US20140151347A1 - Method of forming a weld notch in a sheet metal piece - Google Patents

Method of forming a weld notch in a sheet metal piece Download PDF

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Publication number
US20140151347A1
US20140151347A1 US14/094,299 US201314094299A US2014151347A1 US 20140151347 A1 US20140151347 A1 US 20140151347A1 US 201314094299 A US201314094299 A US 201314094299A US 2014151347 A1 US2014151347 A1 US 2014151347A1
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United States
Prior art keywords
sheet metal
metal piece
along
trench
ablation
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US14/094,299
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English (en)
Inventor
James J. Evangelista
Michael Telenko, JR.
Jason E. Harfoot
Jack A. Atkinson
James W. Walther
Anthony M. Parente
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Shiloh Industries Inc
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Shiloh Industries Inc
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Priority to US14/094,299 priority Critical patent/US20140151347A1/en
Assigned to SHILOH INDUSTRIES, INC. reassignment SHILOH INDUSTRIES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: EVANGELISTA, JAMES J., HARFOOT, JASON E., PARENTE, ANTHONY M., TELENKO, MICHAEL, JR., WALTHER, JAMES W., ATKINSON, JACK A.
Publication of US20140151347A1 publication Critical patent/US20140151347A1/en
Assigned to BANK OF AMERICA, N.A., AS ADMINISTRATIVE AGENT reassignment BANK OF AMERICA, N.A., AS ADMINISTRATIVE AGENT NOTICE OF GRANT OF SECURITY INTEREST IN PATENTS Assignors: SHILOH INDUSTRIES, INC.
Assigned to BANK OF AMERICA, N.A., AS ADMINISTRATIVE AGENT reassignment BANK OF AMERICA, N.A., AS ADMINISTRATIVE AGENT NOTICE OF GRANT OF SECURITY INTEREST IN PATENTS Assignors: SHILOH INDUSTRIES, INC.
Priority to US15/912,751 priority patent/US10821546B2/en
Assigned to SHILOH INDUSTRIES, INC. reassignment SHILOH INDUSTRIES, INC. RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: BANK OF AMERICA, N.A., AS ADMINISTRATIVE AGENT
Abandoned legal-status Critical Current

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    • B23K26/365—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/02—Positioning or observing the workpiece, e.g. with respect to the point of impact; Aligning, aiming or focusing the laser beam
    • B23K26/06—Shaping the laser beam, e.g. by masks or multi-focusing
    • B23K26/062—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam
    • B23K26/0622—Shaping the laser beam, e.g. by masks or multi-focusing by direct control of the laser beam by shaping pulses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/0093—Working by laser beam, e.g. welding, cutting or boring combined with mechanical machining or metal-working covered by other subclasses than B23K
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/362—Laser etching
    • B23K26/364—Laser etching for making a groove or trench, e.g. for scribing a break initiation groove
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/38—Removing material by boring or cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/40—Removing material taking account of the properties of the material involved
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/18—Sheet panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/34—Coated articles, e.g. plated or painted; Surface treated articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/02—Iron or ferrous alloys
    • B23K2103/04—Steel or steel alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/50—Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26

Definitions

  • the present disclosure generally relates to sheet metal pieces and, more particularly, to sheet metal pieces that are coated with one or more thin material layers and are used in welding processes.
  • sheet metal made of high-strength or hardenable steel alloys are now being made with one or more thin coating material layers, such as aluminum- and zinc-based layers.
  • these coating material layers can impart desirable qualities to the sheet metal, their presence can contaminate welds, thereby reducing weld strength, integrity, etc. This is particularly true if the coated sheet metal piece is being butt welded or lap welded to another sheet metal piece.
  • a method of forming a weld notch in a sheet metal piece that comprises the steps of: (a) providing a sheet metal piece having a plurality of material layers; (b) forming an ablation trench along the sheet metal piece by removing at least a portion of the plurality of material layers along an ablation path so that the ablation trench is spaced away from an edge of the sheet metal piece; and (c) cutting the sheet metal piece along the ablation trench to form the weld notch.
