Multi-Laser Resistance Cladding for Direction-Independent Joining
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Solution Overview
Problem
Existing devices for electrical resistance deposition melting, such as resistance welding and soldering, are direction-dependent and require high laser energy, making them costly and inefficient, especially when compared to electrical devices for melting additional materials.
Innovation Solution
A device with multiple laser emitters positioned to irradiate laser energy from different directions, allowing for direction-independent resistance deposition melting by selectively or coordinately adjusting laser energy based on the feed device's movement, thereby supporting the melting process in a direction-dependent manner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional resistance welding or resistance brazing is used to join dissimilar materials, then the process is simple and fast, but it causes material loss through spatter and vaporization and produces harmful emissions
Solution Approach 1:
An additional material is introduced as an intermediary between the two dissimilar base materials. This additional material acts as a mediator that facilitates joining while significantly reducing spatter and vaporization compared to direct resistance welding of dissimilar materials, thereby reducing material loss and harmful emissions
Solution Approach 2:
The invention combines resistance welding with laser beam technology, replacing part of the thermal-mechanical resistance welding process with optical energy from laser beams. This substitution allows for more controlled melting and joining with reduced material loss
2Loss of substance
If laser beam welding is used to join dissimilar materials, then material loss is reduced, but the device complexity and cost increase
Solution Approach 1:
The invention merges resistance welding technology with laser beam technology into a hybrid process. This combination allows the system to leverage the advantages of both methods: reduced material loss from laser welding while maintaining the simplicity and speed benefits of resistance welding, avoiding the need for complex standalone laser welding equipment
Solution Approach 2:
The device is designed to perform multiple functions: it can conduct resistance welding, apply laser beams, and feed additional material. This multi-functionality allows the system to handle dissimilar material joining with reduced material loss while maintaining operational efficiency
3Productivity
If high joining speeds are achieved through resistance welding, then productivity is high, but the quality and reproducibility of joints deteriorate
Solution Approach 1:
The system incorporates sensors that detect parameters such as joint temperature, melting behavior, and material properties in real-time. This feedback is used to dynamically adjust process parameters like current, voltage, and laser power, ensuring consistent joint quality and reproducibility even at high joining speeds
Solution Approach 2:
The invention employs dynamic adjustment of process parameters during the joining operation. The system can adaptively modify current intensity, laser beam power, and feeding speed based on real-time conditions, enabling high productivity while maintaining consistent joint quality through continuous optimization
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
Enables flexible and precise control over the resistance deposition melting process, reducing costs and improving efficiency by using adjustable laser power and flexible laser beam arrangements to optimize weld or solder seams.
Implementation Method 1
an electrical current supply unit for generating an electric flux between the base material and the additive material for melting the additive material and/or the base material
Implementation Method 2
a first laser emitter at a first laser emitter position and a second laser emitter at a second laser emitter position are aligned with the processing zone in such a way that, by means of a first laser beam from the first laser emitter and by means of a second laser beam from the second laser emitter, it is possible to emit laser energy from different laser emitter positions so as to support the resistance deposition melting process
Data Source
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AI summary
The invention relates to a device for electrical resistance cladding, in particular resistance welding or resistance brazing, of an additive material onto a processing surface of a base material in a processing zone, comprising a feeding device for feeding the additive material into the processing zone along a reference axis and an electrical current supply unit for generating an electric flux between the base material and the additive material for melting the additive material and/or the base material, wherein a first laser emitter at a first laser emitter position and a second laser emitter at a second laser emitter position are aligned with the processing zone in such a way that, by means of a first laser beam from the first laser emitter and by means of a second laser beam from the second laser emitter, it is possible to emit laser energy from different laser emitter positions.so that, by means of the first laser beam and/or the second laser beam, a processing-dependent action in the processing zone is enabled to support the resistance deposition melting process. Furthermore, the invention relates to a method for applying an additive material and the use of a device mentioned above.