Laser Weld Repair for Steel Floor Slab Root Cracks
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Solution Overview
Problem
Conventional laser welding methods fail to effectively remove deck growth cracks that pierce the deck plate, despite being able to eliminate bead growth cracks, necessitating the removal of paved portions on steel floor slabs for repair.
Innovation Solution
A repairing laser welding method that irradiates a laser beam along the welding bead at the root part of the joint between the deck plate and U-rib, targeting the contact point between the two materials to melt and eliminate both bead and deck growth cracks without removing the paved portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional laser welding method irradiates along the bead growth direction, then bead growth cracks can be eliminated, but deck growth cracks that pierce the deck plate cannot be removed
Solution Approach 1:
The patent changes the irradiation approach from a single linear path along the bead to a two-dimensional scanning pattern that covers both the bead surface and the root part including the contact point. This dimensional expansion enables the laser to address both bead growth cracks and deck growth cracks simultaneously.
Solution Approach 2:
The irradiation process is divided into multiple segments: irradiating along the welding bead, irradiating the root part, and specifically targeting the contact point between deck plate and U-rib. This segmentation allows each area to be treated with appropriate laser parameters for effective crack removal of different types.
2Reliability
If paved portion is removed for repair, then both types of cracks can be addressed, but traffic regulation is required and construction complexity increases
Solution Approach 1:
The patent replaces the mechanical removal of paved portions with a non-contact laser irradiation method. The laser beam melts and removes cracks without requiring physical access to the crack locations, eliminating the need to remove overhead paved portions and avoiding traffic regulation.
Solution Approach 2:
The laser beam acts as an intermediary that can reach and treat cracks at difficult-to-access locations through the paved portion without physically removing it. The laser energy penetrates and melts the cracks from above, allowing repair while maintaining the paved portion in place.
3Ease of manufacture
If laser irradiates only along the welding bead, then the process is simple, but deck growth cracks piercing the deck plate remain untreated
Solution Approach 1:
The patent performs preliminary identification of the contact point location between the deck plate and U-rib before laser irradiation. This preliminary positioning ensures that the subsequent laser irradiation systematically covers all necessary areas including the root part and contact point, guaranteeing complete crack removal while maintaining 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
The method enables the removal of both bead and deck growth cracks using a laser beam, maintaining the integrity of the steel floor slab without traffic regulation or removal of paved portions.
Implementation Method 1
melting and eliminating a crack by irradiation with a laser beam
Implementation Method 2
the irradiation with the laser beam is performed along a welding bead at the root part while the laser beam is aimed at a contact point between the first welded material and the second welded material
Data Source
AI summary
Irradiation with a laser beam is performed along a welding bead, while the laser beam is aimed, as an irradiation point of the laser beam, at a contact point between a deck plate and a U-rib that is contained in a non-welded portion of a root part, from a side of the welding bead of the root part. Thereby, it is possible to remove a crack beginning at the non-welded portion of the root part generated at a joining portion between the deck plate and the U-rib of a steel floor slab, by the irradiation with the laser beam.