  • a method of forming a weld notch in a sheet metal piece that comprises the steps of: (a) providing a sheet metal piece having a plurality of material layers; (b) forming an ablation trench along the sheet metal piece by removing at least a portion of the plurality of material layers along an ablation path, wherein the ablation trench is defined in part by surfaces that oppose each other across the width of the ablation trench; and (c) removing a portion of the sheet metal piece that includes one of the opposing surfaces formed in step (b) to form the weld notch, wherein the weld notch is partly defined by the other of the opposing surfaces.
  • a method of forming a weld notch in a sheet metal piece that comprises the steps of: (a) providing a sheet metal piece having opposite first and second sides and a sheared edge extending therebetween, wherein material from a coating material layer along the first side extends at least partially along the sheared edge toward the second side in a shearing direction; (b) removing some of the coating material layer from the sheet metal piece along a pre-determined trim line location; and (c) separating the sheet metal piece into first and second pieces along the trim line location, wherein the first piece includes a newly formed weldable edge substantially free of material from the coating material layer and the second piece includes the sheared edge.
  • FIGS. 1A-C are cross-sectional views of a conventional weld joint joining sheet metal pieces that did not have weld notches formed therein before welding;
  • FIG. 2 is a perspective view of an edge region of an exemplary sheet metal piece, including weld notches on opposite sides of the sheet metal piece;
  • FIG. 3 is a cross-sectional view of a portion of the sheet metal piece of FIG. 2 ;
  • FIG. 4 is an enlarged portion of the cross-sectional view of the sheet metal piece of FIG. 3 showing some of the thin material layers;
  • FIG. 5 is a perspective view of an exemplary ablation process forming an ablation trench in a sheet metal piece
  • FIG. 6 is a cross-sectional view of the sheet metal piece of FIG. 5 ;
  • FIG. 7 is a cross-sectional view of the sheet metal piece of FIG. 6 , where a portion of the edge region has been removed to form a weld notch;
  • FIG. 8 is the cross-sectional view of FIG. 6 , showing expulsed material being ejected from the ablation site;
  • FIG. 9 is a cross-sectional view of a dual-beam ablation process forming an ablation trench with a non-uniform depth in a sheet metal piece;
  • FIG. 10 is a cross-sectional view of the sheet metal piece of FIG. 9 , where a portion of the edge region has been removed to form a weld notch with a non-uniform depth;
  • FIG. 11 illustrates an example of overlapping laser spots that may be used with the ablation process of FIG. 9 , along with a corresponding energy distribution for the overlapping laser spots;
  • FIG. 12 illustrates another example of overlapping laser spots that may be used with the ablation process of FIG. 9 , along with a corresponding energy distribution for the overlapping laser spots;
  • FIG. 13 is a cross-sectional view of an offset ablation process forming an ablation trench with a non-zero angle of incidence in a sheet metal piece;
  • FIG. 14 is a cross-sectional view of the sheet metal piece of FIG. 13 , where a portion of the edge region has been removed to form a weld notch;
  • FIG. 15 is a perspective view of a sheet metal piece with an ablation trench formed away from the edge region.
  • FIG. 16 is a perspective view of two sheet metal pieces formed by cutting the sheet metal piece of FIG. 15 along the ablation trench, where each of the two sheet metal pieces includes a weld notch along a newly formed edge region.
  • the sheet metal pieces disclosed herein can be made with weld notches located along one or more edges, where the weld notches are characterized by the absence of certain material constituents so that they do not unacceptably contaminate nearby welds.
  • a sheet metal piece can be produced so that material from one or more coating material layers is reduced or removed at a weld notch located along the sheet metal edge. This, in turn, can prevent contamination by the coating material layers of a nearby weld joint formed along the sheet metal edge and thereby preserve the strength and/or durability of the weld joint in subsequent processes or during its service life.
  • a trench ablation process can be used to form high quality weld notches in a manner that is relatively insensitive to sheet metal edge conditions.
  • each of the sheet metal pieces 12 , 12 ′ has a base material layer 14 and multiple thin material layers 16 , 18 covering opposite surfaces of the base material layer.
