LASER WELDING METHOD
20200009686 ยท 2020-01-09
Assignee
Inventors
- Shuhei Ogura (Nagakute-shi, JP)
- Hiroki SUGINO (Toyota-shi, JP)
- Ryuta Matsuo (Aichi-gun, JP)
- Ryosuke KAWAI (Okazaki-shi, JP)
- Kazuho Takishita (Okazaki-shi, JP)
US classification
- 1/1
Cpc classification
B23K26/211
PERFORMING OPERATIONS; TRANSPORTING
B23K26/16
PERFORMING OPERATIONS; TRANSPORTING
B23K31/003
PERFORMING OPERATIONS; TRANSPORTING
B23K26/062
PERFORMING OPERATIONS; TRANSPORTING
B23K26/0608
PERFORMING OPERATIONS; TRANSPORTING
International classification
B23K26/32
PERFORMING OPERATIONS; TRANSPORTING
B23K26/06
PERFORMING OPERATIONS; TRANSPORTING
B23K26/062
PERFORMING OPERATIONS; TRANSPORTING
B23K26/211
PERFORMING OPERATIONS; TRANSPORTING
Abstract
Provided is a laser welding method for performing lap welding on a plurality of laminated metal plates by applying a laser beam to the metal plates. The metal plates are constituted by n pieces of metal plates laminated in order from a first metal plate to an n-th metal plate, n being an integer not less than 2. The laser welding method includes: forming a recess serving as an escape route for gas by applying a first laser beam from the first metal plate side, the escape route penetrating through the first metal plate to an (n1)th metal plate in the laminating direction to reach the n-th metal plate; and forming a welding pool around the recess so as to maintain the shape of the recess, the welding pool being formed by applying a second laser beam to the outside of the recess.
Claims
1. A laser welding method for performing lap welding on a plurality of laminated metal plates by applying a laser beam to the metal plates, the metal plates being constituted by n pieces of metal plates including at least one metal plate that generates gas due to melting, the metal plates being laminated in order from a first metal plate to an n-th metal plate, n being an integer not less than 2, the laser welding method comprising: forming a recess serving as an escape route for the gas by applying a first laser beam from a first metal plate side, the escape route penetrating through the first metal plate to an (n1)th metal plate in a laminating direction to reach the n-th metal plate; and forming a welding pool around the recess in the metal plates so as to maintain a shape of the recess, the welding pool being formed by applying a second laser beam to an outside of the recess.
2. The laser welding method according to claim 1, wherein: the metal plate that generates the gas due to melting is a metal plate on which a metal plating layer having a melting point lower than that of a base material is formed; and the gas is a vapor of the metal plating layer.
3. The laser welding method according to claim 1, wherein: the metal plate that generates the gas due to melting is a casting plate; and the gas is hydrogen gas dissolved in the casting plate at a time of casting.
4. The laser welding method according to claim 1, further comprising filling the recess with molten metal by applying a third laser beam to the welding pool after the welding pool is formed.
5. The laser welding method according to claim 1, wherein a position of a focus of the second laser beam in the laminating direction is deeper than a position of a focus of the first laser beam in the laminating direction.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Features, advantages, and technical and industrial significance of exemplary embodiments of the disclosure will be described below with reference to the accompanying drawings, in which like numerals denote like elements, and wherein:
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DETAILED DESCRIPTION OF EMBODIMENTS
[0049] With reference to the drawings, the following describes embodiments to carry out the disclosure.
Embodiment 1
[0050]
[0051] Here, in a case where the galvanized steel plate is melted, when zinc vapor is generated, the zinc vapor is hard to be relieved because the welding structure 10 is configured such that the welded portion 15 does not penetrate through the third steel plate 13 (the welding structure 10 is formed by non-penetration welding). However, in the welding structure 10, the high-quality welded portion 15 is formed without poor welding, though no gap through which the zinc vapor is relieved is provided between the first steel plate 11 and the second steel plate 12 and between the second steel plate 12 and the third steel plate 13. The following more specifically describes the laser welding method of the present embodiment that enables formation of the welding structure 10 without poor welding.
