Laser Welding of Plated Metal Sheets With a Gas-Release Gap
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for laser welding of galvanized steel plates require embossing to prevent blowholes, increasing process complexity and making continuous welding on continuous plate materials unsuitable.
Innovation Solution
A method and apparatus that introduce a predetermined gap in the thickness direction between the metal members to release evaporated gases during laser welding, eliminating the need for embossing and allowing flat plate materials to be welded without defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If embossing is applied to form a gas discharge path, then blowhole occurrence is prevented, but the number of processes increases and continuous welding on continuous plate material becomes unsuitable
Solution Approach 1:
The invention transitions from forming a gas discharge path through lateral embossing (2D surface modification) to creating a gap in the thickness direction (3D spatial separation). This dimensional change allows gas escape without requiring additional embossing processes, resolving the contradiction between blowhole prevention and process simplicity.
Solution Approach 2:
The gap in the thickness direction is formed in advance during material handling or positioning, before welding begins. This preliminary action ensures gas discharge paths are already established, eliminating the need for embossing during or after welding, thus preventing blowholes without increasing process complexity.
2Reliability
If embossing is applied to form a gas discharge path, then blowhole occurrence is prevented, but continuous welding on continuous plate material becomes unsuitable
Solution Approach 1:
By creating a gap in the thickness direction rather than using embossed surface features, the invention enables gas discharge without interrupting continuous material flow. This allows continuous welding on continuous plate material while maintaining blowhole prevention, resolving the contradiction between reliability and productivity.
3Reliability
If a gap is provided in the thickness direction, then gas release is enabled and blowholes are prevented, but the manufacturing process becomes more complex
Solution Approach 1:
The gap formation is performed as a preliminary step during material positioning or handling, before the welding process begins. This approach integrates gap creation into existing material preparation steps rather than adding a separate embossing process, thus enabling blowhole prevention without significantly increasing manufacturing process complexity.
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
Prevents blowhole formation by allowing gas release during laser welding of flat metal plates, maintaining joint strength and simplifying the manufacturing process without increasing the number of processes.
Implementation Method 1
the first metal member and the second metal member are joined together by laser welding
Implementation Method 2
the component-evaporated gas generated from the plated layer to be released through the gap
Data Source
Figure 1~2
Figure 3A~3B
Figure 4
AI summary
Provided is a manufacturing method for a joint body 1 having a blank material 2 plated with a metal material and a hoop material 20 plated with a metal material joined together by placing the hoop material 20 on the blank material 2 and causing a laser oscillation system 25 to irradiate a surface of the hoop material 20 with laser light 26 to form a joint portion 5 including a line-shaped welded portion 4 where the blank material 2 and the hoop material 20 are joined together. In this manufacturing method, the hoop material 20 is supplied to be placed on the blank material 2 and form a predetermined gap d between the blank material 2 and the hoop material 20, and the hoop material 20 is irradiated with a laser at a position where the predetermined gap d is located between the blank material 2 and the hoop material 20 to join the blank material 2 and the hoop material 20 together by laser welding.