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WO2017035728A1 - Procédé pour souder au laser des pièces d'acier - Google Patents

Procédé pour souder au laser des pièces d'acier Download PDF

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Publication number
WO2017035728A1
WO2017035728A1 PCT/CN2015/088563 CN2015088563W WO2017035728A1 WO 2017035728 A1 WO2017035728 A1 WO 2017035728A1 CN 2015088563 W CN2015088563 W CN 2015088563W WO 2017035728 A1 WO2017035728 A1 WO 2017035728A1
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WO
WIPO (PCT)
Prior art keywords
workpiece
steel
laser beam
workpiece stack
stack
Prior art date
Application number
PCT/CN2015/088563
Other languages
English (en)
Inventor
David S. Yang
Wu Tao
Jing Zhang
Justin Allen WOLSKER
Original Assignee
GM Global Technology Operations LLC
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 GM Global Technology Operations LLC filed Critical GM Global Technology Operations LLC
Priority to PCT/CN2015/088563 priority Critical patent/WO2017035728A1/fr
Publication of WO2017035728A1 publication Critical patent/WO2017035728A1/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
    • B23K26/20—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
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • B23K26/082—Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
    • 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
    • B23K26/322—Bonding taking account of the properties of the material involved involving coated metal parts
    • 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
    • B23K2101/006—Vehicles
    • 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

Definitions

  • the technical field of this disclosure relates generally to laser welding and, more particularly, to a method of laser welding together two or more overlapping steel workpieces.
  • Laser welding is a metal joining process in which a laser beam is directed at a metal workpiece stack-up to provide a concentrated energy source capable of effectuating a weld joint between the overlapping constituent metal workpieces.
  • two or more metal workpieces are first aligned and stacked relative to one another such that their faying surfaces overlap and confront to establish a faying interface (or faying interfaces) within an intended weld site.
  • a laser beam is then directed at a top surface of the workpiece stack-up. The heat generated from the absorption of energy from the laser beam initiates melting of the metal workpieces and establishes a molten weld pool within the workpiece stack-up.
  • the molten weld pool penetrates through the metal workpiece impinged upon by the laser beam and into the underlying metal workpiece or workpieces to a depth that intersects each of the established faying interfaces. And, if the power density of the laser beam is high enough, a keyhole is produced directly underneath the laser beam and is surrounded by the molten weld pool.
  • a keyhole is a column of vaporized metal derived from the metal workpieces within the workpiece stack-up that may include plasma.
  • the laser beam creates the molten weld pool in very short order—typically miliseconds—once it impinges the top surface of the workpiece stack-up.
  • the laser beam is advanced along the top surface of the workpiece stack-up while tracking a predetermined weld path, which has conventionally involved moving the laser beam in a strict forward direction without any side-to-side variation.
  • Such advancement of the laser beam translates the molten weld pool along a corresponding course relative to top surface of the workpiece stack-up and leaves behind molten workpiece material in the wake of the advancing weld pool.
  • This penetrating molten workpiece material cools and solidifies to form a weld joint comprised of re-solidified workpiece material.
  • the resultant weld joint fusion welds the overlapping steel workpieces together.
  • a vehicle door body may be fabricated from an inner door panel and an outer door panel that are joined together by a plurality of laser welds.
  • the inner and outer door panels are first stacked relative to each other and secured in place by clamps.
  • a laser beam is then sequentially directed at multiple weld sites around the stacked panels in accordance with a programmed sequence to form the plurality of laser weld joints.
  • the laser beam is directed at the stacked panels and conveyed along a predefined laser beam travel path, which may be configured to produce the weld joint in any suitable overall shape including, for example, as a circular spot weld joint, a stitch weld joint, or a staple weld joint.
  • a predefined laser beam travel path which may be configured to produce the weld joint in any suitable overall shape including, for example, as a circular spot weld joint, a stitch weld joint, or a staple weld joint.
