Laser-Welded Plate Member Cooling to Prevent Molding Cracks
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Solution Overview
Problem
Laser wobble welding of plate materials results in reduced hardness and tensile strength near the welded portion, leading to a risk of crack formation during molding due to thermal effects.
Innovation Solution
Implementing a cooling method using metallic cooling members with a flow path for cooling media during laser welding to inhibit thermal expansion and hardness reduction near the welded areas, and applying pressure with an elastic member during molding to prevent elongation and cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser wobble welding is used to join plate materials, then welding efficiency and automation are improved, but the tensile strength of the welded portion decreases due to thermal effects
Solution Approach 1:
The patent applies preliminary cooling action by positioning cooling members in contact with the plate materials before and during the laser welding process. This preliminary cooling prevents excessive heat accumulation in the thermally affected portions, thereby maintaining material hardness and tensile strength while still enabling efficient laser wobble welding.
Solution Approach 2:
The patent implements local quality control by applying cooling specifically to the thermally affected portions near the welded area, rather than cooling the entire workpiece uniformly. This localized cooling approach maintains the tensile strength where needed most (near the weld) while allowing the welding process to proceed efficiently.
2Manufacturing precision
If laser welding is performed on thin plate materials, then manufacturing precision is improved, but crack formation risk increases due to reduced hardness in thermally affected portions
Solution Approach 1:
The cooling members are positioned and activated before and during the welding process to preemptively prevent the thermal softening that leads to cracks. This preliminary cooling action ensures that thin plate materials maintain sufficient hardness throughout the welding process, reducing crack formation risk while preserving welding precision.
Solution Approach 2:
The cooling members act as an intermediary element between the laser heat source and the plate material. They mediate the thermal effects by absorbing and dissipating excess heat, thereby protecting the thin plate material from thermal damage and maintaining its mechanical properties during welding.
3Strength
If cooling members are added to the welding system, then tensile strength is maintained, but device complexity increases
Solution Approach 1:
The cooling members are designed to be self-cooling through natural convection or simple fluid circulation, eliminating the need for complex active cooling systems. The members themselves serve as the cooling mechanism, reducing system complexity while maintaining tensile strength through effective heat dissipation.
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 occurrence of cracks in welded members by maintaining the tensile strength of the welded and thermally affected portions, allowing for successful molding without thermal strain or burn-through, even with thin stainless steel plates.
Implementation Method 1
cooling a portion situated near the first portion of the first plate material and a portion situated near the second portion of the second plate material when performing the laser welding
Implementation Method 2
forming a welded member by joining a first portion of a plate-shaped first plate material and a second portion of a plate-shaped second plate material by laser welding
Data Source
AI summary
A method of manufacturing a member includes forming a welded member by joining a first portion of a plate-shaped first plate material and a second portion of a plate-shaped second plate material by laser welding. The method also includes cooling a portion situated near the first portion of the first plate material and a portion situated near the second portion of the second plate material when performing the laser welding.