Multiclad Fiber Beam Splitting for High-Speed Laser Weld Quality
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Solution Overview
Problem
Laser welding technologies face limitations in achieving high-quality weld seams with minimal spatter, humping, and edge notches, particularly in full penetration welding, which restricts productivity and mechanical strength.
Innovation Solution
An optical apparatus utilizing a multiclad fiber with a core and ring fiber structure, where the input laser beam is variably split between leading and trailing partial beams, allowing for optimized energy distribution between core and ring zones, enabling high-speed welding with improved seam quality on both the top and underside of the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser welding is performed with a single beam to achieve high welding speed, then productivity is improved, but weld seam quality deteriorates due to spatter formation, humping, and edge notches
Solution Approach 1:
The laser beam is divided into multiple partial beams (at least three: leading partial beams and trailing partial beam) that act on the workpiece in sequence. This segmentation allows different zones of the material to be processed with optimized energy distribution, reducing spatter and humping while maintaining high welding speed.
Solution Approach 2:
Leading partial beams are positioned to act on the workpiece before the main welding zone, preparing the material by pre-heating or pre-melting the surface. This preliminary action reduces the thermal shock and spatter formation when the main beam passes, improving weld seam quality.
2Strength
If full penetration welding is performed to achieve complete material melting through the workpiece, then mechanical strength is improved, but weld seam quality deteriorates due to increased spatter and humping on both top and underside
Solution Approach 1:
Different partial beams are assigned different energy levels and positions to create localized quality variations. Leading partial beams provide controlled pre-heating in specific zones, while the trailing beam completes penetration, ensuring full strength without excessive spatter in any single location.
Solution Approach 2:
The leading partial beams perform preliminary heating and material preparation before the main welding action, reducing the intensity required for full penetration and thereby minimizing spatter and humping while still achieving complete penetration for mechanical strength.
3Device complexity
If a single laser beam is used to simplify the apparatus, then device complexity is reduced, but energy distribution control is insufficient for optimizing both welding speed and seam quality
Solution Approach 1:
A single laser source is segmented into multiple partial beams through optical elements, maintaining apparatus simplicity while enabling flexible energy distribution control. The segmented beams can be independently positioned and energized to optimize both welding speed and seam quality.
Solution Approach 2:
The optical apparatus includes dynamic control mechanisms that allow real-time adjustment of the energy distribution among partial beams. This enables adaptable control of the welding process to optimize for different material thicknesses, welding speeds, and quality requirements.
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
The apparatus achieves high-quality weld seams with reduced spatter and humping, enhanced mechanical strength, and increased productivity by allowing flexible power distribution between partial beams, optimizing the welding process for full penetration welding.
Implementation Method 1
The laser beam source has a multiclad fiber having a core fiber and at least one ring fiber and a second setting facility. The second setting facility is configured to variably split an input laser beam at a first fiber end of the multiclad fiber between the core fiber and the at least one ring fiber.
Implementation Method 2
a collimation optical unit configured to collimate the provided laser beam of the laser beam source
Implementation Method 3
a beam splitter device configured to split the collimated laser beam among a plurality of partial beams
Implementation Method 4
a focusing optical unit configured to focus the partial beams onto the workpiece to be welded
Implementation Method 5
a laser beam source configured to provide a laser beam
Data Source
AI summary
A laser welding optical apparatus includes: a laser beam source; a collimation optical unit collimating the provided laser beam; a beam splitter splitting the collimated laser beam into partial beams, the beam splitter having a first setting facility, which variably sets the splitting of the collimated laser; and a focusing optical unit focusing the partial beams onto the welding workpiece The laser beam source has a multiclad fiber having a core and ring fiber, and a second setting facility, which variably splits an input laser beam at an end of the multiclad fiber between the core and ring fiber. A second end of the multiclad fiber provides the laser beam for the collimation optical unit. The beam splitter splits the collimated laser beam among two leading and trailing partial beams. The first setting facility sets the energy distribution between the leading and the trailing partial beams.