 1:
The patent utilizes periodic oscillation of the laser beam in two dimensions, creating a scanning pattern that repeatedly cycles through different positions. This periodic action allows the laser to spend controlled time in each region, ensuring adequate heating and cooling cycles even at high overall welding speeds, thereby maintaining both productivity and weld quality
Solution Approach 2:
The patent implements dynamic scanning patterns where the laser beam continuously adjusts its position, speed, and oscillation parameters during welding. This dynamic control enables the system to maintain optimal heating and cooling rates throughout the weld process, preserving weld quality while achieving high productivity through efficient path planning
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 allows for improved weld quality by ensuring appropriate heating and cooling, accommodating parts with different thicknesses and materials, and efficiently adapting to curved surfaces, thereby enhancing the productivity and flexibility of the welding process.
Implementation Method 1
projecting an energy beam onto an interface area... so as to produce a primary spot... to melt a portion of both parts
Implementation Method 2
laser welding... producing an effective spot by two-dimensional scanning of the primary spot... to melt a portion of both parts
Implementation Method 3
two-dimensional energy distribution... optimized heating and cooling curves... better controlling different aspects of the process, such as the cooling of the weld pool
Data Source
AI summary
A method for establishing a weld joint comprises the step of projecting an energy beam such as a laser beam (2) onto an interface area (103) between two parts (101, 102) to be joined. The beam (2) is projected onto the interface area (103) so as to produce a primary spot on the interface area (103), and the beam (2) is repetitively scanned in two dimensions in accordance with a scanning pattern so as to establish an effective spot (21) on the object, the effective spot (21) having a two-dimensional energy distribution. The effective spot (21) is displaced along a track (104) over the interface area (103) so as to progressively melt mating portions of the first part (101) and the second part (102) so as to form the weld joint (105). The effective spot (21) can feature an asymmetric energy distribution.