Rotating Laser Hybrid Welding Reducing Root Reinforcement
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Solution Overview
Problem
Laser welding processes often result in root concavity and convex weld root reinforcements that disrupt fluid flow and reduce fatigue life in welded articles, particularly in applications like fluid transport, due to limitations in joint fit-up and accessibility.
Innovation Solution
A hybrid welding process combining a stationary fusion apparatus (such as arc welding) with a rotatable fusion apparatus (like laser welding) to form a weld, where the rotation of the laser beam reduces inaccessible root reinforcements and creates a stable common molten pool, minimizing disruptions to fluid flow and fatigue life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If laser welding is used to achieve deeper penetration, then welding depth is improved, but root concavity and convex weld root reinforcements are formed that disrupt fluid flow and reduce fatigue life
Solution Approach 1:
The patent combines laser welding and arc welding processes into a hybrid welding system. The laser beam provides deep penetration while the arc welding simultaneously fills root concavity and controls root reinforcement geometry. This merging of two welding processes resolves the contradiction by achieving deep penetration without the harmful root concavity and excessive convex reinforcement that would reduce fatigue life.
Solution Approach 2:
The patent changes the parameters of the welding process by introducing rotational motion to the laser beam. The rotating laser beam distributes heat more evenly and prevents excessive heat concentration that leads to root concavity. Additionally, the process parameters (laser power, rotation speed, travel speed) are optimized to achieve the desired weld geometry with minimal root reinforcement, thereby improving fatigue life while maintaining deep penetration.
2Manufacturing precision
If filler material is added to fill root concavity, then weld completeness is improved, but weld face reinforcement increases which disrupts fluid flow
Solution Approach 1:
The patent changes the welding parameters by using a rotating laser beam with controlled rotation speed and power. This rotational motion distributes the heat input more uniformly along the weld seam, preventing excessive melting and minimizing root concavity formation. As a result, less filler material is needed to fill the root, and the weld face reinforcement is reduced to a minimum level that does not significantly disrupt fluid flow, thus resolving the contradiction between weld completeness and fluid flow disruption.
3Adaptability or versatility
If arc welding is used to fill joint gaps, then joint fit-up tolerance is improved, but welding depth and penetration are reduced compared to laser welding
Solution Approach 1:
The patent merges laser welding and arc welding processes in a hybrid system where each process complements the other. The laser beam provides deep penetration for tight joint gaps, while the arc welding simultaneously fills larger joint gaps and root concavity. This combination resolves the contradiction by achieving both deep penetration (laser advantage) and tolerance to joint fit-up variations (arc advantage) in the same welding process.
4Device complexity
If a stationary fusion apparatus is used for welding, then process simplicity is maintained, but inaccessible root reinforcement remains difficult to remove
Solution Approach 1:
The patent inverts the conventional approach by making the fusion apparatus (laser) rotatable rather than stationary. This inversion allows the laser beam to rotate around the weld area, creating more uniform heating and reducing excessive root reinforcement on the inner surface. The rotational motion enables the laser to access and treat areas that would otherwise be inaccessible to a stationary laser, thereby improving ease of repair while maintaining relatively simple process equipment.
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 hybrid welding process enhances consistency, reduces root reinforcement requirements, and decreases the need for re-working, resulting in a welded article with improved fluid dynamics and extended fatigue life by forming a substantially planar or reduced root reinforcement geometry.
Implementation Method 1
Rotation of the rotatable fusion apparatus along a rotation path generates centrifugal force that stirs a common molten pool formed by interaction of the first directed weld energy and the second directed weld energy
Implementation Method 2
A welding process includes generating a first directed weld energy from a stationary fusion apparatus, and generating a second directed weld energy from a rotatable fusion apparatus
Implementation Method 3
a stationary arc welding apparatus and a rotatable laser beam apparatus
Data Source
AI summary
A welding process, welding system and welded article are disclosed. The welding process includes generating a first beam from a stationary fusion apparatus and generating a second beam from a rotatable fusion apparatus. The first beam and the second beam form a weld in an article. The welding system includes a stationary fusion apparatus and a rotatable fusion apparatus directed at an article to be welded, the stationary fusion apparatus and rotatable fusion apparatus being arranged and disposed to form a single weld in the article. The welded article includes a first element welded to a second element, the welded article having a decreased root reinforcement, in an inaccessible region, from that of a hybrid stationary fusion apparatus.