T-Joint Laser Welding With Beam Weaving for Position Tolerance
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Solution Overview
Problem
Conventional laser welding methods are sensitive to positional deviations of the laser beam, leading to issues like burning-through and requiring complex preparation of workpieces, which limits tolerance and increases manufacturing time.
Innovation Solution
A laser welding method that forms a T coupling by superimposing a side surface of one member on the lower surface of another and irradiates the upper surface with a laser beam that is moved in a weaving pattern along the side surface, enhancing positional deviation tolerance by reducing penetration depth and increasing bead width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional laser welding method is used with projection and recess structures, then welding reliability is improved, but manufacturing complexity and time increase
Solution Approach 1:
The invention extracts and eliminates the complex projection and recess structures from the workpieces. Instead of modifying the workpiece geometry to achieve welding reliability, the patent uses a simplified flat-surface T-coupling configuration combined with laser beam weaving to achieve the same welding quality without the additional structural complexity.
Solution Approach 2:
The invention introduces dynamic laser beam weaving motion to compensate for the lack of static geometric features like projections and recesses. The laser beam dynamically oscillates in a weaving pattern during welding, which controls the molten pool behavior to achieve reliable welding on simple flat surfaces, thereby reducing manufacturing complexity while maintaining reliability.
2Manufacturing precision
If projection and recess structures are formed to ensure proper welding, then welding quality is improved, but manufacturing time increases
Solution Approach 1:
The invention performs preliminary laser beam weaving pattern setup and optimization before actual welding. By pre-configuring the weaving parameters (amplitude, frequency, speed) based on material properties and joint geometry, the process achieves high welding quality directly without requiring time-consuming formation of projection and recess structures.
Solution Approach 2:
The invention changes the laser processing parameters by introducing weaving motion parameters (amplitude, frequency, velocity) in addition to conventional laser parameters (power, speed, focus). This parameter expansion allows achieving high welding quality on simple flat joints, eliminating the need for time-consuming mechanical preparation of complex geometries.
3Manufacturing precision
If laser beam position is precisely controlled to avoid burning through, then welding precision is improved, but tolerance to positional deviation decreases
Solution Approach 1:
The invention applies dynamic laser beam weaving that intentionally introduces controlled positional variations during welding. The weaving motion creates a time-averaged heat distribution that is less sensitive to initial positioning errors, thereby increasing tolerance to positional deviation while maintaining welding precision through the dynamic control of the weaving pattern.
Solution Approach 2:
The invention changes from a static single-point laser beam to a dynamic weaving pattern with controllable amplitude and frequency. By adjusting these weaving parameters, the process can accommodate larger positional deviations while maintaining weld quality, thus improving adaptability without sacrificing precision.
4Strength
If deep penetration is achieved for strong welding, then weld strength is improved, but positional deviation tolerance decreases
Solution Approach 1:
The invention uses dynamic laser beam weaving to control the molten pool behavior during welding. The oscillating beam creates a wider, shallower molten pool with enhanced mixing, which achieves sufficient weld strength through improved metallurgical bonding rather than deep penetration alone. This dynamic approach simultaneously increases positional deviation tolerance by distributing heat over a larger area.
Solution Approach 2:
The invention changes the penetration profile by introducing weaving motion that transforms deep, narrow penetration into controlled shallow-to-moderate penetration with wider bead width. This parameter transformation maintains weld strength through enhanced lateral mixing and bonding while significantly improving tolerance to positional deviations.
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 improves tolerance to positional deviations and gap filling, allowing for more reliable and efficient welding by maintaining a large bead width and shallow penetration, thus enabling welding even with larger deviations and reducing manufacturing complexity.
Implementation Method 1
an upper surface of the second member opposite to the lower surface is irradiated with a laser beam so that the first member and the second member are welded to each other by the laser beam
Implementation Method 2
the laser beam is moved in a direction along the side surface of the first member while being weaved
Data Source
AI summary
A laser welding method according to the present disclosure includes a coupling forming step and a welding step. In the coupling forming step, a T coupling is formed by superimposing a side surface of a first member and a lower surface of a second member on each other. In the welding step, an upper surface of the second member opposite to the lower surface is irradiated with a laser beam so that the first member and the second member are welded to each other by the laser beam. Moreover, in the welding step, the laser beam is moved in a direction along the side surface of the first member while being weaved.