[0052] Laser Welding Device
[0053]
[0054] As illustrated in
[0055] The condensing lens 62 is configured to be movable in the up-down direction by an actuator (not shown), and by moving the condensing lens 62 in the up-down direction, its focal distance is adjusted in the up-down direction. Therefore, in the laser welding device 50 of the present embodiment, in a case where the top face of the workpiece W is assumed as a base (0), when a focus F is shifted to a + side or a side, a defocus state or an in-focus state is easily achievable.
[0056] Laser Welding Method
[0057] Next will be described the laser welding method of the present embodiment using the laser welding device 50. However, prior to this, the following will first describe a laser welding method in the related art in a case where lap welding is performed on a plurality of metal plates including a galvanized steel plate, for easy understanding of the disclosure.
[0058]
[0059] As such, as the laser beam LB is applied to enlarge the welding pool 116, zinc plating having a melting point lower than a base material (the steel plate) is sublimated, so that an amount of zinc vapor inside the welding pool 116 increases. In a case where non-penetration welding in which the second steel plate 112 is not penetrated is performed and no gap is provided between the first steel plate 111 and the second steel plate 112, there is no escape route for generated zinc vapor 119, and the zinc vapor 119 remains inside the welding pool 116. On this account, in a case where a large amount of zinc vapor 119 is generated, the zinc vapor 119 pops (expands) and blows off the molten metal 118, as illustrated in
[0060] In view of this, in the laser welding method of the present embodiment, before the welding pool 16 is formed in the first to third steel plates 11, 12, 13, an escape route for zinc vapor (plating vapor) to be generated when the first to third steel plates 11, 12, 13 are melted is secured.
[0061] More specifically, the laser welding method of the present embodiment includes: a recess forming step of forming a recess 17 serving as an escape route for zinc vapor by applying a first laser beam LB1 from the first steel plate 11 side, as illustrated in
[0062] Recess Forming Step
[0063]
[0064] In the recess forming step, in order to form the recess 17 quickly without taking time, the first laser beam LB1 with a relatively high output is applied once (the number of emission times is one).
[0065] However, when the first laser beam LB1 with a relatively high output is applied in a high energy density state, energy of blowing off the molten metal 18 by the spatter becomes too strong, and the molten metal 18 blown off upward might hit the laser welding device 50 and damage the laser welding device 50. On this account, as illustrated in
[0066] Further, in the recess forming step, the recess 17 is formed in a relatively small range, so that a scanning speed V1 of the first laser beam LB1 with which scanning is performed to draw a circle may be relatively low. Besides, the first laser beam LB1 may not necessarily be applied while scanning is performed to draw a circle, and the first laser beam LB1 may be applied in a state where its movement is stopped.
[0067] Note that, the output, the number of emission times, the laser focus position in the laminating direction, and the scanning speed as described above are just examples, and the first laser beam LB1 may be applied under other conditions, provided that the recess 17 can be formed to penetrate through the first and second steel plates 11, 12 in the laminating direction and reach the third steel plate 13.
[0068] Fusing Step
[0069]
[0070] At this time, if the laser beam LB is applied with a relatively high output, all the molten metal might be blown off in some cases. Accordingly, in the fusing step, the second laser beam LB2 with a relatively low output is applied. In order to surely melt the second and third steel plates 12, 13, the second laser beam LB2 is applied in an in-focus state where its focus F reaches the third steel plate 13, as illustrated in
[0071] Further, in the fusing step, the welding pool 16 is formed around the recess 17 in the first to third steel plates 11, 12, 13 such that the shape of the recess 17 is maintained as illustrated in
[0072] Note that the number of heat-input times of the second laser beam LB2 may be one time or several times. For example, when the zinc vapor 19 is relieved from the recess 17 and a desired welding pool 16 is formed by applying the second laser beam LB2 once around the recess 17 at an intermediate speed, the number of heat-input times may be one time, or for example, when the welding pool 16 is enlarged by applying the second laser beam LB2 around the recess 17 several times to secure a desired joining strength, the number of heat-input times may be several times.
