Laser Welding Beam Shaping for Mixed-Material Welding Zones
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Solution Overview
Problem
Conventional laser welding methods for components of different materials are slow due to the time-consuming process of adjusting scanner optics to vary the laser beam spot size, leading to delays in manufacturing, especially when welding multiple components of varying materials to a common base part.
Innovation Solution
The method involves directing a laser beam onto a workpiece using scanner optics and varying the splitting of laser energy between a core fraction and a ring fraction to adjust the effective spot size without moving the scanner optics, allowing for rapid adaptation to different materials and minimizing splatter and pores by optimizing the intensity profile and seam width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the scanner optics distance from the workpiece is varied to adjust spot size for different materials, then welding quality is improved, but the manufacturing speed deteriorates due to time-consuming adjustments
Solution Approach 1:
The patent changes the optical parameter (spot size) by varying the laser beam propagation path length through different optical configurations rather than moving the scanner optics physically. This allows spot size adjustment for different materials while maintaining constant scanner positioning, thus preserving manufacturing speed.
Solution Approach 2:
The patent replaces the mechanical adjustment system (moving scanner optics) with an optical system adjustment (changing beam propagation path). Instead of mechanically displacing the scanner to change spot size, the invention uses optical means to achieve the same effect without mechanical movement, eliminating adjustment time.
2Manufacturing precision
If the scanner optics are displaced to adjust spot size for different materials, then welding precision is improved, but the process complexity increases due to additional adjustment mechanisms
Solution Approach 1:
The patent makes the laser beam propagation path adjustable through multiple configurations within the same optical system, allowing the system to serve multiple welding conditions (different spot sizes for different materials) without requiring separate adjustment mechanisms for each material type.
Solution Approach 2:
The patent introduces dynamic adjustability in the optical path configuration, allowing the beam propagation path length to be changed on-the-fly between welding operations. This dynamic optical configuration enables spot size adaptation without mechanical displacement of the scanner optics.
3Manufacturing precision
If the laser beam spot size is adjusted by moving the workpiece relative to the focal plane, then welding quality for different materials is improved, but the production time increases due to repeated positioning delays
Solution Approach 1:
The patent pre-configures multiple laser beam propagation paths with different lengths corresponding to different spot sizes. The appropriate path is selected in advance based on the material to be welded, eliminating the need for real-time positioning adjustments during the welding process and reducing positioning delays.
Solution Approach 2:
The patent introduces an optical path as an intermediary between the laser source and the workpiece. By adjusting the optical path length rather than the physical position of components, the system achieves spot size variation without direct mechanical intervention, thus eliminating positioning delays.
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 significantly accelerates the welding process by maintaining constant scanner optics positioning, reducing downtime, and ensuring high-quality welds with minimal defects, particularly suitable for welding aluminum-based cathodes and copper-based anodes in battery manufacturing.
Implementation Method 1
various optical elements (usually a collimation lens or collimation lens system and a focusing lens or focusing lens system)
Implementation Method 2
an adjustable deflecting instrument (usually a mirror that can be adjusted with piezo elements), with which the alignment of the laser beam emerging from the scanner optics can be varied
Implementation Method 3
directing a laser beam onto the workpiece... welding a first component to a base part of the workpiece
Data Source
AI summary
A method for laser welding of a workpiece includes directing a laser beam onto the workpiece by using scanner optics, and in an arbitrary order with the laser beam, welding a first component to a base part of the workpiece at least in a first welding zone, and welding a second component to the base part in a second welding zone. A laser energy of the laser beam is capable of being split variably at least between a core fraction corresponding to a core beam of the laser beam, and a ring fraction corresponding to a ring beam of the laser beam that encloses the core beam. The splitting of the laser energy between the core fraction and the ring fraction is selected differently for welding in the first welding zone and for welding in the second welding zone.