Laser Welding Plenum for Argon Shielding and By-Product Extraction
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Solution Overview
Problem
Laser welding of hollow titanium fan blades generates by-products such as metallic vapors and soot, which are not effectively removed during the process, potentially causing oxidation and compromising the structural integrity of the blades.
Innovation Solution
A device comprising a housing with a first circumferential plenum for delivering argon gas and a second circumferential plenum for removing by-products, utilizing a vacuum source to draw in and remove vapors and soot through a system of inlet and outlet holes, ensuring a continuous argon environment during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a continuous flow of argon enters the open-top container to protect the fan blade during welding, then the fan blade remains submerged in argon free from air, but by-products such as metallic vapors and soot accumulate at the top of the argon bath
Solution Approach 1:
The patent extracts harmful by-products (metallic vapors and soot) from the argon atmosphere using a vacuum system with suction nozzles positioned near the welding zone. This removes the harmful factors while preserving the protective argon environment, resolving the contradiction between oxidation protection and by-product accumulation.
Solution Approach 2:
The patent introduces an intermediary vacuum system that mediates between the protective argon atmosphere and the harmful by-products. The vacuum system acts as a mediator to selectively remove by-products without disrupting the argon shielding, allowing both oxidation protection and by-product removal to coexist.
2Manufacturing precision
If the laser welds the cover to the internal ribs and racetracks on a twisted surface, then the welding reaches strategic locations, but small variations in height occur requiring articulation of the blade's sub-fixture and independent robot arm
Solution Approach 1:
The patent employs dynamic articulation of the blade's sub-fixture and independent robot arm to adapt to the twisted surface geometry. This dynamic adjustment allows the laser to maintain precise welding positions despite height variations, resolving the contradiction between welding accuracy and system complexity.
3Ease of manufacture
If external clamps secure the blade body to the base fixture and clamp the cover to the blade body, then tack welds can be made at pre-determined locations, but the device requires complex clamping and positioning mechanisms
Solution Approach 1:
The patent uses external clamps to pre-position and secure the blade body and cover before welding begins. This preliminary clamping action establishes stable tack weld locations and ensures proper alignment, simplifying the subsequent welding process while maintaining manufacturing precision.
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
Effectively maintains an argon environment around the welding area, preventing oxidation and ensuring the structural integrity of the titanium fan blades by continuously removing by-products, thus enhancing the welding process.
Implementation Method 1
A vacuum source is connected to the by-product outlet to draw flow through the by-product inlet holes and through the by-product outlet
Implementation Method 2
A gas source is connected to the gas inlet and delivers a gas through the gas outlet holes
Data Source
AI summary
A laser welding by-product removal device comprises a housing that includes distal and proximate ends separated along a central axis by a peripheral sidewall. A first plenum circumscribes the peripheral sidewall at the proximate housing end and includes a gas inlet and a first plenum base surface that includes a plurality of gas outlet holes. A second plenum circumscribes the peripheral sidewall between the first plenum and the distal housing end, where the second plenum includes a second plenum base surface, radially inner and outer sidewalls that extend axially distal from the second plenum base surface. The second plenum includes a top surface extending between the radially inner and outer sidewalls, and a by-product outlet in the top surface, where at least one of the second plenum base surface and the radially outer sidewall includes a plurality of by-product inlet holes.