Single-Groove Laser Welding for Thick Steel Plate Joints
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Solution Overview
Problem
Existing laser welding methods for thick steel plates require machining bevels on both parts to be welded, making the process cumbersome and costly.
Innovation Solution
A laser welding method for thick steel plates that forms a groove on only one plate, using a defined grooving angle and laser power to weld with a filler, simplifying the process and reducing costs by eliminating the need for bevels on both plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bevels are machined on both parts to be welded, then welding quality is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies asymmetry by machining a groove only on one of the two steel plates to be welded, rather than symmetrically machining both plates. This asymmetric approach reduces manufacturing complexity while maintaining welding quality, as the single groove provides sufficient access for the laser beam to weld through the entire joint thickness.
Solution Approach 2:
The patent extracts the groove formation step from both plates and applies it to only one plate. By taking out the unnecessary groove machining from the second plate, the manufacturing process is simplified while the essential welding function is preserved through the single groove and laser welding combination.
2Reliability
If bevels are machined on both parts to be welded, then welding quality is improved, but processing time and cost increase
Solution Approach 1:
The asymmetric groove configuration on one plate reduces the total machining time compared to symmetric groove machining on both plates, while still achieving the necessary welding quality through laser welding with filler material.
3Productivity
If laser power is increased to weld thick steel plates, then welding speed is improved, but heat-affected zone and distortion increase
Solution Approach 1:
The patent segments the welding process into multiple passes with filler material addition. Instead of attempting to weld the entire thick plate joint in a single high-power pass, the process divides the weld into layers, each deposited and solidified before the next is added. This segmentation allows lower power per pass, reducing heat-affected zone and distortion while maintaining overall welding speed through efficient multi-pass deposition.
Solution Approach 2:
The groove is preliminarily formed on one plate before welding begins, providing a prepared pathway for the laser beam and filler material. This preliminary action allows subsequent welding passes to be more efficient and controlled, reducing the need for excessive power and minimizing thermal distortion.
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 method simplifies the welding process and reduces costs by forming a groove on one plate, ensuring efficient joining with a filler region, achieving a combined thickness of 4-6 mm layers.
Implementation Method 1
using a laser to weld the joint face having the groove through the filler to form a filler region, wherein the laser has a power of between 7,000 and 20,000 watts
Implementation Method 2
The laser welds the joint face to form a molten region extending along the joint line
Implementation Method 3
After the filler region is cooled and solidified, the thick steel plates are combined with each other
Implementation Method 4
After the molten region and the filler region are cooled and solidified, the thick steel plates are combined with each other
Implementation Method 5
the protective gas is provided to remove a plasma generated during welding of the laser
Data Source
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AI summary
A thick steel plate assembly welded by laser welding and a laser welding method thereof are disclosed. The thick steel plate assembly comprises two steel plates (100) and a filler region (400). The steel plates (100) are joined. A joint face (1) of the steel plates (100) extends along a joint line (L). At least one portion of the joint face (1) of one of the thick plate steels (100) is formed with a groove (2) along a grooving line (L2). A grooving angle ( θ 1) is defined between the grooving line (L2) and the joint line (L1). The grooving angle ( θ 1) is between 3 degrees and 15 degrees. A bottom width (W1) of the groove (2) is between R0 and R10 mm. The filler region (400) is formed by feeding a filler into the groove (2) and using a laser (200) to weld the joint face (1) having the groove (2) through the filler. After the filler region (400) is cooled and solidified, the thick steel plates (100) are combined with each other. A thickness (T) of each filler layer in the filler region (400) is between 4 and 6 mm. Thus, the process can be simplified greatly and the cost can be reduced.