Stepped Hybrid Weld Seam for Low-Distortion Working Cylinders
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Solution Overview
Problem
Existing hydraulic working cylinder designs face challenges with high heat input leading to thermal distortion, scaling, and high material and energy consumption, particularly in large cylinders, and laser welding is expensive and uneconomical.
Innovation Solution
A stepped hybrid weld seam is employed, comprising a lower laser weld seam without filler metal and an upper laser hybrid weld seam with filler material, allowing precise positioning and reduced energy input, using lower-power laser systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If MAG welding is used to achieve deep weld seams for high forces, then weld strength is improved, but heat input increases causing thermal distortion and scaling
Solution Approach 1:
The weld seam is segmented into two distinct zones: a lower penetration zone for deep fusion and an upper cap zone for surface coverage. This segmentation allows each zone to be optimized independently - the lower zone uses parameters for deep penetration while the upper zone uses lower heat input for capping, thereby reducing overall thermal distortion and scaling while maintaining weld strength.
Solution Approach 2:
Different welding parameters and techniques are applied to different regions of the weld seam. The lower zone receives high energy input for deep penetration, while the upper zone receives controlled lower energy input for capping. This local differentiation of welding quality allows the weld to achieve both deep strength and surface integrity without subjecting the entire seam to high heat input.
2Strength
If deep weld seams are produced for high forces, then weld strength is improved, but welding wire consumption increases
Solution Approach 1:
The welding process is segmented into two phases: penetration welding that creates the deep fusion zone with minimal filler material, and cap welding that adds the final bead profile. This segmentation reduces overall wire consumption because the penetration phase relies on base metal fusion rather than extensive filler material, and the cap phase uses controlled amounts of wire only where needed for surface coverage.
3Strength
If deep weld seams are produced for high forces, then weld strength is improved, but energy consumption increases
Solution Approach 1:
The welding energy input is segmented into two distinct phases with different energy levels. The penetration phase uses high energy density for deep fusion, followed by a cap phase that uses lower energy input for surface capping. This temporal and spatial segmentation of energy input reduces total energy consumption compared to maintaining high energy levels throughout the entire weld duration.
Solution Approach 2:
The welding process employs periodic action with two distinct cycles: a high-energy penetration cycle followed by a lower-energy cap cycle. This periodic variation in energy input allows the weld to achieve deep penetration during the high-energy phase while reducing overall energy consumption during the cap phase, thereby lowering total energy requirements for producing high-strength welds.
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 solution provides a robust, economical, and efficient weld-coupled working cylinder assembly with minimized thermal distortion and reduced material costs, achieving high-quality welds with lower energy consumption.
Implementation Method 1
The welding filler material and the working cylinder component and attachment part weld seam surfaces in the upper weld seam zone are melted by means of a laser beam
Implementation Method 2
the working cylinder component and the attachment part are connected to one another in a positive-substance manner by means of a laser weld seam produced without a gap and without welding filler metal
Data Source
AI summary
A working cylinder assembly has a cylinder component, an attachment part and a weld seam. The weld seam is a stepped hybrid weld seam, which has a lower weld seam zone and an upper weld seam zone. In the lower weld seam zone, the cylinder component has a lower cylinder component seam surface and the attachment part has a lower attachment part seam surface. The lower seam surfaces have a butt joint and the lower weld seam zone is a laser weld seam. In the upper weld seam zone, the cylinder component has an upper cylinder component seam surface and the attachment part has an upper attachment part seam surface. The upper weld seam zone is a laser hybrid weld seam with a welding filler material in an upper weld seam space defined by the surface separation (5.3) between the upper seam surfaces (5.1, 5.2).