Oscillating Laser Focal Point for Low-Distortion Wire Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional laser-based welding systems cause intense, localized heat damage due to fixed beams, which is undesirable in various applications.
Innovation Solution
The use of a continuously fed electrode wire preheated for laser welding systems, where the focal point of the laser beam is moved in multiple dimensions to control heat distribution and reduce thermal distortion, thereby improving puddle convection and stability in welding and additive manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a fixed laser beam is used for welding, then high laser intensity can be achieved, but intense localized heat damage occurs
Solution Approach 1:
The patent applies dynamics by transitioning from a fixed laser beam to a moving focal point that oscillates in multiple dimensions. The laser focal point is dynamically positioned using scanners (acousto-optic, electro-optic, or mechanical) to create controlled motion patterns, transforming the static heat application into a dynamic process that distributes heat more effectively while maintaining high intensity.
Solution Approach 2:
The patent implements periodic action through oscillating the laser focal point in controlled patterns (circular, linear, or complex trajectories). This periodic motion creates cyclic heating and cooling zones that prevent excessive localized heat accumulation, allowing the laser to maintain high intensity while periodically redistributing thermal energy across the weld zone.
2Speed
If a fixed laser beam is used for welding, then high welding speed can be achieved, but thermal distortion increases
Solution Approach 1:
The dynamic oscillation of the laser focal point creates a moving heat zone that prevents excessive thermal accumulation in any single location. This dynamic approach allows maintaining high welding speed while the periodic motion distributes thermal energy, reducing overall thermal distortion and improving dimensional stability of the welded structure.
3Productivity
If conventional laser welding is used, then efficient joining can be achieved, but heat affected zone is large
Solution Approach 1:
The periodic oscillation of the laser focal point creates a distributed heating pattern where heat is applied cyclically across multiple zones rather than concentrated in one area. This periodic action maintains high joining efficiency by keeping the material in the molten state through sustained thermal input while the oscillation prevents excessive heat diffusion, thereby reducing the heat affected zone area.
4Speed
If high laser power is used, then high welding speed can be achieved, but residual stress increases
Solution Approach 1:
The dynamic oscillation of the laser focal point distributes the thermal input across a larger volume of material, reducing thermal gradients and minimizing the formation of residual stresses. This dynamic approach allows maintaining high welding speed with high laser power while the continuous motion prevents excessive heat concentration that would lead to high residual stress accumulation.
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 reduces thermal distortion, residual stress, and heat affected zones, while maintaining high laser intensity with lower power levels, resulting in improved weld quality and reduced environmental hazards in additive manufacturing.
Implementation Method 1
Laser welding is a welding technique used to join multiple pieces of metal through the use of a laser. The beam provides a concentrated heat source
Implementation Method 2
The beam provides a concentrated heat source, enabling a precise control of the heat input
Implementation Method 3
a continuously fed electrode wire to be preheated for use in laser welding systems
Data Source
AI summary
Systems and methods of a laser welding device are disclosed. The laser welding device includes a laser generator configured to generate welding-type lasing power. A lens focuses the welding-type lasing power at a focal point on a workpiece to generate a puddle during a welding-type operation. A wire feeder is configured to feed wire to the puddle generated by the laser generator. A laser scanner controls the lens to move the focal point of the welding-type lasing power in multiple dimensions over the workpiece during the welding-type operation. In some examples, the feed wire is used in an additive manufacturing process.