  • the process of laser welding inner and outer door panels (as well as other vehicle part components such as those used to fabricate hoods, deck lids, load-bearing structural members, etc. ) is typically an automated process that can be carried out quickly and efficiently.
  • zinc-coated steel workpieces include an outer coating of zinc for corrosion protection.
  • Zinc has a boiling point of about 906°C, while the melting point of the base steel substrate it coats is typically greater than 1300°C.
  • high-pressure zinc vapor is readily produced at the surfaces of the steel workpieces.
  • the zinc vapor produced at the faying surfaces of the stacked steel workpieces is forced to diffuse into and through the molten weld pool created by the laser beam unless an alternative escape outlet is provided through the workpiece stack-up.
  • the workpieces are oftentimes scored with a laser beam or mechanically dimpled before laser welding takes place to create spaced apart protruding features on one or more of the faying surfaces of the steel workpieces.
  • the protruding features impose a gap of about 0.1–0.2 millimeters between the faying surfaces of the steel workpieces, which provides an escape path to guide zinc vapors away from the weld site during the laser welding process.
  • a method of laser welding a workpiece stack-up that includes overlapping steel workpieces is disclosed.
  • the workpiece stack-up includes two or more steel workpieces, and at least one of those steel workpieces (and preferably all of the steel workpieces) includes an outer coating of zinc. While the zinc coating is desirable for its ability to protect the underlying bulk steel substrate from corrosion and other forms of deterioration, zinc has a relatively low boiling point and is easily vaporized during laser welding by the intense localized heat generated in the vicinity of the functioning laser beam.
  • the laser welding method involves providing a workpiece stack-up that includes two or more overlapping steel workpieces (e.g, two or three overlapping steel workpieces) .
  • the steel workpieces are superimposed on each other such that a faying interface is formed between the faying surfaces of each pair of adjacent overlapping steel workpieces.
  • the workpiece stack-up includes first and second steel workpieces having first and second faying surfaces, respectively, that overlap and confront one another to establish a single faying interface.
  • the workpiece stack-up includes an additional third steel workpiece situated between the first and second steel workpieces.
  • first and second steel workpieces have first and second faying surfaces, respectively, that overlap and confront opposed faying surfaces of the third steel workpiece to establish two faying interfaces.
  • first and second steel workpieces may be separate and distinct parts or, alternatively, they may be different portions of the same part, such as when an edge of one part is folded back over on itself and hemmed over a free edge of another part.
  • a laser beam is directed at, and impinges, a top surface of the workpiece stack-up to create a molten steel weld pool that penetrates into the workpiece stack-up and intersects each faying interface established within the workpiece stack-up.
  • the power density of the laser beam is selected to carry out the laser welding method in either conduction welding mode or keyhole welding mode. In conduction welding mode, the power density of the laser beam is relatively low, and the energy of the laser beam is conducted as heat through the steel workpieces to create only the molten steel weld pool.
  • the molten steel weld pool created during conduction welding mode is relatively shallow, typically having a width at the top surface of the workpiece stack-up that is greater than a penetration depth of the molten steel weld pool into the workpiece stack-up.
  • the power density of the laser beam is high enough to vaporize the steel workpieces and produce a keyhole directly underneath the laser beam within the molten steel weld pool.
  • the keyhole provides a conduit for energy absorption deeper into workpiece stack-up which, in turn, facilitates deeper and narrower penetration of the molten steel weld pool.
  • the molten steel weld pool created during keyhole welding mode typically has a width at the top surface of the workpiece stack-up that is less than the penetration depth of the weld pool.
  • the laser beam is advanced relative to the top surface of the workpiece stack-up along one or more predefined travel paths following creation of the molten steel weld pool.
  • the laser beam is advanced from a start point to an end point, which may be the same or different points on the top surface, to thereby translate the molten steel weld pool along a course that corresponds to the travel path of the laser beam.
  • Such advancement of the laser beam leaves behind molten steel workpiece material in the wake of the travel path of the laser beam and the corresponding course of the weld pool.
  • This molten workpiece material quickly cools and solidifies into a weld joint comprised of re-solidified steel that autogenously fusion welds the steel workpieces together.