[0073] As such, by applying the second laser beam LB2 to the outside of the recess 17 in an in-focus state so as to maintain the shape of the recess 17, the zinc vapor 19 generated in the course of forming and enlarging the welding pool 16 gathers in the center of the welding pool 16, and the zinc vapor 19 is discharged to the outside via the recess 17 while the recess 17 is filled with molten metal flowing therein from the bottom side where the heat input is high, as illustrated in the enlarged view of
[0074] Then, after the application of the second laser beam LB2 is finished, the molten metal constituting the welding pool 16 flows into the recess 17 at a stretch from the bottom side of the recess 17, so that the zinc vapor 19 is discharged to the outside while the recess 17 is filled with the molten metal from the bottom side, as illustrated in
[0075] Note that, the output, the laser focus position in the laminating direction, and the scanning speed as described above are just examples, and the second laser beam LB2 may be applied under other conditions, provided that the welding pool 16 can be formed around the recess 17 in the first to third steel plates 11, 12, 13 such that the shape of the recess 17 is maintained.
[0076] Filling Step
[0077]
[0078] In the filling step, when the laser beam LB is applied with a relatively high output, all the welding pool 16 might be blown off in some cases. Accordingly, the third laser beam LB3 with a relatively low output is applied once or several times (the number of emission times is one to several times). Further, for the same reasons, the third laser beam LB3 is applied in a defocus state where its focus F is placed above the first steel plate 11 as illustrated in
[0079] Further, in the filling step, in order to smooth the surface 16a of the welding pool 16 without taking time, the scanning speed V3 of the third laser beam LB3 with which scanning is performed to draw a circle is set to be relatively high so that the welding pool 16 is stirred.
[0080] Note that the output, the number of emission times, the laser focus position in the laminating direction, and the scanning speed as described above are just examples, and the third laser beam LB3 may be applied under other conditions, provided that the remaining recess 17 can be filled up.
[0081] As described above, in the laser welding method of the present embodiment, the recess 17 is formed by the application of the first laser beam LB1 such that the recess 17 penetrates through the first and second steel plates 11, 12 in the laminating direction and reaches the third steel plate 13, and the welding pool 16 is formed around the recess 17 by the application of the second laser beam LB2 such that the shape of the recess 17 is maintained. Accordingly, even in a case where the amount of the zinc vapor 19 generated by melting of the first to third steel plates 11, 12, 13 is large, the zinc vapor 19 thus generated can be relieved to the outside via the recess 17. Therefore, even in a case where a large amount of the zinc vapor 19 is generated, it is possible to restrain the zinc vapor 19 from popping (expanding) and blowing off the molten metal, thereby making it possible to restrain occurrence of poor welding.
[0082] Further, since the remaining recess 17 is filled with the molten metal by the application of the third laser beam LB3, the surface 15a of the welded portion 15 obtained by solidifying the welding pool 16 can be formed in a smooth shape.
[0083] Further, the second laser beam LB2 applied such that the position of its focus F in the laminating direction is deeper than the position of the focus F of the first laser beam LB1 in the laminating direction, in other words, the second laser beam LB2 applied with a relatively high energy density is applied to the outside of the recess 17, so that parts, around the recess 17, in the second and third steel plates 12, 13 can be melted by high heat input.
Example 1
[0084] Next will be described an example of an experiment performed to check the effect of the laser welding method of the present embodiment.
[0085] In Example 1, a galvanized steel plate having a thickness of 0.6 mm was prepared as the first steel plate 11, a galvanized steel plate having a thickness of 0.7 mm was prepared as the second steel plate 12, and a galvanized steel plate having a thickness of 1.8 mm was prepared as the third steel plate 13. These galvanized steel plates were laminated in order of the first to third steel plates 11, 12, 13 and subjected to the laser welding method using the laser welding device 50. More specifically, in order to perform the laser welding method under more disadvantageous conditions, non-penetration welding was performed in a round welding pattern by setting a gap between the steel plates to 0 (mm) so as to eliminate an escape route for zinc vapor. Note that the setting of the gap to 0 (mm) was achieved in such a manner that the first to third steel plates 11, 12, 13 placed on a jig 70 were pressed by a clamp 71 as illustrated in
[0086] As a result of such an experiment, it was found that the welding structure 10 having the high-quality welded portion 15 as illustrated in
Embodiment 2
[0087] The present embodiment is different from Embodiment 1 in that a welding structure 20 is constituted by aluminum die-casting plates 21, 22. The following mainly describes points different from Embodiment 1.
