Laser Welding with Ultrasonic Oxide Removal to Suppress Bubbles
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Solution Overview
Problem
In laser welding methods, high heat input during temporary fixation and laser beam irradiation can cause bubbles to form, leading to spatter and joining defects, as well as leakage defects due to large bubbles.
Innovation Solution
The method involves a preparation process where the first and second members are ultrasonically vibrated to remove their oxide films, allowing direct joining without high heat input, followed by laser beam irradiation to weld the members at a lower temperature, thereby suppressing bubble formation and defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high heat input is applied during temporary fixation and laser beam irradiation to ensure proper welding, then welding strength is improved, but bubbles form and grow leading to spatter and joining defects
Solution Approach 1:
The oxide films are removed in advance through mechanical means (sandblasting, shot peening, or chemical etching) before the welding process. This preliminary action eliminates the harmful oxide layer that would otherwise require high heat input to break through, allowing subsequent welding to be performed at lower temperatures without forming large bubbles or spatter.
Solution Approach 2:
The patent replaces thermal-mechanical breaking of oxide films (which requires high heat input) with purely mechanical removal methods (sandblasting, shot peening, etching). This substitution eliminates the need for excessive heat during the welding process, preventing bubble formation while achieving reliable oxide-free bonding.
2Length of moving object
If high heat input is applied during laser beam irradiation to ensure welding penetration, then welding depth is improved, but large bubbles form causing leakage defects
Solution Approach 1:
Oxide film removal is performed as a preliminary step before welding, eliminating the need for high heat input during the welding process itself. This allows adequate welding penetration to be achieved at lower temperatures, preventing the formation of large bubbles that would cause leakage defects.
Solution Approach 2:
The patent changes the temperature parameter during welding by removing oxide films beforehand. This parameter change allows the welding process to operate at lower temperatures while still achieving sufficient penetration depth, thereby preventing bubble formation and leakage defects.
3Manufacturing precision
If high heat input is applied during temporary fixation to ensure member alignment, then positioning accuracy is improved, but bubbles form and grow leading to spatter
Solution Approach 1:
Oxide film removal is performed as a preliminary action before temporary fixation and welding. This eliminates the need for high heat input during positioning, allowing accurate alignment to be achieved without generating spatter from bubble formation.
Solution Approach 2:
The patent replaces thermal fixation (which causes spatter) with mechanical fixation methods that do not require high heat input. Combined with preliminary oxide film removal, this substitution achieves accurate positioning without generating harmful spatter.
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 reduces heat input, preventing large bubble formation and associated defects, enhancing the reliability of the welding process by minimizing spatter and leakage issues.
Implementation Method 1
joining the second base member to the first base member by ultrasonically vibrating the first and second members
Implementation Method 2
welding the second base member to the first base member by irradiating the laser beam on a portion at which the second base member is joined to the first base member
Data Source
AI summary
A laser welding method includes a preparation process and a welding process. The preparation process including preparing a joining member in which a second member is joined to a first member. The welding process includes welding the second member to the first member by irradiating a laser beam on the joining member. The first member includes a first base member and a first oxide film. The second member includes a second base member and a second oxide film. The preparation process includes removing the first and second oxide films and joining the second base member to the first base member by ultrasonically vibrating the first and second members. The welding process includes welding the second base member to the first base member by irradiating the laser beam on a portion at which the second base member is joined to the first base member.