  • material layers that could be found on sheet metal stock, including various types of surface treatments, coating material layers such as aluminum- and zinc-based material layers (e.g., aluminum compounds), oils and other oxidation preventing substances, contaminants from the manufacturing or material handling processes, and oxidation layers, to name but a few.
  • a laser beam or other welding tool is used to melt some of the sheet metal located in edge regions 20 , 20 ′ so that a certain amount of the thin material layers 16 , 18 becomes embedded within the resulting weld joint 22 . Unless first removed, these unwanted constituents could have a negative impact on the overall strength and quality of the weld joint.
  • FIG. 2 there is shown an exemplary sheet metal piece 12 that may be formed by the present method and subsequently welded to an adjacent piece along an edge region 20 .
  • the sheet metal piece 12 includes opposite first and second sides 24 , 26 , and the edge region 20 is located along an edge 28 that is to be welded.
  • the particular edge region 20 shown in FIG. 2 includes two weld notches 30 , 30 ′, where the two weld notches extend along the edge region on opposite sides 24 , 26 of the sheet metal piece 12 .
  • Each weld notch 30 , 30 ′ is defined by a first notch surface 32 and a second notch surface 34 that intersect or join each other.
  • a weld notch can: include one or more off-axis or offset notch surfaces, have a uniform or non-uniform depth and/or width, differ from other weld notches located on the same sheet metal piece in terms of size, shape, configuration, etc., or be part of an edge region located along a straight edge, a curved edge, multiple straight or curved edges, or some other part of the sheet metal piece, to cite several possibilities.
  • FIG. 3 is a cross-section of the edge region 20 of the sheet metal piece 12 that is shown in FIG. 2 .
  • the illustrated sheet metal piece 12 includes multiple material layers, including the base material layer 14 , intermediate material layers 16 , and coating material layers 18 .
  • the base material layer 14 is the central or core material layer (e.g., a steel core) and is sandwiched between the intermediate material layers 16 and the coating material layers 18 .
  • the base material layer 14 makes up the majority of the thickness T of the sheet metal piece 12 and thus may contribute significantly to the mechanical properties of the sheet metal piece.
  • the coating material layers 18 are located over opposite surfaces of the base material layer 14 and are the outermost layers of the sheet metal piece 12 .
  • Each coating material layer 18 is relatively thin with respect to the base material layer 14 and may be selected to enhance one or more characteristics of the sheet metal piece (e.g., corrosion resistance, hardness, weight, formability, appearance, etc.).
  • the coating material layer 18 may also be selected for use or compatibility with subsequent processes, such as heat treatment or inter-diffusion processes, for example.
  • Each intermediate material layer 16 is located between the base layer 14 and one of the coating layers 18 , and is in contact with each in this embodiment.
  • the intermediate material layer 16 includes at least one constituent in common from each of the immediately adjacent layers 14 , 18 , such as an atomic element or chemical compound.
  • the intermediate material layer 16 may be a reaction product of the base and coating material layers 14 , 18 .
  • a dip coating process in which the base material layer is immersed or passed through a molten bath of the coating material, can result in a chemical reaction at the interface of the base material layer and the molten bath, and the reaction product is the intermediate material layer 16 .
  • the base material layer 14 is steel and the coating material layer 18 is an aluminum alloy.
  • the molten bath of aluminum alloy reacts with the base material layer at its surface to form the intermediate material layer 16 , which includes iron-aluminum (Fe x Al y ) intermetallic compounds such as Fe 2 Al 5 .
  • the intermediate material layer 16 can have a higher content of the base material layer constituent (e.g., iron) in areas closer to the base material layer 14 , and a higher content of the coating material layer constituent (e.g., aluminum) in areas closer to the coating material layer 18 .
  • the intermediate material layer 16 may be irregular along its opposite surfaces as depicted in the enlarged view of FIG. 4 .
  • the sheet metal piece 12 may include other, additional material layers as well, and is not limited to the particular arrangement described here.
  • the base material layer 14 is a high-strength or hardenable steel alloy such as a boron steel alloy or a high-strength low-alloy (HSLA) steel.
  • HSLA high-strength low-alloy
  • the coating material layer 18 may be selected to help prevent oxidation during heat treatment, to be lighter in weight than the base material layer 14 , and/or to interdiffuse with the other layers of the sheet metal piece 12 during subsequent heat treatment.
