Laser Welding Beam Layout for Strong Welds With Less Spatter
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Solution Overview
Problem
Laser welding often results in spatter generation and insufficient weld strength due to inadequate energy density distribution, leading to issues with molten pool formation.
Innovation Solution
A laser welding apparatus that radiates a beam to both a main and an auxiliary region on the welding surface, with the auxiliary region positioned adjacent or forward to the main region, allowing for a deep molten pool formation in the main region and a shallow pool in the auxiliary region to absorb spatter, thereby reducing spatter generation while achieving strong welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a high intensity beam is radiated to form a deep molten pool for strong welding, then weld strength is improved, but spatter generation increases
Solution Approach 1:
The beam radiation region is divided into a main region for deep molten pool formation and an auxiliary region for spatter absorption. This segmentation allows different functional zones within the overall radiation area, enabling strong welding while controlling spatter through dedicated regions.
Solution Approach 2:
Different regions of the beam radiation area are assigned different intensity characteristics. The main region has higher intensity for deep penetration and strong welding, while the auxiliary region has lower intensity specifically for absorbing spatter. This local differentiation of beam quality resolves the contradiction between weld strength and spatter control.
2Productivity
If beam intensity is rapidly increased to achieve deep molten pool quickly, then welding efficiency is improved, but spatter generation increases
Solution Approach 1:
The auxiliary region is positioned on the forward side of the main region in the welding direction, creating a preliminary zone that prepares the material for the high-intensity main beam. This preliminary action of low-intensity radiation reduces spatter generation before the main welding action occurs, maintaining efficiency while controlling harmful effects.
Solution Approach 2:
The auxiliary region acts as an intermediary zone between the incoming material and the high-intensity main beam. It provides a transition area that reduces spatter generation through low-intensity radiation, mediating the interaction between the beam and material to achieve efficient welding with reduced spatter.
3Use of energy by moving object
If beam is radiated only to the main region for focused welding, then energy concentration is improved, but weld width and strength are insufficient
Solution Approach 1:
The main region and auxiliary region are merged into a single beam radiation area with coordinated intensity distributions. Both regions contribute to the overall welding process - the main region provides focused energy for penetration while the auxiliary region contributes to weld width and strength, achieving both energy concentration and sufficient weld dimensions.
Solution Approach 2:
The solution extends the beam radiation from a single focused point (main region only) to a two-dimensional area encompassing both main and auxiliary regions. This dimensional expansion allows energy to be distributed across different spatial zones, maintaining concentration in the main region while adding width contribution from the auxiliary region for enhanced weld strength.
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 configuration effectively reduces spatter formation and enhances weld strength by creating a deep molten pool in the main region and a shallow pool in the auxiliary region, allowing for stable keyhole formation and improved weld quality across various directions and materials.
Implementation Method 1
A laser welding apparatus of the present disclosure radiates a beam to a welding surface in at least a part of a plurality of members
Implementation Method 2
each radiation target region first receives a low intensity beam toward the auxiliary region, and then receives a high intensity beam toward the main region
Implementation Method 3
part of the melted base material moves outward, and then generates spatter when coming out of the molten pool
Data Source
AI summary
A radiator in a laser welding apparatus radiates a beam to a main region and an auxiliary region on a welding surface. The auxiliary region is positioned to be adjacent to the main region or to be apart from the main region. A welding direction is a direction in which a beam radiation region moves during laser welding. The auxiliary region includes at least an area positioned on a forward side of the main region in the welding direction. The radiator radiates the beam in a setting such that at least one peak occurs in each of the main region and the auxiliary region.