Laser Lap Welding Paths for Filling Plate Interspace
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Solution Overview
Problem
The existing spiral laser welding method struggles to adequately fill the interspace between metal plates, leading to poor welding quality, as it often results in insufficient molten metal in the main welding path.
Innovation Solution
A welding method that involves forming a continuous auxiliary welding path and a main welding path with turning points, where molten metal from the auxiliary path is supplied to the main path, and includes features like varying energy application and welding speed around turning points to enhance filling and reduce solidification cracking, with the option of inclining the plates for increased design margin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If welding is performed only by the spiral manner, then the welding process is simple, but the interspace between metal plates cannot be adequately filled
Solution Approach 1:
The welding path is divided into two distinct segments: an auxiliary welding path that generates molten metal, and a main welding path that fills the interspace. This segmentation allows each path to perform its specific function optimally, resolving the contradiction between simple process and adequate filling.
Solution Approach 2:
The auxiliary welding path performs preliminary action by generating and accumulating molten metal before the main welding path operates. This preliminary molten metal generation ensures sufficient material is available for interspace filling during the main welding process.
2Productivity
If the main welding path is formed quickly, then productivity is improved, but gaps may occur due to insufficiency of molten metal
Solution Approach 1:
The auxiliary welding path performs preliminary molten metal generation at a controlled pace, ensuring sufficient material accumulation before the high-speed main welding path begins operation. This eliminates gaps while maintaining high productivity.
Solution Approach 2:
The auxiliary welding path serves the main welding path by automatically generating and supplying molten metal to the welding zone. This self-service mechanism ensures continuous material availability without external intervention.
3Manufacturing precision
If energy is applied uniformly along the welding path, then the process is simple to control, but excessive melting occurs on the vertically lower side and insufficiency on the vertically upper side
Solution Approach 1:
The energy application is made non-uniform with different characteristics at different locations: higher energy on the vertically upper side where molten metal is insufficient, and lower energy on the vertically lower side where excessive melting occurs. This local quality adjustment resolves the distribution imbalance.
Solution Approach 2:
The welding process introduces asymmetric energy distribution to counteract the symmetric gravitational effect. The laser energy is deliberately applied asymmetrically with respect to the vertical axis, providing more energy to the upper side and less to the lower side.
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 method improves welding quality by ensuring adequate filling of the interspace between plates, reduces the occurrence of gaps and solidification cracking, and increases design flexibility by effectively utilizing molten metal and adjusting energy distribution.
Implementation Method 1
welding an upper plate and a lower plate overlapped with the upper plate by irradiating a surface of the upper plate with a laser beam
Implementation Method 2
molten metal is generated in the auxiliary welding path, and the molten metal can be supplied to the main welding path
Data Source
AI summary
Provided is a welding method enabling enhancement of quality of welding between an upper plate and a lower plate. One aspect of the present disclosure is the welding method including welding the upper plate and the lower plate overlapped with the upper plate by irradiating a surface of the upper plate with a laser beam. The welding includes: forming an auxiliary welding path that is continuous and includes a reciprocating or circling path; and forming a main welding path that intersects a welding advancing direction and that includes turning points, after formation of the auxiliary welding path.