  • the coating material layer 18 is pure aluminum (Al) or an aluminum alloy, such as an Al-silicone (Al—Si) alloy.
  • Other possible compositions for coating material layer 18 include pure zinc and zinc alloys or compounds (e.g., where the underlying material is galvanized).
  • the intermediate material layer 16 may include iron and aluminum in the form of inter-metallic compounds such as FeAl, FeAl 2 , Fe 3 Al or Fe 2 Al 5 .
  • the intermediate material layer 16 may also include an alloy of constituents from adjacent layers.
  • Some exemplary material layer thicknesses range from about 0.5 mm to about 2.0 mm for the base material layer 14 , from about 1 ⁇ m to about 15 ⁇ m for the intermediate layer 16 , and from about 5 ⁇ m to about 100 ⁇ m for the coating material layer 18 .
  • these ranges are non-limiting, as individual layer thicknesses depend on several factors specific to the application and/or the types of materials employed.
  • the base material layer 14 can be a material other than steel, such as an aluminum alloy or some other suitable material, in which case the thickness may be outside of the exemplary range above.
  • the method described herein may be used with sheet metal pieces having more or less material layers than shown in the figures. Skilled artisans will also appreciate that the figures are not necessarily to scale and that the relative thicknesses of layers 14 - 18 may differ from those illustrated in the drawings.
  • the weld notch 30 is a portion of the edge region 20 of the sheet metal piece 12 where some material has been removed or omitted from the otherwise uniform layered structure.
  • the weld notch 30 promotes a high quality weld joint along edge 28 when the sheet metal piece is welded to another piece, and may do so via a configuration that reduces or eliminates the coating material layer 18 and/or the intermediate material layer 16 in the edge region 20 so that it does not become a part of a subsequent weld joint.
  • the weld notch 30 has a notch width W and notch depth D, each being relatively constant along the length of edge 28 in this particular embodiment.
  • the notch width W is the distance from edge 28 to the first notch surface 32
  • the notch depth D is the distance from the first side 24 (i.e., the outer surface of the coating material layer 18 ) to the second notch surface 34 .
  • the weld notch 30 is square with the sheet metal piece, as shown in this particular example, the notch width W is equal to the width of the second notch surface 34 , and the notch depth D is equal to the width of the first notch surface 32 .
  • the dimensions of the weld notch 30 may be related to the thickness T of the sheet metal piece, to the intended size of the weld joint to be formed at edge 28 , and/or to one or more material layer thicknesses.
  • notch width W is in a range from about 0.5 to about 1.5 times the thickness T.
  • the notch width W is in a range from about 0.5 mm to about 4 mm.
  • the notch width W may also be at least one half of the width of the intended weld joint.
  • the notch depth D for the example shown in FIG. 3 is greater than the thickness of the coating material layer 18 and less than the combined thickness of the intermediate and coating material layers 16 , 18 , but this is not necessary and may differ in some of the other exemplary embodiments.
  • the weld notch 30 can also be described with relation to certain characteristics of the notch surfaces 32 , 34 .
  • the first notch surface 32 includes material from both the intermediate material layer 16 and the coating material layer 18 .
  • the second notch surface 34 includes material from the intermediate material layer 16 only, and the first and second notch surfaces intersect along a junction or corner 36 that is positioned or located in the intermediate material layer.
  • the weld notch 30 is formed in the sheet metal piece 12 by removing the entire coating material layer 18 and a portion of the intermediate material layer 16 along edge region 20 .
  • the weld notch may be formed by removing only a portion of the coating material layer 18 , or by removing the entire coating and intermediate material layers 18 , 16 and a portion of the base material layer 14 .
  • Each of the notch surfaces 32 , 34 may also include striations, witness lines, or other indicators of the type of process used to remove material at the weld notch location.
  • the method includes using a laser ablation process to form an ablation trench 130 along the edge region 20 and subsequently removing a portion 138 of the edge region to form the weld notch 30 .
  • a laser beam 102 is directed at the edge region 20 from a laser source (not shown) to form the ablation trench 130 along the edge region.
