WO2007060479A1 - Soudage au laser d'aciers galvanises sans interstice a l'aide d'un laser semi-conducteur supermodule - Google Patents

Soudage au laser d'aciers galvanises sans interstice a l'aide d'un laser semi-conducteur supermodule Download PDF

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Publication number
WO2007060479A1
WO2007060479A1 PCT/GB2006/050398 GB2006050398W WO2007060479A1 WO 2007060479 A1 WO2007060479 A1 WO 2007060479A1 GB 2006050398 W GB2006050398 W GB 2006050398W WO 2007060479 A1 WO2007060479 A1 WO 2007060479A1
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WO
WIPO (PCT)
Prior art keywords
laser
output
welding
weld
supermodulated
Prior art date
Application number
PCT/GB2006/050398
Other languages
English (en)
Inventor
Mohammed Naeem
Original Assignee
Gsi Group Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Gsi Group Limited filed Critical Gsi Group Limited
Publication of WO2007060479A1 publication Critical patent/WO2007060479A1/fr

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Classifications

    • 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
    • B23K26/0665—Shaping the laser beam, e.g. by masks or multi-focusing by beam condensation on the workpiece, e.g. for focusing
    • 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
    • B23K26/20—Bonding
    • B23K26/21—Bonding by welding
    • B23K26/24—Seam welding
    • B23K26/244—Overlap seam welding
    • 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
    • B23K26/20—Bonding
    • B23K26/32—Bonding 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
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/04—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for holding or positioning work
    • B23K37/0426—Fixtures for other work
    • 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
    • B23K2103/08—Non-ferrous metals or 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

