Laser Welded Blank Strength Estimation via Micro-Hardness Scaling
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Solution Overview
Problem
Current methods lack the ability to accurately determine the strength of a weld seam in laser welded blanks, especially when different materials are used, leading to potential failures during stamping or collision events.
Innovation Solution
A method involving forming indentations to determine micro-hardness values of the blanks and weld seam, calculating a scale-up ratio, and using finite elemental analysis (FEA) simulations with scaled-up micro-hardness values to assess the weld seam's strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If physical tests are conducted on the weld seam to determine its strength, then accurate strength determination is achieved, but the process is time-consuming and cannot be simulated using computer simulations
Solution Approach 1:
The patent creates a digital copy of the weld seam through FEA simulation, replicating the physical weld seam's geometric and material properties in a virtual model. This digital twin allows for virtual testing and analysis without requiring physical prototypes or extensive physical testing, thereby reducing time while maintaining assessment accuracy.
Solution Approach 2:
The patent replaces the mechanical physical testing system with a computational FEA simulation system. Instead of conducting physical tensile tests or bend tests on actual weld seams, the invention uses numerical methods to simulate the welding process and predict weld seam strength, eliminating the need for time-consuming physical experimentation.
2Productivity
If the weld seam is ignored in simulations, then the simulation process is simpler and faster, but incorrect conclusions are drawn about the LWB's ability to withstand strains
Solution Approach 1:
The patent performs preliminary characterization of the weld seam's material properties through micro-hardness testing and scaling relationships before conducting the FEA simulation. This preliminary action establishes accurate material models for the weld seam, ensuring that when the weld seam is included in the simulation, it accurately represents real-world behavior and leads to reliable predictions of LWB performance.
3Adaptability or versatility
If different materials are used for the first and second blanks, then material optimization for vehicle body components is achieved, but determining the weld seam strength becomes difficult due to rapid cooling and material intermixing
Solution Approach 1:
The patent transforms the difficult-to-measure weld seam strength parameter into a measurable micro-hardness parameter through indentation testing. By establishing a relationship between micro-hardness and tensile strength through scaling relationships, the invention converts an indirect and difficult measurement into a direct and straightforward measurement, enabling easy assessment of weld seam strength in dissimilar material joints.
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 method allows for the estimation of weld seam strength, enabling the determination of whether a laser welded blank can withstand forming processes or collision events, thereby preventing potential failures.
Implementation Method 1
A laser welded blank (LWB) is formed by laser welding a first blank to a second blank
Implementation Method 2
forming a plurality of indentations in the first blank, the second blank, and the weld seam to determine an average value of a micro-hardness (Vickers) of each of the first blank, the second blank, and the weld seam
Data Source
AI summary
A method for estimating the strength of a laser welded blank including a first blank and a second blank joined together by a weld seam. The method may include forming a plurality of indentations in the first blank, the second blank, and the weld seam to determine an average value of a micro-hardness (Vickers); determining a scale-up ratio K; multiplying the scale-up ratio K by the average values of the micro-hardness of each of the first blank, the second blank, and the weld seam to obtain a scaled-up average value of the microhardness of each of the first blank, the second blank, and the weld seam; running a finite elemental analysis (FEA) simulation using the scaled-up average values of the microhardness; and based on the results of the simulation, determining whether the strength of the laser welded blank is sufficient to withstand being subjected to a forming process.