Multi-Beam Laser Welding of Metal Foils Without Hole Formation
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Solution Overview
Problem
Existing laser welding methods for metal foils often result in poor quality welds due to the risk of holes or tears forming when high power density is used, and inadequate energy penetration when power density is too low.
Innovation Solution
A welding method and apparatus that utilize a laser welding apparatus with a diffractive optical element to divide laser light into multiple beams, dispersing their positions so that their centers do not overlap within a prescribed area on the workpiece surface. Each beam is set to have a power density that prevents holes from forming in the metal foils, and the power density and beam positions are adjusted to form a weld pool that penetrates through the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high power density is used in laser welding of metal foils, then welding penetration is improved, but holes or tears form in the metal foils
Solution Approach 1:
The laser beam is divided into multiple beams (e.g., 7 beams) that irradiate the workpiece simultaneously at different positions. Each beam delivers lower power density individually, preventing holes and tears, while the combined effect achieves sufficient welding penetration through the metal foils.
2Object-affected harmful factors
If low power density is used in laser welding of metal foils, then holes and tears are prevented, but adequate energy penetration is not achieved
Solution Approach 1:
Multiple laser beams with lower individual power densities are combined to irradiate the workpiece simultaneously. The cumulative energy from all beams achieves adequate penetration through the metal foils while each beam's lower power density prevents the formation of holes and tears.
3Manufacturing precision
If multiple beams are used to improve welding quality, then penetration and quality are enhanced, but the optical system complexity increases
Solution Approach 1:
A diffractive optical element is introduced as an intermediary component to automatically divide the single laser beam into multiple beams. This element simplifies the overall system by replacing complex mechanical beam splitting mechanisms with a compact optical component that achieves multi-beam generation through diffraction.
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 lap welding by ensuring that the weld pool penetrates through the entire thickness of the metal foils without forming holes or tears, thereby improving the consistency and reliability of the welding process.
Implementation Method 1
irradiating a surface of the workpiece with the beams of the laser light by dispersing positions of the beams such that centers of the beams do not overlap with each other within a prescribed area on the surface
Implementation Method 2
Laser welding is a welding method in which a welding part of the workpiece is irradiated with laser light so as to melt the welding part with the energy of the laser light
Implementation Method 3
melting an irradiated part of the workpiece and performing welding
Data Source
AI summary
A welding method includes: disposing a workpiece formed by stacking a plurality of metal foils in an area to be irradiated with laser light that contains a plurality of beams; irradiating a surface of the workpiece with the beams of the laser light by dispersing positions of the beams such that centers of the beams do not overlap with each other within a prescribed area on the surface; melting an irradiated part of the workpiece and performing welding; and setting each of the beams to have a power density with which no hole opens in the metal foils, and setting the power density of the beams and dispersing irradiating positions to be emitted so as to form a weld pool penetrating the workpiece by the beams.