Laser Welding Enclosure Flow Control for Laminar Particle Removal
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Solution Overview
Problem
Laser welding systems face defects due to metal vapor and solid particles emitted from the melt pool, which are not effectively removed by conventional gas circulation methods, leading to turbulence and further defects.
Innovation Solution
An apparatus with actuatable barriers and a controller ensures uniform, laminar gas flow by adjusting the cross-sectional areas of inlet and outlet openings to create a pressure differential, enhancing gas flow uniformity and removing particles effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If gas circulation rate is increased to remove metal vapor and solid particles, then particle removal effectiveness is improved, but turbulence is generated which causes additional defects
Solution Approach 1:
The patent changes the flow regime parameter from turbulent to laminar by adjusting gas flow characteristics. Specifically, it uses a laminar flow generator to create controlled laminar flow conditions that maintain sufficient particle removal capability while eliminating turbulence-induced defects. This parameter change resolves the contradiction by finding an optimal flow regime that achieves particle removal without generating harmful turbulence.
Solution Approach 2:
The patent replaces the conventional mechanical gas circulation system with a laminar flow generator that produces controlled laminar flow. This substitution transforms the approach from high-velocity turbulent circulation to controlled laminar flow, achieving particle removal through streamlined flow patterns rather than chaotic turbulence, thereby eliminating the harmful effects while maintaining removal effectiveness.
2Object-affected harmful factors
If gas circulation rate is reduced to eliminate turbulence, then turbulence-induced defects are prevented, but particle removal effectiveness deteriorates
Solution Approach 1:
The patent changes the flow regime parameter from laminar to controlled laminar with enhanced flow characteristics. By using a laminar flow generator, it creates a specific flow pattern that maintains laminar conditions (avoiding turbulence) while increasing the effectiveness of particle removal through optimized flow velocity and distribution. This resolves the contradiction by showing that laminar flow can be sufficiently effective when properly controlled.
3Object-generated harmful factors
If conventional gas circulation is used in closed environment, then particle removal is attempted, but turbulence pulls particles back into melt pool causing defects
Solution Approach 1:
The patent changes the flow regime from turbulent to laminar to prevent particle recirculation. Laminar flow characteristics ensure that gas flows in smooth, predictable patterns that carry particles away from the melt pool without creating eddies or recirculation zones that would pull particles back. This parameter change resolves the contradiction by achieving reliable particle removal in closed environments without compromising weld quality.
Solution Approach 2:
The patent replaces the conventional turbulent gas circulation system with a laminar flow generator that creates controlled laminar flow patterns. This substitution eliminates the chaotic flow patterns that cause particle recirculation and weld defects, providing reliable particle removal while maintaining high weld quality in closed environment welding applications.
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 solution achieves effective removal of metal vapor and solid particles while preventing additional defects by maintaining a stable, laminar gas flow during laser welding.
Implementation Method 1
circulating gas over the melt pool during welding to blow the vapor and particles away from the process area
Implementation Method 2
the cross-sectional area of the first opening is larger than the cross-sectional area of the second opening so that a pressure at the inlet is greater than a pressure at the outlet
Data Source
AI summary
A laser welding system for welding a component and reducing defects in the weld by ensuring uniform, laminar gas flow over a process area of the system. The laser welding system comprises a laser for welding the component, a platform for supporting the component, an enclosure surrounding the platform, a first actuatable barrier, a second actuatable barrier, an actuator, and a controller. The enclosure includes a plurality of walls, one of the walls having an inlet and another wall having an outlet. The inlet and outlet each having an opening having a cross-sectional area for letting gas flow through. The first and second barriers are configured to modify the cross-sectional areas of the openings when actuated. The actuator is configured to actuate the barriers, and the controller is configured to direct the actuator to actuate the barriers so that the cross-sectional area of the first opening is larger than the cross-sectional area of the second opening so that a pressure at the inlet is greater than a pressure at the outlet.