  • Energy provided by the laser beam 102 is transferred to the sheet metal piece 12 in the form of thermal energy at an ablation site or laser spot 104 , melting and/or vaporizing material at the ablation site in order to remove material from one or more layers of the sheet metal piece.
  • the laser beam 102 follows a path 106 along the edge region 20 to form the trench 130 in the desired configuration and location.
  • the ablation trench 130 may be formed by removing all or some of the coating material layer 18 , all or some of the intermediate material layer 16 , and/or some of the base material layer 14 along the ablation path 106 . In certain applications where it is important that there be very little, if any, material layer contaminants in a resulting weld, it can be useful to completely remove both of the material layers 16 and 18 in the area of the ablation trench 130 so that the base material layer 14 is exposed.
  • the sheet metal piece 12 is shown with an ablation trench 130 ′ already formed along the edge region on the opposite side 26 of the sheet metal piece. It should be appreciated that non-laser methods may be used to form the ablation trench, such as scraping, grinding and/or other mechanical techniques for removing material.
  • the sheet metal piece 12 may be held stationary while the laser beam 102 moves along the path 106 .
  • the sheet metal piece 12 is moved or indexed while the laser beam 102 remains stationary.
  • Other techniques, such as moving both the laser source and the sheet metal piece, may be employed as well.
  • Some portions of the path 106 can be straight or rectilinear, as shown in FIG. 5 , while other portions can be contoured, curved or curvilinear; it is not necessary for the ablation trench 130 to follow a straight path 106 , as paths having other configurations can be followed instead.
  • Any suitable laser or other comparable light emitting device may be used to form ablation trenches, and may do so using a variety of operating or equipment parameters.
  • the laser source is a Q-switched laser, but other continuous wave and pulsed laser types may be used instead such as various nanosecond, femtosecond and picosecond pulsed lasers.
  • the laser spot or footprint 104 can be round, square, rectangular, elliptical, or any other suitable shape, as will be subsequently explained.
  • selectable or adjustable operating parameters for the laser source may include: laser power, pulse frequency, pulse width, pulse energy, pulse power, duty cycle, spot area, the overlap between successive laser pulses, and the speed of the laser source relative to sheet metal piece 12 , to cite a few possibilities. Any combination of these operating parameters may be selected and controlled by the present method based on the particular needs of the application.
  • the ablation trench 130 is formed so that it is spaced away from a starting edge 128 of the sheet metal piece 12 .
  • the laser beam 102 does not impinge the starting edge 128 of the sheet metal piece during the laser ablation process, according to this particular embodiment.
  • the laser spot 104 is spaced from the starting edge 128 by a distance L as it moves along path 106 .
  • the trench 130 can be formed by a single pass of the laser beam 102 along the x-direction, where the laser spot 104 has the same width W′ as the desired trench and removes the desired amount of material in one pass.
  • the trench is formed in multiple passes of the laser beam 102 along the x-direction at different distances from the starting edge 128 .
  • the trench 130 may be formed in a single pass of the laser beam along the x-direction with the laser beam moving back and forth in the y-direction during the single pass in the x-direction; this technique results in numerous short passes in the y-direction, where each pass is spaced from an adjacent pass by a small distance in the x-direction.
  • the resulting ablation trench 130 includes one or more surfaces that subsequently define the final weld notch 30 of FIG. 7 .
  • the ablation trench 130 includes first, second, and third trench surfaces 132 , 134 , and 136 , some of which subsequently define the final weld notch 30 .
  • the surfaces 132 - 136 are generally orthogonal with respect to each other and with respect to the sheet metal piece 12 .
  • the first and third surfaces 132 , 136 oppose one another across the width of the trench 130 with the second trench surface 134 extending therebetween.
  • a portion 138 of the edge region 20 is removed from the sheet metal piece 12 after the ablation trench 130 is formed, resulting in weld notch 30 .
  • At least a portion of the second trench surface 134 remains with the sheet metal piece 12 to become the second notch surface 34 of the resulting weld notch 30 .
  • the first trench surface 132 becomes the first weld notch surface 32
  • the third trench surface 136 is discarded with the removed portion 138 .
