Laser Welding Beveled Fin Gap Tolerance
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Solution Overview
Problem
The challenge in laser welding of a workpiece and a fin member is that dimensional tolerances can lead to gaps, causing inconsistent heat input and potentially defective welds, as existing methods require adjusting welding conditions to accommodate these gaps.
Innovation Solution
A laser welding method where the fin member has a beveled portion that creates a predetermined space between the workpiece and the fin member, regardless of the gap presence, allowing stable filler metal feeding and consistent heat input, and enabling welding without changing the welding conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If more filler metals are provided to fill the gap between the workpiece and the fin member, then the gap can be filled, but the heat input around the gap increases causing defective welding
Solution Approach 1:
The fin member is pre-formed with a beveled portion that creates a predetermined space before welding begins. This preliminary geometric configuration ensures that the space for filler metal is already established, eliminating the need to increase filler metal quantity to accommodate gaps, thereby preventing excessive heat input while still achieving complete gap filling
2Reliability
If the welding conditions are adjusted to suppress defective welding, then the quality improves, but the welding operation becomes complicated
Solution Approach 1:
The beveled portion is pre-formed on the fin member to establish a predetermined space that accommodates gaps. This preliminary geometric preparation allows the welding process to proceed under consistent, standardized conditions without requiring real-time adjustments or complex control mechanisms, thereby maintaining weld quality while simplifying the welding operation
Solution Approach 2:
The invention changes the geometric parameter of the fin member by adding a beveled portion, which transforms the variable gap condition into a controlled predetermined space. This parameter change allows the welding process to maintain consistent heat input and filler metal feeding rates regardless of dimensional tolerances, simplifying the welding operation while ensuring reliable weld quality
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 ensures stable filler metal feeding and consistent heat input, preventing defective welds by maintaining consistent welding conditions even with gaps, and allows for effective joining of the workpiece and fin member.
Implementation Method 1
applies a laser beam between the workpiece and the fin member to join the workpiece and the fin member
Implementation Method 2
applies a laser beam between the workpiece and the fin member to join the workpiece and the fin member
Data Source
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AI summary
A nozzle as a welded structure includes a nozzle body (5), and a buckling prevention fin (6) joined to the nozzle body (5) by laser welding, in which an end of the buckling prevention fin (6) before laser welding is disposed to face the nozzle body (5), an installed state of the nozzle body (5) and the buckling prevention fin (6) includes an installed state in which a gap (G) is formed between the nozzle body (5) and the buckling prevention fin (6), and the buckling prevention fin (6) has a beveled portion (51) which is beveled at the end facing the nozzle body (5).