Laser Welding Airflow Control for Weld Plume Uniformity
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Solution Overview
Problem
Laser welding processes are hindered by weld plumes, which reduce welding efficiency and quality due to inconsistent air flow velocities, creating gradients that lead to poor weld plume control and dead zones.
Innovation Solution
An active air flow system with adjustable secondary inlets and a controller using air flow mapping and particle image velocimetry (PIV) to regulate air flow velocities and adjust the laser beam angle, ensuring consistent air flow distribution and plume management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If air flow is increased to remove weld plume, then plume removal effectiveness improves, but air flow velocity gradients increase creating dead zones
Solution Approach 1:
The air flow system is divided into multiple secondary inlets (first, second, third secondary inlets) with independent flow control valves, allowing segmented regulation of air flow across different regions of the work piece to achieve uniform velocity distribution while maintaining high plume removal effectiveness
Solution Approach 2:
Each secondary inlet is equipped with its own flow control valve, enabling local adjustment of air flow velocity to match the specific plume generation characteristics at different locations on the work piece, thereby eliminating dead zones while maintaining high overall productivity
2Reliability
If air flow velocity is increased to improve plume control, then plume management improves, but laser beam absorption and scattering increase
Solution Approach 1:
The system dynamically adjusts air flow velocity through programmable flow control valves based on real-time welding conditions and pre-characterized plume generation maps, maintaining the minimum necessary velocity for plume control while minimizing laser beam energy loss through absorption and scattering
3Stability of the object's composition
If multiple secondary inlets are added to improve air flow distribution, then air flow uniformity improves, but system complexity increases
Solution Approach 1:
Multiple secondary inlets are designed with identical or similar structures, each equipped with its own flow control valve, allowing the system to achieve complex air flow distribution patterns through simple, repeatable modular units that can be controlled through a centralized programming approach
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
The system maintains a steady, low weld plume throughout the welding process, improving weld quality and efficiency by optimizing air flow gradients and directing the laser beam for enhanced air flow velocity.
Implementation Method 1
the air monitoring system includes a particle image velocimetry (PIV) system configured to generate the air flow mapping
Implementation Method 2
An active air flow system with adjustable secondary inlets and a controller using air flow mapping and particle image velocimetry (PIV) to regulate air flow velocities
Implementation Method 3
a primary inlet coupled to an air source and one or more secondary inlets coupled to the primary inlet... to increase an average air flow velocity at a beam spot of a welding laser
Data Source
AI summary
Aspects of the disclosure include air flow systems configured to regulate air flow when laser welding to improve laser weld quality. An exemplary air flow system can include a primary inlet coupled to an air source and one or more secondary inlets coupled to the primary inlet. At least one of the one or more secondary inlets can include an internal valve. Each internal valve is actuatable between a fully open state, a fully closed state, and an intermediate state. The air flow system can further include an outlet coupled to each of the one or more secondary inlets downstream of the internal valve and a controller configured to adjust a position of each internal valve. The controller is configured to adjust the position of each internal valve based on an air flow mapping to increase an average air flow velocity along a laser beam of a welding laser.