Laser Beam Welding With Trailing Beam Control for Stable Weld Seams
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Solution Overview
Problem
High-speed laser beam welding methods face challenges in maintaining weld seam quality due to disruptive backflow in capillary regions, particularly at high relative speeds between the laser beam and components, which affects the stability and quality of the weld.
Innovation Solution
The method involves monitoring the molten bath using a recording device to adjust the distance, laser power, and movement of a trailing laser beam relative to the leading beam, ensuring parameters are adapted based on real-time data evaluation to maintain optimal conditions for weld seam quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the relative speed between the laser beam and components is increased to improve productivity, then welding speed and output are improved, but weld seam quality deteriorates due to disruptive backflow in capillary regions
Solution Approach 1:
The patent employs a recording device to monitor the molten bath in real-time and uses this feedback to dynamically adjust the distance between the trailing laser beam and the leading laser beam. This closed-loop control system allows the welding process to maintain optimal parameters despite high relative speeds, preventing backflow disruptions while sustaining high productivity.
Solution Approach 2:
The distance between the trailing laser beam and the leading laser beam is made dynamically adjustable rather than fixed. The system continuously modifies this distance based on real-time molten bath conditions, enabling the welding process to adapt to varying speeds and maintain quality even at high relative speeds between 0.1 m/s and 0.5 m/s.
2Reliability
If a trailing laser beam is added to improve weld seam quality and prevent backflow, then weld seam stability is improved, but device complexity increases
Solution Approach 1:
The trailing laser beam serves multiple functions: it heats the material in the trailing area to prevent backflow, stabilizes the molten bath, and its distance can be dynamically adjusted to adapt to different welding conditions. This multi-functional approach justifies the added complexity by providing multiple benefits from a single additional component.
3Adaptability or versatility
If the distance between the trailing laser beam and leading laser beam is fixed, then device complexity is reduced, but adaptability to different welding conditions and speeds is limited
Solution Approach 1:
A recording device monitors the molten bath conditions and provides real-time feedback to the control system. This feedback mechanism enables automatic adjustment of the trailing laser beam's distance from the leading beam, allowing the system to adapt to different welding speeds and conditions without requiring complex manual intervention.
Solution Approach 2:
The patent replaces complex mechanical adjustment mechanisms with a control system that uses optical monitoring (recording device) and electronic control to adjust the trailing laser beam's position. This substitution of mechanical systems with optical-electronic control reduces the overall mechanical complexity while improving adaptability.
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 enables high-quality weld seams even at high relative speeds by dynamically controlling the trailing laser beam, preventing disruptive backflow and enhancing the stability and quality of the weld, particularly suitable for applications like fuel cell bipolar plate welding.
Implementation Method 1
a laser beam is moved along a joining zone of the components, wherein the material of the components is melted in the area of the joining zone
Implementation Method 2
the material of the components is melted in the area of the joining zone
Implementation Method 3
a further laser beam is used at a distance from or in the trailing area of the laser beam, which heats the material of the components in the joining zone
Implementation Method 4
more stable flow rates with lower flow velocities can be achieved within the melt in the trailing area
Data Source
AI summary
The invention relates to a method for welding components (1, 2) by means of a laser beam (11), in which the laser beam (11) is moved along a joining zone (16) of the components (1, 2), wherein the material of the components (1, 2) is melted in the region of the joining zone (16), wherein the melt solidifies to form a weld seam (24) at a distance from the laser beam (11), and wherein a region (20) trailing the laser beam (11) is heated by means of a further laser beam (26).