  • This invention relates to laser welding of zinc coated steel sheets.
  • the welding heat can vaporise the zinc coating at approximately 900 0 C, which is significantly lower than the melting point of the steel.
  • the low boiling point of zinc causes a vapour to form during the so-called key-hole process, which needs to escape from the weld pool.
  • the zinc vapour can become trapped in the solidifying weld pool resulting in excessive undercut and weld porosity.
  • a common type of joint is a lap joint wherein two, three or more layers are joined and this effect is particularly critical in such lap joints where two layers of zinc are present at the interface between the sheets.
  • producing a controlled gap of around 0.1 to 0.2 mm at the sheet interface can circumvent these problems and systems achieving this have already been installed in car production for the welding of double or triple layer sheets for roof welding.
  • a dual elliptical beam system attempts to overcome this problem by combining a parabolic elliptical beam mirror with a wedge shaped roof top mirror.
  • the aim of this is to further lengthen the key-hole for zinc gas escape and success has been achieved with this approach for galvannealed steels.
  • a laser beam eg a Nd:YAG laser
  • a beam splitting lead to generate two generally circular beams as shown in Figure 2(c).
  • the dual beam inter-beam distance parameter is confined in a very narrow range for a robust process and, when the two beams separate too far, the rear beam generates a concavity in the rear key-hole wall. This results in a non-stable structure for the liquid metal in the weld pool at the rear key-hole wall and a result fluid flow may lead to spattering and porosity in the weld.
  • the present invention arose in an attempt to provide an improved method and apparatus for lap joint welding of zinc coated steels.
  • a method for laser welding a lap joint between two or more zinc coated steel sheets comprising holding the sheets together so that there is substantially no gap between them along the desired weld line and applying an output from a supermodulated solid state laser along the desired weld line, thereby to weld the joint.
  • 'supermodulated' means a laser in which a laser beam is modulated to have a peak power greater than the rated CW power of the laser producing the beam. Techniques for this are described in applicant's co-pending application WO 03/071639, which is incorporated herein by reference and to which the reader is referred.
  • the method may comprise using an optically pumped solid state laser apparatus having a rated CW output power of around 100 watts or more, the method comprising: modulating an optical pump to directly generate a modulated laser output beam having peak power greater than the rated CW output power, the pump being controllable with a time varying electrical signal so as to provide average output power up to the rated CW power; focusing the output beam and applying the output beam to the lap joint to be welded.
  • the output of the laser is a sine wave or square wave.
  • the method is such that the laser output has a beam off and a beam on period and wherein energy is stored in the power supply during the beam off time and this energy is applied to a laser medium forming part of the laser during turn on time of the laser, resulting in a short duration of high peak power.
  • the high peak power may be, for example, up two times the CW rating of the laser.
  • the invention further provides apparatus for welding a lap joint between two or more zinc coated steel sheets, comprising a laser having an active laser medium and a pumping means, means for modulating the pumping means so as to obtain a supermodulated output from the laser, means for directing the laser to a joint to be welded and means for clamping the two or more zinc coated steel sheets so as substantially prevent gaps between the sheets at the desired weld location.
  • laser welding apparatus for laser welding zinc coated steel
  • the system comprising a solid state laser apparatus with a rated CW output power, the system comprising a solid state resonator comprising at least one solid state laser medium, at least one reflector and at least one output coupler; a pump and super modulating power supply for modulating the pump so that the pumps the at least one solid state laser medium to generate a modulated laser output beam having peak power greater than the rated CW output power; an optical system for focusing the output beam means and directing the beam to the site to be welded.
  • the invention also provides a method for welding lap joints between zinc-coated steel surfaces, comprising providing weld energy from a supermodulated laser.
  • Figures 2(a), (b) and (c) show different spot configuration of previous
  • Figure 3 is a schematic view of a laser pumping chamber
  • Figure 4 shows a laser resonator
  • Figure 5 is a graph of power over time for a CW input
  • Figure 6 is a graph of power over time for a supermodulator sine wave input
  • Figure 7 is a graph of power over time for a square wave input
  • Figure 8 is a schematic view of zinc -coated steel being welded
  • Figures 9(a) and (9b) show welds made with embodiments of the present invention
  • Figure 10 shows schematically a clamping mechanism
  • Figure 11 shows a clamping mechanism
  • Figure 12 shows a lever clamp.
  • a CW laser typically comprises a laser resonator 1 including at least one laser rod 2 (which may be a Nd: YAG element or other element) which is mounted between two flat mirrors 3 and 4.
  • Mirror 3 is a high reflectivity rear mirror and mirror 4 is a partially transmissive front mirror 4 known as the output coupler.
  • the laser rod 2 is pumped by one or more pumping element such as lamps 5 which are powered by an electrical source 6 (eg AC source that generally includes a resonant circuit).
  • the source 6 is designed to produce an output of about 15 KW average power and 30 KW peak power.
  • CW lasers have a rated average power and this is shown in Figure 5 at level "CW". This level may be 1000 W as shown in the figure or more a different level.
  • the CW laser is generally modulated by altering the power supply to the one or more pumping lamps 5 up to the CW level, depending upon the power requirement at any time during the welding operation, as shown in Figure 5.
  • the level L may be dynamically varied up to the CW level to control the welding operation. Alternatively, a DC power supply may be used.
  • the CW output is one that can be maintained for 100% of the time as an average level and the laser power L is varied up to this to control a welding operation.
  • FIG 4 shows a typical laser resonator.
  • This resonator may include two flooded ceramic cavities 10 and 11, each housing a respective Nd: YAG rod 12, 13. Alternatively, dry gold cavities might be used, for example.
  • Each chamber includes two arc lamps fitted with electrodes for AC excitation, typically up to 8 KW per lamp at 25 to 30 KHz.
  • the resonator may be formed between two flat mirror 14 and 15 which are spaced a desirable amount apart to give predetermined resonator pitch. The space may for example 1500 mm to give a resonator pitch of 750 mm.
