Multi-Region Laser Welding to Reduce Sputter and Strength Loss
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Solution Overview
Problem
Laser welding methods face challenges in reducing sputter generation, which leads to material loss and potential equipment damage, especially when welding electric circuits, resulting in insufficient strength and functional issues.
Innovation Solution
A laser welding method and apparatus that utilize a laser beam with a main power region and auxiliary power regions, where the main power region has a higher power than the auxiliary regions, and the power ratio between them is within the range of 144:1 to 1:9, to stabilize the molten pool and reduce sputter generation by positioning auxiliary beams in front of the main beam during the sweeping process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional laser beam welding is used, then welding speed and productivity can be maintained, but sputter generation increases causing material loss and equipment contamination
Solution Approach 1:
The laser beam is divided into multiple beams (first, second, and third beams) with different power levels and positions. The high-power first beam leads the welding process, while lower-power second and third beams follow behind, creating a segmented beam structure that reduces sputter generation while maintaining welding productivity
Solution Approach 2:
Different regions of the laser beam are assigned different power characteristics. The first beam has high power density for efficient melting and welding, while the second and third beams have lower power densities that prevent excessive sputter generation, creating localized quality variations in the beam profile
2Strength
If high power laser beam is used to maintain welding strength, then welding quality is improved, but sputter generation increases causing equipment damage
Solution Approach 1:
The welding process uses multiple laser beams with different power levels instead of a single high-power beam. The first high-power beam ensures adequate welding strength, while the subsequent lower-power beams reduce the overall sputter generation that would occur with continuous high-power irradiation
Solution Approach 2:
The high-power first beam performs the primary melting and welding action in advance, preparing the molten pool before the lower-power second and third beams arrive. This preliminary action ensures welding strength is achieved while the subsequent beams operate at lower power levels, reducing sputter generation
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 effectively reduces sputter generation across various sweep speeds and beam configurations, enhancing welding strength and efficiency while minimizing material loss and equipment contamination.
Implementation Method 1
Laser welding is a welding method in which area to be welded in a workpiece is irradiated with laser beam and the area is melted by the energy of the laser beam
Implementation Method 2
the area is melted by the energy of the laser beam. A liquid pool of the metallic material melted, the liquid pool being called a molten pool, is formed at the area irradiated with the laser beam
Data Source
AI summary
A welding method includes: emitting laser beam toward a workpiece including a metal to melt and weld a part of the workpiece, the part being where the laser beam has been emitted to. Further, the laser beam includes a main power region and at least one auxiliary power region, a power of the main power region is larger than a power of each of the at least one auxiliary power region, and a ratio between the power of the main power region and the total of powers of the at least one auxiliary power region is in a range of 144:1 to 1:9.