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[0090] As such, as the laser beam LB is applied to enlarge the welding pool 126, a large amount of hydrogen gas 129 dissolved in the first and second aluminum die-casting plates 121, 122 at the time of casting is precipitated as air bubbles. Then, air bubbles (the hydrogen gas 129) that are not discharged until the welding pool 126 is solidified remain in a welded portion 125 as blowholes 130, as illustrated in
[0091] In view of this, in the laser welding method of the present embodiment, prior to forming the welding pool 26 in the first and second aluminum die-casting plates 21, 22, an escape route for hydrogen gas 29 to be precipitated when the first and second aluminum die-casting plates 21, 22 are melted is secured, similarly to Embodiment 1.
[0092] More specifically, the laser welding method of the present embodiment includes: a recess forming step of forming a recess 27 serving as an escape route for the hydrogen gas 29 by applying the first laser beam LB1 from the first aluminum die-casting plate 21 side to blow off a molten metal 28, as illustrated in
[0093] Hereby, even in a case where a large amount of the hydrogen gas 29 dissolved in the first and second aluminum die-casting plates 21, 22 at the time of casting is precipitated as air bubbles when the first and second aluminum die-casting plates 21, 22 are melted, the welding pool 26 can be formed while the hydrogen gas 29 thus precipitated is relieved to the outside via the recess 27. Hereby, it is possible to restrain blowholes from being formed in the welded portion 25 obtained by solidifying the welding pool 26.
Example 2
[0094] Next will be described an example of an experiment performed to check the effect of the laser welding method of the present embodiment.
[0095] In the example, an aluminum die-casting plate having a thickness of 2.5 mm was prepared as the first aluminum die-casting plate 21, and an aluminum die-casting plate having a thickness of 2.5 mm was prepared as the second aluminum die-casting plate 22. These aluminum die-casting plates were laminated in order of the first and second aluminum die-casting plates 21, 22 and subjected to the laser welding method using the laser welding device 50. More specifically, in order to perform the laser welding method under more disadvantageous conditions, penetration welding was performed in a round welding pattern by setting a gap between the aluminum die-casting plates to 0 (mm) so as to eliminate an escape route for hydrogen gas, as the present example. Note that, similarly to
[0096] Further, as a comparative example, the first and second aluminum die-casting plates 121, 122 having a thickness of 2.5 mm were laminated and subjected to the laser welding method in the related art.
[0097] Results of shearing tension tests performed on the comparative example and the present example are illustrated in
Other Embodiments
[0098] The disclosure is not limited to the above embodiments and can be carried out in other various forms without departing from the spirit or main feature of the disclosure.
[0099] In the above embodiments, the disclosure is applied to the first to third steel plates 11, 12, 13 and to the first and second aluminum die-casting plates 21, 22 laminated without any gap. However, the disclosure is not limited to this, and the disclosure may be applied to a plurality of metal plates laminated with a gap.
[0100] Further, in the above embodiments, the recesses 17, 27 do not penetrate. However, the disclosure is not limited to this, and the recesses 17, 27 may penetrate through the third steel plate 13 and the second aluminum die-casting plate 22.
[0101] In Embodiment 1, the first to third steel plates 11, 12, 13 are each constituted by a galvanized steel plate, but the disclosure is not limited to this, provided that at least one of the first to third steel plates 11, 12, 13 is constituted by a galvanized steel plate, and the other steel plates may be constituted by other metal plates.
[0102] In Embodiment 2, the welding structure 20 is constituted by the first and second aluminum die-casting plates 21, 22, but the disclosure is not limited to this, and the welding structure may be constituted by an aluminum die-casting plate and another metal plate.
[0103] Thus, the above embodiments are just examples in every respect and must not be interpreted restrictively. Further, modifications and alterations belonging to an equivalent range of Claims are all included in the disclosure.
INDUSTRIAL APPLICABILITY
[0104] With the disclosure, it is possible to relieve generated gas and perform high-quality welding without being influenced by an amount of gas to be generated at the time of welding, so that the disclosure is extremely advantageous when the disclosure is applied to a laser welding method for performing lap welding on a plurality of laminated metal plates.