Laser-Welded Aluminum-Coated Blanks Without Coating Removal
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Solution Overview
Problem
Existing methods for laser welding steel substrates with aluminum or aluminum alloy coatings face issues such as reduced mechanical properties and increased risk of weak fractures due to aluminum entering the weld zone, requiring additional steps like coating removal or partial ablation, which increase costs and complexity.
Innovation Solution
A method involving laser welding with oscillating movements and dynamic power control to dilute aluminum throughout the weld zone, eliminating the need for coating removal and filler materials, ensuring uniform mechanical properties and avoiding intermetallic formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser welding is performed on steel substrates with aluminum or aluminum alloy coatings using conventional linear welding paths, then welding can be completed, but aluminum enters the weld zone causing reduced mechanical properties and increased risk of weak fractures
Solution Approach 1:
The patent applies dynamic oscillating movements to the laser beam during welding, transforming the static linear welding path into a dynamic oscillating path. This oscillation distributes aluminum more uniformly throughout the weld zone, preventing localized accumulation that would create brittle intermetallics and weak fracture points, thereby maintaining weld strength while preserving welding efficiency
Solution Approach 2:
The patent changes the welding parameters by implementing oscillating motion patterns (amplitude, frequency, waveform) and dynamic power control during the welding process. These parameter modifications allow the laser to effectively distribute aluminum and control the welding zone chemistry, achieving strong welds without requiring filler materials or pre-welding coating removal
2Strength
If coating removal or partial ablation is performed before welding to prevent aluminum contamination, then weld quality improves, but additional processing steps are required increasing costs and complexity
Solution Approach 1:
Instead of removing the aluminum coating before welding, the patent extracts the harmful effect by using oscillating laser movements to distribute the aluminum uniformly throughout the weld zone. This eliminates the need for separate coating removal steps while achieving the same goal of preventing harmful aluminum concentration in the weld
Solution Approach 2:
The welding process itself performs the function of coating management through oscillating movements that automatically distribute aluminum during welding. The process is self-regulating, requiring no external pre-treatment or additional equipment for coating removal, thereby simplifying the overall process
3Ease of manufacture
If aluminum is allowed to enter the weld zone during conventional welding, then welding can proceed without additional steps, but intermetallic formation occurs leading to weaker joints
Solution Approach 1:
The patent converts the harmful effect of aluminum entering the weld zone into a beneficial outcome by using oscillating laser movements to distribute the aluminum uniformly throughout the weld zone. This prevents localized intermetallic formation and creates a more homogeneous weld structure, transforming what would be a defect into a quality improvement while maintaining manufacturing simplicity
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 maintains the tensile strength of the weld zone comparable to the surrounding component, reduces the need for additional processing steps, and avoids the formation of weak intermetallics, resulting in a stronger and more cost-effective welding process.
Implementation Method 1
laser welding the first and second blanks following a welding path
Implementation Method 2
laser welding the first and second blanks
Implementation Method 3
the laser beam is combined with at least one electric arc to melt the metal and weld said workpiece(s)
Implementation Method 4
the laser beam is combined with at least one electric arc to melt the metal and weld said workpiece(s)
Implementation Method 5
hot deforming and quenching the welded blanks to form a component
Data Source
AI summary
The present invention relates to a method for joining a first blank and a second blank, wherein at least one of the first and second blanks comprises at least a layer of aluminum or an aluminum alloy. In particular, the method comprises placing the first and second blanks for welding; laser welding the first and second blanks following a welding path thus forming a tailor welded blank, wherein the welding path combines a linear movement along a welding direction and oscillating movements substantially transverse to the welding direction and then hot deforming and quenching the tailor welded blank to form a component, wherein the welding is done without using a filler.