  • the cavities 10 and 11 are arranged to give a symmetrical periodic resonator controlled by three apertures 16, 17 and 18 placed at the centre point and close to the respective mirrors 14 and 15.
  • the resonator output through output coupler 15 (which has 50% reflectance) is directed via turning mirrors 21 and 22 and imaged to an appropriate size (eg nine times) using optical system 19, 20, then launched into an optical fibre 23 of desired length (eg 5 m).
  • the fibre is then directed so that the beam output from it can be used to weld steel joints.
  • the beam may be applied direct from the output of the fibre 23 or via focusing or beam shaping optics, as is shown schematically in Figure 8.
  • the average power is the average power at the workpiece at the end of the lamp life.
  • This modulation or pulsing is usually accomplished by storing some energy in the power supply during the beam off time, as is clearly described in the aforesaid International patent application WO 03/071639. Extra energy is then sent to the lasing medium during turn on of the laser and results in a short duration of high peak power.
  • Such lasers can produce three different outputs, ie CW, sine wave and square wave.
  • demand range is meant the range between 0 to 100% of available input power and from simmer to maximum power.
  • the laser begins to produce power at about 50% demand, approximately half its rated power at about 70% demand and full rated power at approximately 90 to 100% demand.
  • Sine wave operation is illustrated schematically in Figure 6.
  • the laser output is super modulated as described in the aforesaid International patent application to produce output 30.
  • the parameters used are demand range and frequency.
  • the configuration is one of 100% mean power and 50% depth.
  • the frequency is set between the values of 100 to 1000 Hz or thereabouts.
  • the demand range varies between 0% and 100%, with 40% being the approximate threshold for laser operation. 70% produces approximately half the laser rated average power and 90 to 100% produces full rated power.
  • the depth values ranges from 0 to 100%. If the depth value is set to 0% then the laser operates in CW mode with sinusoidal output.
  • the depth value is set to 100% with a demand range 100% then the peak power of the laser will be 200% of the rated average power and the minimum value will be 0 W at the trough of the sinusoidal wave form. If the depth value is set to 50% with a demand range of 100% (ie as in the figure) then the peak power will be 150% of the average power and the minimum power at the trough of the sinusoidal output will 50% of the rated average power. Adjusting the demand range changes the peak at minimum powers of the sinusoidal output but the waveform shrinks in proportion to the mean power that the demand ranges calls for, so there is no 'clipping' of the sinusoidal waveform at 0% or 200%. Note that adjusting the frequency does not affect the depth value of the laser, simply the frequency of the sinusoidal output.
  • Figure 7 illustrates square wave operation.
  • the parameters used are demand range, peak power and frequency.
  • the frequency is typically set between the values of 100 to 1,000 Hz.
  • the percentage on-time or duty cycle of the laser operating in square wave mode is determined by the ratio of the demand range to the peak power.
  • the duty cycle and frequency determine the actual on-time or pulse size.
  • the duty cycle is 100/200 or 50% on-time. Because the laser is operating at 500 Hz, the pulse period is 1/500 or 2 ms. 50% of 2 ms is 1 ms so that a laser operating on these parameters will be operating at 500 Hz with pulse-width (or on-time) of 1 ms and a peak power of 200% of the rated power (ie 2 KW). This is shown by the square wave plot 31 of Figure 7. Note that these parameters are produced at the full 1,000 W rated average power of the laser since the demand range is set 100%.
  • Figure 8 shows schematically an apparatus for applying a super modulated laser beam to a joint for welding it.
  • the beam is applied via an output fibre 23 which may be of 600 ⁇ m diameter.
  • a JK 1002 CW laser of Lumonics Limited was fitted with such a fibre.
  • the fibre terminates in an output housing 32 including a set of focusing optics (not shown).
  • focusing optics Preferably, with zinc -coated steels, no gas shielding is used.
  • the housing and focusing optic focuses the laser down to the topsheet surface 33 of a lap connection 34 between two sheets of zinc -coated steel 35, 36.
  • the two sheets are clamped tightly together to ensure that there is no gap between them.
  • the laser beam is focused at the topsheet surface.
  • the welding has been performed with CW and square wave output, although sinusoidal output is equally useful.
  • the steel In typical zinc-coated steel sheets, the steel is of about 0.8 mm thick depth and this is coated on both sides with a zinc layer of approximately 10 ⁇ m.
  • FIGS 9(a) and (b) shows cross-sections of welds made with a modulated laser beam in which the parameters used were laser power of 1,000 W used at 150% peak power (super modulation) with a modulation frequency of 600 Hz, a spot size of 0.48 mm and at a speed of 2.5 m per minute.
  • Figure 9(a) shows a top bead and Figure 9(b) shows a side cross-section. No porosities or pin holes were observed in these weld cross-sections.
  • lap joints in tightly clamped specimens of zinc -coated steel sheet can be made with a square wave modulated laser output.
  • welds can be obtained which have highly acceptable visually sound appearance with no internal cracks and no zinc gas blowholes or pitting on the top surface of the material.
  • the reason for the success of welding is mainly due to venting of the zinc vapour through the stable keyhole.
  • Super modulation techniques using square waves, sine waves or other waves may be used for different speeds of welding, for example and for lap joints of more than two layers.
  • Figure 10 to 12 show non-limiting examples of clamping mechanisms.
  • a sample 100 comprising overlapping sheets 101a, 101b, overlapped at the welding line, is clamped between fixed upper plates 102, 103 and a floating lower plate 104.
  • the lower plate may be fixed and the upper plates floating.
  • the floating plate is movable towards and away from the fixed plates as shown by arrow A, to clamp the sample tightly between the plates.
  • Plates 102 and 103 are in line, with as small a gap G between them where the weld line is positioned. By having gap G as small as possible (perhaps a few mm or a few cm) the samples are clamped as near to the weld line as possible.
  • Figure 11 shows a test jig in which the floating plate 104 is acted upon by a plurality of lever clamps 105, shown in more detail in Figure 12.
  • side walls 106 are provided which include cut-outs 107 and 108. Respective projections 109 from the floating plate 104 are retained with these cut-outs. Thus, the cut-outs act as guides ensuring the plate 104 floats only vertically and does not tilt.
  • a base 109 is also provided.
  • Figure 12 shows schematically a lever clamp 105.
  • This comprises a clamp arm 110 threadally mounted on a bolt 111 against a spring 112.
  • the floating plate is pushed up by the lever (against the base) and the spring tension allows the plate 104 (and therefore the sample) to float.

