Laser Welding Edge Geometry with Undercuts
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Solution Overview
Problem
Conventional laser beam welding requires precise alignment and pressure to prevent gaps between edges with rough surfaces, which is complex and challenging, especially at high speeds, as the small laser beam diameter can pass through gaps without melting the edge material.
Innovation Solution
The method involves creating an edge geometry with undercuts that ensure the laser beam hits the edge material, allowing for reliable welding without complex guides or pressure, by forming undercut connecting edges that overlap or interlock, ensuring the laser beam melts the material effectively and creating a stable weld.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional laser beam welding is used with small diameter laser beam, then narrow weld seam shapes can be produced, but the edges must be placed together seamlessly without gaps which requires complex guidance and alignment units
Solution Approach 1:
The edge geometry is prepared in advance by forming undercuts on the edges to be welded. This preliminary action ensures that when the edges are placed together, the undercuts create an overlapping configuration that prevents the laser beam from passing through gaps without melting the edge material, thereby eliminating the need for complex guidance and alignment units during the welding process.
Solution Approach 2:
The undercut geometry is applied locally at the edge regions to be welded, creating a specific local structure with overlapping surfaces. This local modification ensures that the laser beam interacts with the edge material in a controlled manner, melting it reliably even when edges are not perfectly aligned, thus reducing the need for complex alignment mechanisms.
2Reliability
If pressure is applied to place edges against each other to prevent gap formation, then reliable welding can be achieved, but complex guidance or pressing elements are required
Solution Approach 1:
The undercut geometry is formed on the edges before welding, creating an overlapping configuration that passively prevents gap formation during welding. This preliminary structural preparation eliminates the need for pressing elements or complex guidance systems, as the undercut geometry itself ensures reliable edge contact and prevents the laser beam from passing through gaps without melting the material.
3Adaptability or versatility
If edges with rough surfaces are welded, then material variability is accommodated, but gap formation occurs requiring complex guidance
Solution Approach 1:
The undercut geometry is formed on the edges before welding, creating an overlapping configuration that compensates for surface roughness variations. This preliminary structural preparation ensures that even with rough surfaces, the laser beam will intersect with edge material due to the undercut overlap, preventing gap formation and eliminating the need for complex guidance systems.
Solution Approach 2:
The undercut geometry creates a specific local structure at the edge regions that ensures laser beam interaction with material. This local modification makes the welding process insensitive to overall edge roughness, as the undercut configuration guarantees that the laser beam will melt the edge material even when edges are not perfectly aligned, thereby accommodating material variability without complex guidance.
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 ensures a secure and stable welded connection by preventing the laser beam from passing through gaps, allowing for reliable welding of edges with rough surfaces without the need for complex alignment or pressure, and enhancing the stability of the weld seam.
Implementation Method 1
the laser beams used in laser beam welding usually have a very small diameter of a few tenths of a millimeter, which results in very high energy concentrations at the welding point
Implementation Method 2
which results in very high energy concentrations at the welding point and at the same time very narrow weld seam shapes can be produced
Data Source
Figure 1~8
Figure 9~12
AI summary
There is described a method for welding objects (1, 2), in particular metal plates, sheets or profiles, in which at least two edges (9, 10) of the objects (1, 2) are placed against one another and the edges (9, 10) resting against one another are welded together by a laser beam. In the process, an edge geometry is created such that during the welding process the edges (9, 10) resting against one another form mutual undercuts (18, 19) in the direction of the laser beam and/or in the direction of movement of the laser beam.