Laser Welding Structure With Holed Overlap for Stronger Low-Resistance Joints
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Solution Overview
Problem
Existing welding methods face challenges in achieving high bonding strength and low electric resistance, particularly in laser welding techniques where the interface between metal members is irradiated with a laser beam.
Innovation Solution
A welding method involving a first metal member with a pre-formed hole superimposed on a second metal member, where the laser beam is applied in a spiral trajectory to create a melted interface with a eutectic portion, enhancing bonding strength and reducing electric resistance by forming a protruding interface and overlap portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a laser beam is applied to weld a first metal member and a second metal member, then the welding process is simple and fast, but the bonding strength is insufficient and electric resistance is high
Solution Approach 1:
A hole is formed in the first metal member before the welding process. This preliminary action creates a specific structure that guides the laser beam and promotes better metal fusion, resulting in improved bonding strength while maintaining the simplicity and speed of laser welding.
2Productivity
If a laser beam is applied to weld a first metal member and a second metal member, then the welding process is simple and fast, but the electric resistance is high
Solution Approach 1:
A hole is formed in the first metal member before welding. This preliminary structure enables better electrical contact and lower resistance at the interface, while the welding process remains simple and fast using a laser beam.
3Ease of manufacture
If the laser beam is applied to melt the metal members, then welding is achieved, but the interface structure is insufficient for optimal bonding
Solution Approach 1:
A hole is formed in the first metal member before the welding process. This preliminary action creates an optimized interface structure that enhances bonding quality while maintaining the simplicity of the laser welding process.
Solution Approach 2:
The hole creates a localized structure at the welding interface that improves metal fusion and bonding characteristics. This local structural modification enhances the overall interface quality without complicating the global welding process.
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
The method significantly improves bonding strength by 26% and reduces electric resistance by 34%, as demonstrated in the examples, by creating a robust interface and increasing the bonded area between the metal members.
Implementation Method 1
an interface between the two members is irradiated with laser light
Implementation Method 2
the first metal member and the second metal member are melted by irradiation of the laser beam to form a liquid phase portion
Data Source
Figure 1A~1C
Figure 1D
Figure 2
AI summary
The welding structure includes a first metal member and a second metal member that are superimposed and welded together. The first metal member has a hole, and the second metal member has a nugget portion that is solidified again after being melted by heat of laser light. In which a peripheral portion of the hole in the first metal member covers the nugget portion, and a part of the nugget portion is exposed through the hole.