Laser Weld Nugget Spacing for Crack-Resistant Peel Strength
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Solution Overview
Problem
Conventional laser welding methods forming nuggets along an imaginary closed curved line require a larger welding area, making them unsuitable for applications with limited space and resulting in potential solidification cracks and reduced peel strength.
Innovation Solution
A welding method where adjacent nuggets are formed with a central axis distance to diameter ratio of 1.0<p/d≤1.6, preventing solidification cracks and enhancing peel strength by maintaining nuggets farther apart, suitable for small allowance welding points, and applicable to aluminum alloy objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If nuggets are arranged along an imaginary closed curved line, then welding area is increased, but allowance for welding points is insufficient
Solution Approach 1:
The weld is segmented into multiple discrete nuggets arranged along an imaginary straight line or open curved line, rather than forming a continuous closed curved line. This segmentation allows the welding area to be reduced while still providing sufficient welding points, resolving the contradiction between increasing welding area and maintaining adaptability for small allowance applications.
2Area of stationary object
If distance between adjacent nuggets is reduced, then welding area is reduced, but solidification cracks may connect
Solution Approach 1:
The patent optimizes the distance parameter between adjacent nuggets to satisfy 0.5d≤p<d, where p is the distance and d is the nugget diameter. This parameter optimization allows the welding area to be reduced while maintaining sufficient separation between nuggets to prevent solidification cracks from connecting, thus resolving the contradiction between reducing welding area and preventing cracking.
3Strength
If nuggets are placed closer together, then peel strength is improved, but welding imperfections increase
Solution Approach 1:
The patent optimizes the nugget arrangement parameters, specifically setting the distance between adjacent nuggets to satisfy 0.5d≤p<d and arranging them along an imaginary straight line or open curved line. This parameter optimization achieves a balance that provides sufficient peel strength while avoiding welding imperfections such as poor appearance and increased risk of fatigue cracking that would result from placing nuggets too closely together.
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 method prevents welding imperfections like poor appearance and fatigue cracking while improving peel strength by maintaining nuggets at a distance that prevents crack connection and distributing stress effectively.
Implementation Method 1
forming adjacent nuggets in the plurality of objects to be welded by laser welding
Data Source
AI summary
Objects to be welded are joined together by laser welding to form adjacent nuggets. When a distance between central axes of the adjacent nuggets is p and a diameter of the adjacent nuggets in the objects to be welded is d, the adjacent nuggets are formed so as to satisfy an equation 1.0<p/d≤1.6.