Laser Welding Path Control for Inclined Plate Gaps
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Solution Overview
Problem
Conventional welding methods fail to adequately fill the interspace between inclined metal plates with molten metal, leading to poor welding quality, especially when the interspace is large.
Innovation Solution
A laser welding method that adjusts energy application and welding speed around turning points by applying more energy and slowing down the laser beam on the vertically upper side, forming a main welding path with turning points, and using an auxiliary welding path to supply molten metal, while allowing slow cooling at the end point to prevent solidification cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional welding method is used on inclined metal plates with large interspace, then welding process is simple, but molten metal insufficiently fills the interspace resulting in poor welding quality
Solution Approach 1:
The welding method dynamically adjusts the laser beam's movement by introducing turning points in the welding path. The laser beam moves in a serpentine pattern with turning points positioned on both vertically upper and lower sides, allowing the molten metal to be properly distributed and filled in the interspace between inclined metal plates, thereby improving welding quality without requiring complex additional equipment
Solution Approach 2:
The method changes the welding parameters by controlling the laser beam's speed and position at turning points. Specifically, the laser beam is caused to move slower or pause at turning points on the vertically upper side where molten metal tends to accumulate, and moves faster at turning points on the vertically lower side, optimizing molten metal distribution and filling the interspace effectively
2Manufacturing precision
If laser beam moves at constant speed along straight path, then welding process is efficient, but molten metal runs down at turning points causing excessive melting and poor welding
Solution Approach 1:
The welding method employs periodic action by introducing controlled pauses or speed variations at specific turning points during the laser beam's movement. The laser beam moves at normal speed along the welding path but slows down or pauses periodically at turning points on the vertically upper side to prevent molten metal from running down, while maintaining higher speed at turning points on the vertically lower side, thus balancing welding quality and efficiency
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 enhances welding quality, compensates for molten metal insufficiency, reduces excessive melting, and increases design margins for products and jigs, while preventing solidification cracking and gap formation.
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
Data Source
AI summary
One aspect of the present disclosure is a welding method including 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. The welding includes forming a main welding path that intersects a welding advancing direction and that includes turning points. The upper plate and the lower plate are arranged in an inclined manner with respect to a horizontal plane when viewed parallel to the welding advancing direction. In the forming the main welding path, an amount of energy applied by the laser beam in an area in a neighborhood of the turning point on a vertically upper side is designed to be larger than an amount of energy applied by the laser beam in an area in a neighborhood of the turning point on a vertically lower side.