Laser Welding of Thick-Thin Plates With Split Heat Regions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods requiring both laser welding and metal inert gas welding for joining plates of different thicknesses result in high production and equipment costs, and laser welding alone may fail to adequately melt the thicker plate's corner portion, leading to an uneven joint.
Innovation Solution
A method using a single laser beam split into multiple regions, where a first region applies more heat to the thicker plate to melt its corner, and a second region welds it with the thinner plate, ensuring a smooth joint without additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If both laser welding and metal inert gas welding are performed to join plates of different thicknesses, then the joined portion can achieve a smooth shape, but equipment costs and production costs increase due to requiring multiple welding equipment
Solution Approach 1:
The laser beam is divided into multiple regions (first region and second region) with different characteristics. The first region has higher power density to melt the corner portion of the thick plate, while the second region has lower power density for welding the joint between plates. This segmentation allows a single laser device to perform functions that previously required multiple welding equipment.
Solution Approach 2:
A single laser welding device is made multi-functional by equipping it with a beam dividing device that creates multiple laser beam regions. This allows the same device to both melt the corner portion of the thick plate and perform the actual welding, replacing the need for separate laser welding equipment and metal inert gas welding equipment.
2Reliability
If laser welding is performed with output adjusted to prevent thin plate from melting down, then the thin plate is protected from damage, but the amount of heat applied to the thick plate becomes insufficient to melt its corner portion
Solution Approach 1:
Different regions of the laser beam are assigned different power densities tailored to local requirements. The first region concentrated on the thick plate's corner portion has high power density to achieve melting, while the second region at the joint area has lower power density appropriate for welding without damaging the thin plate. This local quality approach allows simultaneous satisfaction of conflicting thermal requirements.
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 melts the thicker plate's corner, forms a smooth joint, reduces equipment costs by using a single laser source, and prevents overheating of the thinner plate, thus achieving a cost-effective and smooth weld.
Implementation Method 1
welding an end surface of a thick plate and an end surface of a thin plate to each other to form the welded member by radiating laser beams at the thick plate and the thin plate
Implementation Method 2
a corner portion that is an end portion of the end surface of the thick plate in thickness directions of the thick plate is heated to melt by the first region passing through at least a vicinity of the end surface of the thick plate
Implementation Method 3
the end surface of the thick plate and the end surface of the thin plate are welded to each other by the second region passing through a vicinity of the corner portion of the thick plate, which has melted by the first region passing through at least the vicinity of the end surface of the thick plate, and a vicinity of the end surface of the thin plate
Data Source
AI summary
A method of manufacturing a welded member, the method including welding end surfaces of a thick plate and a thin plate to each other by laser beams. Irradiation regions irradiated with the laser beams includes a first and a second region. A corner portion of the thick plate is heated to melt by the laser beams via the first region that passes through at least a vicinity of the end surface of the thick plate. The end surfaces are welded to each other by the laser beams via the second region that passes through a vicinity of the corner portion, which has melted by the laser beams via the first region, and a vicinity of the end surface of the thin plate. An amount of heat applied to the thick plate via the first region is greater than that applied to the thin plate via the first region.