  • the weld joint is strong and durable, and its structure and properties are consistently attainable in a manufacturing setting as a result of the peculiar travel path of the laser beam between the start and end points, as will be further explained below.
  • the laser beam is removed from the top surface of the workpiece stack-up.
  • the laser beam in the disclosed method experiences movement in two directions as it is advanced relative to the top surface of the workpiece stack-up. Specifically, while being advanced along any of the one or more laser beam travel paths, the laser beam moves in a forward direction away from the start point and towards the end point and further moves back and forth in a lateral direction transverse to the forward direction. The back and forth movement of the laser beam that occurs while the laser beam is also moving in the forward direction is believed to minimize zinc vapor entrapment within the molten steel weld pool in at least two ways.
  • the lateral movement of the laser beam induces constant changes in the molten metal fluid velocity field within the molten steel weld pool, which disturbs entrained zinc vapors and consequently promotes zinc vapor evolution from the weld pool.
  • the lateral movement of the laser beam heats up a larger portion of the steel workpieces—as compared to a conventional laser beam that moves unidirectionally—and results in more zinc being vaporized and converted into high melting-temperature zinc oxides in and around the travel path of the laser beam.
  • the laser beam can be advanced along myriad travel paths that incorporate both movement in the forward direction and movement back and forth in the lateral direction.
  • the laser beam is oscillated from the start point to the end point in a sinusoidal pattern that includes repeating waves. These repeating waves have peak-to-peak amplitudes and wavelengths that gauge the movement of the laser beam in the lateral direction and the frequency of such movement, respectively.
  • a preferred implementation involving the sinusoidal pattern includes repetitive waves having peak-to-peak amplitudes ranging from 0.1 mm to 6.0 mm and wavelengths ranging from 0.1 mm to 6.0 mm.
  • other laser beam travel paths may be implemented besides those that embody the sinusoidal pattern.
  • Some examples of alternative travel paths include those that embody a rectangular wave pattern, a zig-zag wave pattern, and a continuous loop pattern, to name but a few.
  • Figure 1 is a perspective view of an embodiment of a laser welding apparatus for producing a laser weld joint within a workpiece stack-up that includes two or more overlapping steel workpieces;
  • Figure 2 is a plan view of the top surface of the workpiece stack-up during laser welding in which a laser beam is being advanced relative to the top surface of the workpiece stack-up, wherein the laser beam has created a molten steel weld pool that penetrates into the stack-up and has additionally produced a keyhole within the molten steel weld pool;
  • Figure 3 is a cross-sectional side view of the workpiece stack-up shown in Figure 2;
  • Figure 4 is a cross-sectional view of the workpiece stack-up taken from the same perspective as shown in Figure 3, although here the workpiece stack-up includes three steel workpieces that establish two faying interfaces, as opposed to two steel workpieces that establish a single faying interface as depicted in Figure 3;
  • Figure 5 is a plan view of the top surface of a workpiece stack-up during laser welding in which the laser beam is being advanced relative to the top surface along a travel path from a start point to an end point according to one implementation of the disclosed method to form a weld joint comprised of re-solidified workpiece steel, wherein the advancement of the laser beam comprises movement of the laser beam in a forward direction as well as movement of the laser beam back and forth in a lateral direction transverse to the forward direction;
  • Figure 6 is a plan view of the top surface of a workpiece stack-up during laser welding in which the laser beam is being advanced relative to the top surface along a travel path from a start point to an end point according to another implementation of the disclosed method, wherein the advancement of the laser beam comprises movement of the laser beam in a forward direction as well as movement of the laser beam back and forth in a lateral direction transverse to the forward direction;
  • Figure 7 is a plan view of the top surface of a workpiece stack-up during laser welding in which the laser beam is being advanced relative to the top surface along a travel path from a start point to an end point according to still another implementation of the disclosed method, wherein the advancement of the laser beam comprises movement of the laser beam in a forward direction as well as movement of the laser beam back and forth in a lateral direction transverse to the forward direction;
  • Figure 8 is a plan view of the top surface of a workpiece stack-up during laser welding in which the laser beam is being advanced relative to the top surface along a travel path from a start point to an end point according to yet another implementation of the disclosed method, wherein the advancement of the laser beam comprises movement of the laser beam in a forward direction as well as movement of the laser beam back and forth in a lateral direction transverse to the forward direction;
  • Figure 9 is a plan view of the top surface of a workpiece stack-up showing a travel path the laser beam could follow from a start point to an end point in order to form a circle weld joint according to one embodiment of the disclosed method;
  • Figure 10 is a plan view of the top surface of a workpiece stack-up showing a travel path the laser beam could follow from a start point to an end point in order to form a staple weld joint according to one embodiment of the disclosed method;
  • Figure 11 is a plan view of the top surface of a workpiece stack-up showing a travel path the laser beam could follow from a start point to an end point in order to form a stitch weld joint according to one embodiment of the disclosed method.
