Multi-Spot Laser Welding Contours for Impermeable Aluminum Seams
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Solution Overview
Problem
Laser welding of aluminum-containing components often results in defects such as seam collapses, edge notches, holes, cracks, and pores due to turbulence in the melt pool, leading to impermeability issues and material loss, especially in applications requiring media impermeability.
Innovation Solution
The method involves subdividing a laser beam into multiple partial beams to generate multiple laser spots arranged in a ring formation on the components' surface, using a multifiber to create a core and ring portion in each spot, and traversing a welding contour with a scanner optical unit to achieve deep penetration welding, stabilizing the keyhole and reducing turbulence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If deep penetration laser welding is used to achieve high welding speed, then productivity is improved, but turbulence in the melt pool increases causing seam collapses, edge notches, holes, cracks and pores
Solution Approach 1:
The laser beam is divided into multiple partial beams (e.g., 2-4 beams) that are arranged in specific patterns (linear, triangular, or circular configurations). Each partial beam creates its own keyhole and melt pool region, which stabilizes the overall welding process by distributing the thermal load and reducing turbulent fluctuations in the central melt pool area.
Solution Approach 2:
The invention transitions from a single-point laser welding approach to a multi-point simultaneous welding approach. By arranging laser spots in linear, triangular, or circular patterns, the welding process operates in a distributed spatial configuration that stabilizes the keyhole formation and reduces melt pool turbulence while maintaining high welding speeds.
2Reliability
If multiple laser spots are used to stabilize the keyhole, then weld seam quality is improved, but device complexity increases
Solution Approach 1:
Optical elements such as diffractive optical elements (DOE), microlens arrays, or beam splitting optics are introduced as intermediaries to divide the single laser beam into multiple partial beams. These optical components enable the transformation from a simple single-beam configuration to a complex multi-beam pattern, achieving keyhole stabilization while managing system complexity through specialized optical design.
3Reliability
If soldering is used to join aluminum components, then impermeability is achieved, but the process becomes complex and susceptible to corrosion
Solution Approach 1:
The invention changes the fundamental joining parameter from chemical bonding (soldering or adhesive bonding) to direct metallurgical bonding through laser welding. By using multiple laser spots to create stable keyholes and controlled melt pools, the process achieves impermeable weld seams through direct fusion of aluminum components, eliminating the need for additional solder or adhesive materials and their associated complexity.
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 results in high-quality, media-impermeable weld seams with reduced pores and spatter, enabling reliable and efficient welding of aluminum-containing components with improved keyhole stability and directional independence.
Implementation Method 1
an output laser beam is subdivided into multiple partial beams directed onto the components such that multiple laser spots are generated on a surface of the components
Implementation Method 2
During laser welding, energy is fed in via a laser beam
Implementation Method 3
The welding contour is at least partially traversed by pivoting a first mirror in a controlled manner by a scanner optical unit
Implementation Method 4
a vapor capillary (keyhole) being formed in the component material
Implementation Method 5
During laser welding, energy is fed in via a laser beam... a vapor capillary (keyhole) being formed
Data Source
AI summary
A method for welding at least two aluminum-containing components is provided. Each component has a content of at least 75% by weight of aluminium. The method includes subdividing an output laser beam into multiple partial beams directed onto the components such that multiple laser spots are generated on a surface of the components, and traversing a welding contour on the surface of the components with the multiple laser spots. Laser spot centers of at least three laser spots of the multiple laser spots are arranged in a ring formation. The output laser beam is generated by a multifiber such that each laser spot of the multiple laser spots on the surface of the components has a core portion and a ring portion. The welding contour is at least partially traversed by pivoting a first mirror in a controlled manner by a scanner optical unit.