Laser Beam Weld Path With Stop Points for Hot Crack Resistance
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Solution Overview
Problem
Existing methods for joining workpieces using machining beams, such as laser beams, often result in hot cracks, particularly in materials like aluminum and geometries susceptible to cracking, which can compromise the quality of the weld joint.
Innovation Solution
The method involves superimposing a periodic movement in a two-dimensional path on the feed movement of the machining beam, with specific geometry that includes stop points where the speed component in the transverse direction is zero, allowing for targeted interaction time and heat distribution to prevent hot cracks, using a beam deflecting device and control system to manage the movement and power of the machining beam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If full-penetration welding is used to join workpieces, then welding strength is improved, but hot cracks occur in the weld joint
Solution Approach 1:
The patent applies periodic oscillating movement superimposed on the feed movement of the machining beam along the weld joint. This periodic oscillation prevents hot cracks by periodically disrupting the continuous heat input that causes cracking in full-penetration welding, while still achieving adequate welding strength through controlled parameter variations.
Solution Approach 2:
The patent introduces dynamic parameter variations including oscillating movement in one or two dimensions, periodic changes in beam power, and variable feed rates. These dynamic adjustments allow the welding process to achieve full penetration and strength while avoiding the static conditions that lead to hot cracking.
2Object-affected harmful factors
If oscillating movement is superimposed on the feed movement to prevent hot cracks, then hot crack resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs a multi-functional control system that simultaneously manages oscillating movement in one or two dimensions, beam power modulation, and feed rate control through a single integrated apparatus. This universal system achieves hot crack prevention without proportionally increasing device complexity by combining multiple functions into one coordinated unit.
Solution Approach 2:
The patent utilizes periodic changes in multiple parameters (movement trajectory, beam power, feed rate) to prevent hot cracks. By coordinating these parameter changes through a unified control system, the patent achieves crack resistance while managing complexity through systematic parameter coordination rather than separate control mechanisms.
3Manufacturing precision
If periodic oscillating movement is applied to the machining beam, then weld joint quality is improved, but processing time increases
Solution Approach 1:
The patent maintains continuous welding action by superimposing oscillating movement on the feed movement rather than interrupting the process. The oscillation occurs within the continuous forward progression along the weld joint, ensuring that the useful welding action continues without pause while improving weld quality through the oscillatory component.
Solution Approach 2:
The periodic oscillating movement is designed to occur at optimized frequencies and amplitudes that improve weld quality without significantly extending processing time. The oscillation is superimposed on continuous feed movement, allowing the process to maintain forward progression while incorporating quality-improving periodic variations.
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 effectively reduces the formation of hot cracks, enhancing the quality of the weld joint by optimizing the interaction time and heat distribution, particularly beneficial for materials like aluminum and fillet joints.
Implementation Method 1
forming a weld joint by moving a machining beam, in particular a laser beam
Implementation Method 2
The laser beam is a circular laser beam spot... The laser beam spot can swing in a linear path
Data Source
AI summary
The disclosure relates to methods and systems for joining at least two workpieces, including forming a weld joint by moving a machining beam, e.g., a laser beam, and the at least two workpieces relative to one another along a feed direction, wherein the movement of the machining beam and the two workpieces relative to one another is superimposed with a periodic movement in a movement path, e.g., a two-dimensional movement path, which extends in a transverse direction perpendicularly to the feed direction and, e.g., additionally in the feed direction. The movement path has, between two reversal points in the transverse direction, at least one stop point at which a speed component of the periodic movement in the transverse direction is zero. The invention also relates to computer program products and systems for carrying out the methods.