Rectangular Wire Laser Welding for Uniform Molten Pool Formation
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Solution Overview
Problem
Existing methods for welding rectangular wires using a laser result in uneven heating, as the molten pool formed on one wire is larger than on the other, leading to inconsistent welding.
Innovation Solution
A pulsed laser welding method where the laser is scanned in a direction parallel to the long side of the rectangular wire's end face, using a rotatable transmission optical system to ensure even heating by adjusting the laser's irradiation position, allowing for precise alignment and consistent molten pool formation across both wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a laser is scanned in a loop to form a molten pool on rectangular wires, then welding is achieved, but the molten pool size becomes uneven between the two wires
Solution Approach 1:
The patent applies asymmetry by scanning the laser in a direction parallel to the long side of the rectangular wire end face, rather than using a symmetric loop pattern. This asymmetric scanning approach ensures that the laser energy is distributed more uniformly across both wires, preventing the formation of uneven molten pools and achieving consistent heating and welding results.
2Area of stationary object
If the laser trajectory loop diameter is increased to reach both wire surfaces, then welding coverage is improved, but heating uniformity deteriorates
Solution Approach 1:
The patent transitions from a two-dimensional loop scanning pattern to a one-dimensional linear scanning pattern along the long side of the rectangular wire. This dimensional change allows the laser to cover the necessary welding area while maintaining uniform energy distribution, as the linear path ensures consistent proximity and energy delivery across both wire surfaces without creating hot spots or uneven heating.
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 method ensures that both rectangular wires are heated evenly, resulting in consistent and reliable welding without the need for complex adjustments in the laser irradiation program, simplifying the welding process and improving the quality of the weld.
Implementation Method 1
rectangular wires are welded together by irradiation of a pulsed laser to an area including a boundary between end faces of the conductors of the two rectangular wires
Implementation Method 2
the end face of the rectangular wire is irradiated with the pulsed laser... so that the rectangular wires are welded with each other
Implementation Method 3
Once the pulsed laser has passed through a transmission optical system, the end face of the rectangular wire is irradiated with the pulsed laser. The transmission optical system is rotatable, and an irradiation position of the pulse laser to the end face changes in a first direction according to a rotation phase of the transmission optical system
Data Source
AI summary
A laser welding method includes a preparation process and a welding process. In the preparation process, sides of longitudinal ends of conductors (91) of two rectangular wires (90) are aligned with each other. In the welding process, the two rectangular wires (90) are welded together by a laser irradiation to an area including a boundary between end faces of the conductors (91) of the two rectangular wires (90). Once the laser has passed through a transmission optical system, the end face of the rectangular wire (90) is irradiated with the laser. The transmission optical system is rotatable, and an irradiation position of the laser to the end face changes in a first direction according to a rotation phase of the transmission optical system. In the welding process, the area including the boundary between the end faces of the conductors (91) of the rectangular wires (90) is irradiated with the pulsed laser in such a way that the first direction is parallel to a long side of the end face of the rectangular wire (90), so that the rectangular wires are welded with each other.