  • the first trench surface 132 becomes the first weld notch surface 32 .
  • the first weld notch surface 32 is formed during the laser ablation process.
  • the second notch surface 34 is formed during the ablation process as part of the second trench surface 134 .
  • the weldable edge 28 of the sheet metal piece 12 is formed when portion 138 is removed.
  • the removed portion 138 includes the starting edge 128 of the sheet metal piece 12 , as well as the third trench surface 136 .
  • the removed portion 138 may also include a portion of the second trench surface 134 , as shown in FIG. 7 .
  • Any suitable technique may be used to remove portion 138 from the sheet metal piece 12 in order to form the weld notch 30 and adjacent edge 28 , such as cutting, shearing, milling or trimming with a blade, laser, or other cutting tool.
  • Edge 28 is formed at a pre-determined location or trim line 140 , shown in FIG. 6 , which lies between the first and third surfaces 132 , 136 of the ablation trench 130 .
  • the third trench surface 136 and the trim line 140 are generally co-located so that the entire trench surface 134 remains part of the resulting weld notch 30 —i.e, widths W and W′ are the same.
  • the trim line 140 may be located anywhere between the first and third surfaces 132 , 136 and is spaced from the first trench surface 132 by the desired width W of the finished weld notch 30 .
  • the trim line 140 preferably lies within a central region 142 of the trench 130 , the central region being equally spaced from the first and third surfaces 132 , 136 and comprising 40-60% of the second surface 134 .
  • the starting edge 128 of the sheet metal piece 12 may include material from the coating material layer 18 and/or the intermediate material layer 16 that has been smeared, wiped and/or otherwise pulled along the edge during a previous trimming operation; this is best illustrated in FIG. 6 .
  • the coating material layer 18 and/or the intermediate material layer 16 may wrap around a corner 144 of the sheet metal piece so that it is present along at least a portion of the starting edge 128 .
  • the starting edge 128 was formed in a previous shearing operation in which a shearing blade cut the material in the direction indicated by the downward-pointing arrow.
  • a shearing operation may be performed at a steel mill or a metal-coating facility where the base material layer 14 is first coated and then cut or slit to the desired width for shipment.
  • Forming the weld notch 30 in a process that removes the starting edge 128 eliminates any unintended coating material at the finished edge 28 of the sheet metal piece that could otherwise contaminate the weld joint that is eventually formed at that edge.
  • the expulsed material 146 may include material from the coating material layer 18 and/or the intermediate material layer, it represents a potential weld joint contaminant. Removing portion 138 of the edge region 20 or otherwise trimming the sheet metal piece along the above-described ablation trench 130 can eliminate this potential contaminant. Skilled artisans will realize other advantages in forming the weld notch 30 as described herein.
  • FIGS. 9-12 there is shown an example of a multi-laser or dual-beam ablation process where first and second laser beams 102 , 102 ′ overlap at a composite laser spot 104 ′′, at which the combined energy of the lasers is greatest.
  • the composite or overlapping laser spot 104 ′′ is at approximately the center of the formed trench 130 , and more material removal occurs at the composite spot than at locations where the two laser spots 104 , 104 ′ do not overlap; this is demonstrated by the shape of the ablation trench 130 , which is deeper in the center of the trench.
  • the location of the trim line 140 coincides with the location of the composite laser spot 104 ′′.
  • Such a dual-beam process may be useful for forming a weld notch 30 having a non-constant or non-uniform depth D across its width W, such as the weld notch illustrated in FIG. 10 .
  • this process may remove material from the coating material layer 18 , the intermediate material layer 16 , and the base material layer 14 at the composite laser spot 104 ′′, while only removing material from the coating material layer 18 and/or the intermediate material layer 16 at the non-overlapping portions of the laser spots 104 , 104 ′.
  • the portion of the ablation trench 130 formed at the composite laser spot 104 ′′ may also be used as a visual indicator in the subsequent trimming operation of FIG. 10 where portion 138 is removed.
  • the different color and/or contour of the ablation trench 130 at the deeper center portion of the trench may be perceived by an operator in a manual trimming operation and/or by a vision system or the like in an automated trimming operation.
