A method of laser welding a first aluminum workpiece and a second aluminum workpiece arranged to form a lap joint includes forming a laser weld between the first aluminum workpiece and the second aluminum workpiece and forming a lap through weld joint using a weld speed equal to or greater than 10 meters per minute. The laser weld has less than 10% area fraction keyhole voids, for example, less than 5% area fraction keyhole voids and the lap through weld joint can have a flange length of less than 10 mm. The first aluminum workpiece can be an inner workpiece of a halo assembly of a vehicle door, the second aluminum workpiece can be a channel workpiece of the halo assembly and laser welding the inner workpiece to the channel workpiece forms the halo assembly without the use of mechanical fasteners, thereby decreasing weight and costs of the halo assembly.

A method of laser welding a first aluminum workpiece and a second aluminum workpiece arranged to form a lap joint includes forming a laser weld between the first aluminum workpiece and the second aluminum workpiece and forming a lap through weld joint using a weld speed equal to or greater than 10 meters per minute. The laser weld has less than 10% area fraction keyhole voids, for example, less than 5% area fraction keyhole voids and the lap through weld joint can have a flange length of less than 10 mm. The first aluminum workpiece can be an inner workpiece of a halo assembly of a vehicle door, the second aluminum workpiece can be a channel workpiece of the halo assembly and laser welding the inner workpiece to the channel workpiece forms the halo assembly without the use of mechanical fasteners, thereby decreasing weight and costs of the halo assembly.

One aspect relates to a 3D connector structure for electrically connecting at least one flat electrode to at least one connection wire. The 3D connector structure has at least two connectors which are spatially separate from one another. The connectors in each case have an electrically conductive material, a first side and a second side. The second side of each connector is connected to an electrical connection element. A spacing of at least 100 μm is constructed between the first side and the second side of each connector.

One aspect relates to a 3D connector structure for electrically connecting at least one flat electrode to at least one connection wire. The 3D connector structure has at least two connectors which are spatially separate from one another. The connectors in each case have an electrically conductive material, a first side and a second side. The second side of each connector is connected to an electrical connection element. A spacing of at least 100 μm is constructed between the first side and the second side of each connector.

A laser welding method includes a pretreatment process and a welding process. At least one metal member of the plurality of metal members is formed from a metal-plated steel plate in which a base metal has been covered with a coating material that has a melting point lower than the base metal. In the pretreatment process, with the position of the first metal member in the in-plane direction fixed, processing is performed from the front surface of the first metal member to form on the back surface, a protrusion that bulges from the back surface. Then, in the welding process, the first metal member in which a protrusion has been formed is superposed on a second metal member with the protrusion therebetween while maintaining the position in the in-plane direction, and laser light is irradiated on the superposed region to weld the plurality of metal members to each other.

A laser welding method includes a pretreatment process and a welding process. At least one metal member of the plurality of metal members is formed from a metal-plated steel plate in which a base metal has been covered with a coating material that has a melting point lower than the base metal. In the pretreatment process, with the position of the first metal member in the in-plane direction fixed, processing is performed from the front surface of the first metal member to form on the back surface, a protrusion that bulges from the back surface. Then, in the welding process, the first metal member in which a protrusion has been formed is superposed on a second metal member with the protrusion therebetween while maintaining the position in the in-plane direction, and laser light is irradiated on the superposed region to weld the plurality of metal members to each other.

A device and associated method for joining, via a laser welder, a first workpiece to a second workpiece is described. This includes arranging the first and second workpieces in a stack, including overlapping a portion of the first workpiece with a portion of the second workpiece. The laser welder generates a first laser beam and coincidentally controls the laser welder to traverse a desired weld path that is disposed on the top surface of the first workpiece. The laser devices generates a second laser beam and coincidentally controls the laser welder to traverse the desired weld path. Generating, via the laser welder, the first laser beam includes operating the laser welder at a pulsed operation and at a first power level. Generating, via the laser welder, the second laser beam includes operating the laser welder at a continuous operation and at a second power level.

A welding method for joining a first plate made of a material other than steel and a second plate made of steel includes a step of making a hole through each of the first plate and the second plate, a press-fitting step, an overlapping step, and a filling and welding step. A shaft portion of a joining assist member being solid, being made of steel, and having an outer shape with step having the shaft portion and a flange portion is press-fitted in the hole of the first plate. The first plate and the second plate is overlapped such that the shaft portion faces the hole of the second plate. The hole of the second plate is filled with a weld metal and the second plate and the joining assist member are welded.

A method of welding a support on a slide profile, which comprises: a) providing a support having a wall with an inner face, and providing a profile having a wall with an outer face, b) positioning the interface support with the inner face of its wall against the outer face of the wall of the profile, c) creating a welding joint between the wall of the support and the wall of the profile by moving a laser beam relative to the wall of the profile, while keeping the laser beam in a position such that it successively passes through, from an emitting source: the wall of the profile, then the wall of the support, while remaining within the material of the wall of the support.

An experiment of processing a device is performed to acquire type 1 information and type 2 information indicating processing conditions, and type 3 information and type 4 information indicating results of the processing, derive a first relation between the type 1 information, the type 2 information, and the type 3 information, and a second relation between the type 1 information, the type 2 information, and the type 4 information, and generate and output a model that estimates the type 4 information indicating a result of the processing by using the first relation and the second relation with the type 2 information and the type 3 information that are measured during the processing as inputs.