Laser-Welded Nut Assembly With Pressed Contact to Prevent Joint Gaps
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Solution Overview
Problem
Existing welding methods for nuts and steel plates often result in reduced joint strength due to gaps and weld defects caused by thermal expansion or contraction during laser welding.
Innovation Solution
A method of manufacturing a welded member by bringing a nut into close contact with the welding surface of a metal member and irradiating the nut with a beam from the opposite side to perform laser welding, thereby reducing gaps and weld defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the nut and steel plate are separated during laser welding to allow beam irradiation, then the beam can reach the welding area, but gaps remain and joint strength is reduced
Solution Approach 1:
The nut is pressed against the steel plate before laser welding begins, establishing close contact in advance. This preliminary action ensures that when the laser beam irradiates the welding area, the components remain in intimate contact, preventing gap formation and maintaining joint strength while allowing effective beam energy delivery
2Strength
If the nut is pressed against the welding surface to eliminate gaps, then joint strength improves, but thermal expansion or contraction causes the nut to tilt and creates weld defects
Solution Approach 1:
The pressing force is applied dynamically during the welding process rather than statically before welding. This allows the system to adapt to thermal expansion and contraction forces in real-time, maintaining contact between the nut and steel plate while accommodating dimensional changes, thereby preventing both gaps and tilting
Solution Approach 2:
The pressing force parameters are optimized to provide sufficient contact pressure to eliminate gaps without excessive force that would cause tilting. By carefully controlling the magnitude and distribution of the pressing force, the method achieves a balance between eliminating gaps and preventing thermal expansion-induced deformation
3Manufacturing precision
If a small beam diameter is used to precisely weld projections, then welding precision improves, but deep holes form in welded portions reducing joint strength
Solution Approach 1:
The beam diameter is optimized to a specific range that balances precision and strength. By selecting an appropriate beam diameter that is not too small, the method achieves sufficient welding precision while avoiding the formation of deep holes in the welded portions, thereby maintaining joint strength
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 improves the joint strength between the nut and the metal member by ensuring close contact and minimizing thermal expansion-induced defects during the welding process.
Implementation Method 1
irradiating a portion of the nut in close contact with the welding surface with a beam from a side opposite to the welding surface of the plate-shaped portion to weld the metal member and the nut to each other by laser welding
Implementation Method 2
the nut may tilt during welding due to occurrence of thermal expansion or contraction in a portion irradiated with the beam
Data Source
AI summary
Disclosed is a method of manufacturing a welded member with a metal member and a nut welded to each other. The manufacturing method includes bringing the nut into abutment with a welding surface of a plate-shaped portion of the metal member and pressing at least one of the plate-shaped portion or the nut to bring the nut into close contact with the welding surface. The manufacturing method further includes irradiating a portion of the nut in close contact with the welding surface with a beam from a side opposite to the welding surface of the plate-shaped portion to weld the metal member and the nut to each other by laser welding.