Laser-Welded Plated Joint Body With Gap Venting Against Blowholes
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Solution Overview
Problem
The existing methods for joining plated metal members through welding often result in the formation of blowholes due to the trapping of component-evaporated gas, which can lead to defective joints. Current solutions, such as embossing one of the steel plates, increase the number of processes and are not suitable for continuous welding on continuous plate materials.
Innovation Solution
A manufacturing method and apparatus that involves placing a second metal member on a first metal member and creating a predetermined gap between them. The method uses laser welding to join the members while allowing the component-evaporated gas to escape through the gap, eliminating the need for special processing like embossing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If embossing is applied to form a gas discharge path, then blowhole occurrence is prevented, but the number of processes increases and continuous welding becomes difficult
Solution Approach 1:
The patent extracts the harmful gas from the welding zone by providing a gas discharge path through relative movement between the plated metal member and the counterplate, rather than trying to prevent gas formation. This removes the problematic gas escape route requirement from the plate preparation process itself.
Solution Approach 2:
The patent introduces dynamic relative movement between the plated metal member and the counterplate during welding to create a gas discharge path. This dynamic approach replaces the static embossing method, allowing gas escape without requiring pre-formed protrusions or grooves in the plates.
2Object-generated harmful factors
If a gas discharge path is formed by embossing, then component-evaporated gas can escape, but special processing is required before welding
Solution Approach 1:
The patent uses dynamic relative movement between the plated metal member and counterplate during welding to create the gas discharge path, eliminating the need for static pre-processing like embossing. The gas discharge function is achieved through motion rather than permanent structural modification.
Solution Approach 2:
The patent replaces the mechanical embossing process with a motion-based approach where relative movement between components creates the gas discharge path. This substitutes a complex mechanical pre-processing step with a simpler positioning and movement control system.
3Strength
If plated metal members are welded in direct contact, then welding strength is maximized, but blowholes form due to trapped gas
Solution Approach 1:
The patent introduces the counterplate as an intermediary element that facilitates gas escape during welding. The counterplate creates a controlled gap that allows harmful gas to discharge while maintaining proper welding conditions, acting as a mediator between the plated metal member and the welding zone.
Solution Approach 2:
The patent converts the harmful trapped gas into a beneficial discharged flow by creating a gas discharge path through relative movement. The gas that would normally cause blowholes is now channeled away usefully, transforming a welding defect source into a controlled discharge process.
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 effectively prevents the occurrence of blowholes by allowing the release of component-evaporated gas through the predetermined gap, thereby ensuring a defect-free joint without increasing the number of processes involved in the manufacturing method.
Implementation Method 1
causing a laser oscillation system to irradiate a surface of the second metal member with laser light to form a joint portion
Implementation Method 2
irradiating the second metal member with a laser at a position where the predetermined gap is located between the first metal member and the second metal member to join the first metal member and the second metal member together by laser welding
Data Source
AI summary
Provided is a manufacturing method for a joint body having a blank material plated with a metal material and a hoop material plated with a metal material joined together by placing the hoop material on the blank material and causing a laser oscillation system to irradiate a surface of the hoop material with laser light to form a joint portion including a line-shaped welded portion where the blank material and the hoop material are joined together. In this manufacturing method, the hoop material is supplied to be placed on the blank material and form a predetermined gap d between the blank material and the hoop material, and the hoop material is irradiated with a laser at a position where the predetermined gap d is located between the blank material and the hoop material to join the blank material and the hoop material together by laser welding.