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  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Plasma & Fusion (AREA)
  • Laser Beam Processing (AREA)

Abstract

L'invention concerne un procédé de soudage au laser d'un joint en recouvrement entre deux ou plus de deux tôles (35, 36) d'acier galvanisé, qui comprend les étapes consistant à maintenir les tôles l'une sur l'autre de telle sorte qu'il n'y ait ensuite pas d'interstice à l'emplacement (34) souhaité du soudage et à appliquer la sortie d'un laser semi-conducteur supermodulé le long de la ligne de soudage souhaitée pour ainsi souder le joint.
PCT/GB2006/050398 2005-11-22 2006-11-20 Soudage au laser d'aciers galvanises sans interstice a l'aide d'un laser semi-conducteur supermodule WO2007060479A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB0523693.0A GB0523693D0 (en) 2005-11-22 2005-11-22 Laser welding of zinc coated steels
GB0523693.0 2005-11-22

Publications (1)

Publication Number Publication Date
WO2007060479A1 true WO2007060479A1 (fr) 2007-05-31

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GB (1) GB0523693D0 (fr)
WO (1) WO2007060479A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107414323A (zh) * 2017-06-09 2017-12-01 西安交通大学 评估正弦调制影响高反射率材料激光焊能量耦合行为的方法
CN112658477A (zh) * 2020-12-14 2021-04-16 北京航星机器制造有限公司 一种脉冲双光束激光焊接方法
DE102020105505A1 (de) 2020-03-02 2021-09-02 Trumpf Laser- Und Systemtechnik Gmbh Verfahren zum Laserschweißen zweier beschichteter Werkstücke
WO2023165038A1 (fr) * 2022-03-01 2023-09-07 苏州大学 Appareil de rechargement par laser doté d'un rapport cyclique réglable

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5187346A (en) * 1991-08-29 1993-02-16 General Motors Corporation Laser welding method
EP0564995A1 (fr) * 1992-04-03 1993-10-13 Mitsui Petrochemical Industries, Ltd. Appareil d'irradiation par impulsions laser pour le matériau métallique revêtu
EP0800888A1 (fr) * 1996-03-25 1997-10-15 INPRO Innovationsgesellschaft für fortgeschrittene Produktionssysteme in der Fahrzeugindustrie mbH Procédé de soudage de tÔles zinguées, au moyen d'un laser à solide
WO2003071639A1 (fr) * 2002-02-19 2003-08-28 Gsi Lumonics Ltd Procedes et systemes de traitement au laser d'une piece a travailler, et procedes et appareil de controle de la qualite du faisceau laser
EP1674191A2 (fr) * 2004-12-22 2006-06-28 Schlegel Ag Procédé de fabrication d'un objet comprenant deux toles ainsi que l'objet fabriqué.

Patent Citations (5)

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Publication number Priority date Publication date Assignee Title
US5187346A (en) * 1991-08-29 1993-02-16 General Motors Corporation Laser welding method
EP0564995A1 (fr) * 1992-04-03 1993-10-13 Mitsui Petrochemical Industries, Ltd. Appareil d'irradiation par impulsions laser pour le matériau métallique revêtu
EP0800888A1 (fr) * 1996-03-25 1997-10-15 INPRO Innovationsgesellschaft für fortgeschrittene Produktionssysteme in der Fahrzeugindustrie mbH Procédé de soudage de tÔles zinguées, au moyen d'un laser à solide
WO2003071639A1 (fr) * 2002-02-19 2003-08-28 Gsi Lumonics Ltd Procedes et systemes de traitement au laser d'une piece a travailler, et procedes et appareil de controle de la qualite du faisceau laser
EP1674191A2 (fr) * 2004-12-22 2006-06-28 Schlegel Ag Procédé de fabrication d'un objet comprenant deux toles ainsi que l'objet fabriqué.

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Title
DATABASE COMPENDEX [online] ENGINEERING INFORMATION, INC., NEW YORK, NY, US; ANONYMOUS: "2.5 kW laser diode-pumped YAG laser and applications", XP002418259, Database accession no. E2005389373602 *
ISHIKAWAJIMA HARIMA GIHO; ISHIKAWAJIMA-HARIMA GIHO/IHI ENGINEERING REVIEW SEPTEMBER 2002, vol. 42, no. 5, September 2002 (2002-09-01), pages 256 - 259 *

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107414323A (zh) * 2017-06-09 2017-12-01 西安交通大学 评估正弦调制影响高反射率材料激光焊能量耦合行为的方法
DE102020105505A1 (de) 2020-03-02 2021-09-02 Trumpf Laser- Und Systemtechnik Gmbh Verfahren zum Laserschweißen zweier beschichteter Werkstücke
WO2021175555A1 (fr) 2020-03-02 2021-09-10 Trumpf Laser- Und Systemtechnik Gmbh Procédé de soudage laser de deux pièces revêtues
CN112658477A (zh) * 2020-12-14 2021-04-16 北京航星机器制造有限公司 一种脉冲双光束激光焊接方法
WO2023165038A1 (fr) * 2022-03-01 2023-09-07 苏州大学 Appareil de rechargement par laser doté d'un rapport cyclique réglable

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