  • Overlapping laser spots 104 , 104 ′ may be used to tailor or manipulate the energy distribution of the lasers at the ablation site, as shown in FIGS. 11 and 12 .
  • the round laser spots 104 , 104 ′ shown at the top of FIG. 11 overlap to form the composite laser spot 104 ′′, and the corresponding energy distribution 200 of the composite laser spot is shown in the chart of FIG. 11 .
  • the energy distribution includes a peak or maxima 202 in the region of the composite laser spot 104 ′′ where both laser beams are present.
  • the actual shape of the energy distribution may vary from that shown here depending on several factors, including the individual energy distributions of each laser spot, the distance of the focal plane from each laser spot, and other factors.
  • the composite laser spot 104 ′′ is directed along the intended trim line 140 of the sheet metal piece 12 .
  • FIG. 12 depicts a composite laser spot 104 ′′ where the individual laser spots 104 , 104 ′ are rectangular in shape, as opposed to the previous example where they are circular. Laser spots or footprints having different sizes, shapes, configurations, etc. may be used in lieu of or in addition to those described herein.
  • the angle of incidence ⁇ generally refers to the angle that is formed between a central axis A of the laser beam and a line B that is normal to the side surface of the sheet metal piece, and the angle can be positive or negative.
  • the angle of incidence ⁇ is zero; in the exemplary embodiment shown in FIG. 13 , the angle of incidence ⁇ is between approximately 1° and 45° (e.g., about 10°), but other angles are certainly possible depending on the particular application.
  • a non-zero angle of incidence a can be used to form an ablation trench 130 and a resulting weld notch 30 that is offset with respect to the different material layers of the sheet metal piece 12 .
  • the resulting weld notch 30 shown in FIG. 14 is crooked or tilted. This can have a similar effect on the resulting weld notch as the dual-beam example of FIGS. 9-12 , where it is possible that the base material layer 14 is exposed at the portion of the weld notch 30 nearest the finished edge 28 , and is not exposed along the remainder of the weld notch.
  • the non-zero angle of incidence can form an offset ablation trench 130 that has a non-uniform depth D across its width W, where the depth of the offset weld notch can be managed in order to better control the material composition of a future weld joint.
  • the ablation trench 130 may be formed away from the edge region 20 where the starting edge 128 is arranged.
  • the ablation trench 130 is formed away from the edge region 20 of the sheet metal piece 12 , and the sheet metal piece is subsequently trimmed or cut along the trench at trim line 140 to form two sheet metal pieces 212 and 312 .
  • Each newly formed sheet metal piece 212 , 312 includes a newly formed edge 228 , 328 to be welded, and each edge is located along a newly formed edge region 220 , 320 of each piece.
  • each resulting weld notch 230 , 330 may have a width that is about one half the width of the formed previously formed ablation trench 130 .
  • the sum of the widths of the resulting weld notches 230 , 330 is the same as the width of the ablation trench 130 .
  • the first and third surfaces 132 , 136 of the ablation trench 130 of FIG. 15 become the first weld notch surfaces 332 , 232 of the resulting weld notches 330 , 230 .
  • the second surface of the ablation trench 130 is divided to become the second weld notch surfaces 334 , 234 of the resulting weld notches 330 , 230 .
  • the removed portion 138 of the sheet metal piece is not practically usable to be subsequently welded to another sheet metal piece to form a welded blank assembly—i.e., the distance L is too small and the removed portion 138 is discarded.
  • the technique illustrated in FIGS. 15 and 16 results in first and second sheet metal pieces 212 , 312 , each with weld notches 230 , 330 located along newly formed weldable edges 228 , 328 .
  • the edges can be free from unwanted contaminants such as material from the coating material layer 18 and/or the intermediate material layer 16 .
  • the terms “for example,” “e.g.,” “for instance,” “such as,” and “like,” and the verbs “comprising,” “having,” “including,” and their other verb forms, when used in conjunction with a listing of one or more components or other items, are each to be construed as open-ended, meaning that that the listing is not to be considered as excluding other, additional components or items.
  • Other terms are to be construed using their broadest reasonable meaning unless they are used in a context that requires a different interpretation.
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