Multi-Stage Laser Welding to Reduce Voids and Cracks
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Solution Overview
Problem
Laser welding methods often result in cracks and bubbles in the welded portion, leading to decreased reliability of the apparatus due to inefficiencies in energy distribution and heat management during the joining process.
Innovation Solution
A laser processing method involving multiple irradiation stages, where a high-power first laser light is followed by a second laser light with reduced output, and then a third laser light with further reduced output, to manage heat and prevent void formation in the weld area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-power laser welding is used to improve production efficiency, then productivity increases, but cracks and bubbles occur in the welded portion reducing reliability
Solution Approach 1:
The laser welding process is divided into multiple stages with different power levels. The first stage uses high power (3000W or more) for rapid heating and melting, while the second stage uses reduced power (60-70% of first stage) for controlled cooling and void prevention. This temporal segmentation allows the system to achieve both high productivity and high reliability by optimizing parameters for each phase of the welding process.
2Loss of time
If high laser output is used to reduce processing time, then productivity improves, but void formation increases reducing weld quality
Solution Approach 1:
The laser irradiation is applied periodically in two distinct phases: an initial high-power pulse for rapid material processing, followed by a reduced-power phase for defect elimination. This periodic action with varying intensity allows the system to minimize total processing time while preventing void formation through the second-phase heat treatment.
3Device complexity
If uniform laser power is applied throughout the welding process, then the process is simple, but heat distribution is inefficient causing defects
Solution Approach 1:
The laser power is dynamically adjusted during the welding process rather than maintaining a constant value. The system transitions from a high-power state (3000W or more) to a reduced-power state (60-70% of initial power) based on the real-time thermal state of the workpiece. This dynamic control optimizes energy distribution efficiency while keeping the overall process relatively simple.
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 multi-stage laser processing method effectively reduces void occurrence and enhances the reliability of the weld by controlling energy distribution and heat management, resulting in improved weld quality.
Implementation Method 1
In a first irradiation process, first laser light with a first output value of 3000 W or more is irradiated on a first region of processing object including a metal
Implementation Method 2
In a second irradiation process, second laser light with a second output value that is not less than 60% and not more than 70% of the first output value is irradiated on the first region
Data Source
AI summary
According to an embodiment of the invention, a laser processing method includes a first irradiation process and a second irradiation process. In the first irradiation process, a first laser light is irradiated on a first region of a processing object including a metal. A first output value of the first laser light is 3000 W or more. In the second irradiation process, a second laser light is irradiated on the first region. A second output value of the second laser light is not less than 60% and not more than 70% of the first output value.