Laser Weld Scanning Angle for Vertical Stacked Metal Plates
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Solution Overview
Problem
When welding multiple stacked metal plates upright, the molten pool can become too large due to gravity, leading to a risk of keyhole formation and welding failures such as hole generation.
Innovation Solution
A laser welding method where the laser beam is scanned around the outer periphery of the molten pool, with the scanning start point set between 135 degrees to 315 degrees in the vertical direction, and the irradiation energy density reduced on the upper side to prevent excessive keyhole formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the molten pool is enlarged by scanning the laser beam around the outer periphery, then the welding coverage is improved, but the keyhole becomes too large causing welding failures
Solution Approach 1:
The laser beam scanning starts from a specific position (135-315 degrees) before reaching the vertically upper side of the molten pool, allowing the molten pool to be gradually enlarged while controlling keyhole formation. This preliminary positioning of the scanning start point prevents excessive keyhole enlargement before it occurs.
Solution Approach 2:
The irradiation energy density is reduced specifically on the vertically upper side of the molten pool compared to other regions. This localized energy adjustment prevents excessive melting and keyhole formation in the critical upper region where gravity causes molten metal to accumulate and thin out the plate.
2Strength
If the irradiation energy density is increased to ensure proper welding, then the welding strength is improved, but the keyhole becomes too large causing hole generation
Solution Approach 1:
The irradiation energy density is made non-uniform across the molten pool, with reduced energy density specifically applied to the vertically upper side where keyhole formation is most problematic. This localized energy reduction prevents excessive keyhole enlargement while maintaining adequate welding strength in other regions.
Solution Approach 2:
The scanning starts from a position that allows gradual energy application before reaching the vulnerable upper region, preventing sudden excessive energy concentration that would cause large keyholes and welding failures.
3Device complexity
If the scanning starts from 0 degrees directly above the molten pool, then the welding process is simplified, but the molten pool is not sufficiently enlarged and welding failures occur
Solution Approach 1:
The scanning start point is set to a specific position (135-315 degrees) before the vertically upper side, allowing the molten pool to be properly enlarged through controlled scanning. This preliminary positioning ensures adequate molten pool development while preventing excessive keyhole formation.
Solution Approach 2:
The scanning parameters are optimized by setting the start angle within a specific range (135-315 degrees) and adjusting energy density distribution. These parameter changes enable proper molten pool enlargement while maintaining welding quality and preventing failures.
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 effectively suppresses the occurrence of welding failures by maintaining a smaller keyhole size and preventing hole generation, even with varying gaps between the plates.
Implementation Method 1
irradiating a plurality of stacked metal plates in an upright position with a laser beam to weld the plurality of stacked metal plates
Implementation Method 2
irradiating the plurality of metal plates with the laser beam to form a circular molten pool
Implementation Method 3
the thickness of the vertically upper part of the molten pool in the plate thickness direction decreases due to gravity acting on the molten pool
Data Source
AI summary
A laser welding method for irradiating a plurality of stacked metal plates in an upright position with a laser beam to weld the plurality of stacked metal plates is provided. The laser welding method includes irradiating the plurality of metal plates with the laser beam to form a circular molten pool and scanning the laser beam once around an outer periphery of the molten pool to enlarge the molten pool. In the enlarging of the molten pool, a scanning start point of the laser beam is set within a range from 135 degrees to 315 degrees in a scanning direction of the laser beam, with 0 degrees directly above the molten pool in a vertical direction.