Laser Welding of Thick Steel Plates With Balanced Deep Penetration
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Solution Overview
Problem
Conventional laser welding methods for thick steel plates face challenges in penetration and deformation, requiring additional electric welding, which is time-consuming and prone to defects like uneven welding and deformation.
Innovation Solution
A laser welding method using fiber or disc lasers with specific power, diameter, and travel speed, along with controlled welding angles and dual-sided welding for thicker steel plates, forming a weld bead with controlled depth-to-width ratio, to prevent deformation and ensure uniform welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional electric welding is used for thick steel plates, then welding can be completed, but the process is complicated and time-consuming
Solution Approach 1:
The patent changes the key parameter of laser power from conventional low levels (carbon dioxide gas laser and YAG laser) to ultra-high levels (10,000-25,000 watts). This parameter change enables the laser to penetrate thick steel plates (8-40mm) directly, eliminating the need for complex multi-pass electric welding processes and significantly improving welding speed while simplifying the overall welding process
Solution Approach 2:
The patent replaces the conventional electric welding system with an ultra-high power laser welding system. This substitution eliminates the complexity of electric welding procedures, electrodes, and multiple welding passes, while achieving efficient welding of thick steel plates through direct laser beam penetration and melting
2Device complexity
If conventional laser welding is used for thick steel plates, then the process is simplified, but the laser beam cannot penetrate through the metal plate
Solution Approach 1:
The patent dramatically increases the laser power parameter to 10,000-25,000 watts, which is sufficient to penetrate steel plates with thickness of 8-40mm. This parameter change enables complete penetration welding in a single pass, achieving both process simplicity and adequate penetration depth for thick plates
Solution Approach 2:
The patent introduces dual-sided welding as an additional dimensional approach. By welding from both sides of the steel plate, the effective penetration capability is enhanced, allowing complete fusion through thick plates while maintaining process simplicity and avoiding the need for complex single-sided multi-pass welding
3Device complexity
If single-sided laser welding is used for thick steel plates, then the process is simple, but deformation occurs
Solution Approach 1:
The patent transitions from single-sided welding to dual-sided welding, adding another dimension to the welding process. By applying laser beams from both sides of the steel plate simultaneously or sequentially, the thermal distribution becomes more balanced, preventing localized overheating and deformation while maintaining relatively simple equipment requirements
Solution Approach 2:
The patent uses dual-sided welding to create counterbalancing thermal effects. The laser beams applied from both sides of the plate create opposing thermal fields that balance each other, preventing the asymmetric thermal stress and deformation that would occur with single-sided welding
4Productivity
If high power laser is used for welding, then welding speed increases, but energy consumption increases
Solution Approach 1:
The patent applies ultra-high power laser (10,000-25,000 watts) which exceeds the minimum power needed for most welding applications. This excessive power input enables extremely high welding speeds and complete penetration in a single pass, making the process efficient for thick plates despite the high instantaneous energy consumption
Solution Approach 2:
The patent achieves continuous welding action through high-speed laser traversal (5-30 mm/s) and dual-sided simultaneous welding capability. This continuity eliminates the need for multiple passes, repositioning, and intermediate cooling periods, maintaining high energy utilization efficiency throughout the welding 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
The method simplifies the process, reduces processing time and area, prevents deformation, and achieves uniform welding with improved strength and efficiency, saving energy and materials while reducing labor and carbon emissions.
Implementation Method 1
using a laser to weld the joint from one side of the second steel plate
Implementation Method 2
part of the first steel plate and/or the second steel plate are melted by the laser, thereby joining the first steel plate and the second steel plate
Implementation Method 3
The laser has a laser power between 10,000 and 25,000 watts
Implementation Method 4
part of the first steel plate and/or the second steel plate are melted by the laser
Data Source
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AI summary
A laser welding method for steel plates and a profile steel welded by laser welding are disclosed. The laser welding method comprises the following steps of connecting a first steel plate (1) and a second steel plate (2) to form a joint (A); and using a laser to weld the joint (A) to form a profile steel. The laser has a laser power between 10,000 and 25,000 watts. A weld bead (B) is formed at the joint (A). The weld bead (B) has a weld depth (C) and a weld width (D). The ratio of the weld depth (C) to the weld width (D) is between 1 and 5. Thus, the process can be simplified effectively, the welding time can be shortened, and the processing area can be reduced.