  • the disclosed method of laser welding a workpiece stack-up comprised of two or more overlapping steel workpieces calls for advancing a laser beam relative to a top surface of the workpiece stack-up such that the laser beam experiences movement in forward direction as well as back and forth movement in a lateral direction.
  • Any type of laser welding apparatus including remote and conventional laser welding apparatuses, may be employed to advance the laser beam relative to the top surface of the workpiece stack-up.
  • the operational power density of the laser beam may be selected to perform the method in either conduction welding mode or keyhole welding mode.
  • the laser beam may thus be a solid-state laser beam or a gas laser beam depending on the characteristics of the steel workpieces being joined and the laser welding mode desired to be practiced.
  • a remote laser welding apparatus directs and advances a solid-state laser beam at and along the workpiece stack-up while practicing laser welding in keyhole welding mode.
  • FIG. 1–3 a method of laser welding a workpiece stack-up 10 that includes a first steel workpiece 12 and a second steel workpiece 14 using a remote laser welding apparatus 16 is shown.
  • the first steel workpiece 12 includes an outer surface 18 and a first faying surface 20, and the second steel workpiece 14 includes an outer surface 22 and a second faying surface 24.
  • the outer surface 18 of the first steel workpiece 12 provides a top surface 26 of the workpiece stack-up 10 and the outer surface 22 of the second steel workpiece 14 provides an oppositely-facing bottom surface 28 of workpiece stack-up 10.
  • first and second faying surfaces 20, 24 of the first and second steel workpieces 12, 14 overlap and confront one another to establish a faying interface 30 at least within a predetermined weld site 32.
  • the faying interface 30 is, broadly speaking, established between the portions of the first and second faying surfaces 20, 24 that overlap and confront one another
  • the particular attributes of the faying interface 30 can take on several different forms.
  • the overlapping and confronting portions of the faying surfaces 20, 24 may directly or indirectly contact one another.
  • the faying surfaces 20, 24 are in indirect contact when they are separated by an intermediate material—such as a thin layer of weld-through adhesive or sealer—yet remain in close enough proximity that remote laser welding can still be practiced.
  • the overlapping and confronting portions of the faying surfaces 20, 24 can make complimentary flush contact (direct or indirect) at the weld site 32, meaning that the faying surfaces 20, 24 are closely mated together and are not purposefully separated by gaps or spaces imposed by intentionally formed protruding features.
  • This type of close complimentary contact which allows for small indiscriminate breaks or spaces as a result of acceptable tolerances in the size and shape of the workpieces 12, 14 or otherwise, is permitted since the disclosed method provides another mechanism (i.e., bidirectional laser beam movement) to help counteract the possible adverse effects associated with the boiling of zinc at the faying interface (s) .
  • one or both of the faying surfaces 20, 24 may include protruding features formed by laser scoring, mechanical dimpling, or otherwise, to assist in zinc vapor escape, if desired.
  • the first steel workpiece 12 includes a first base steel substrate 34 and the second steel workpiece 14 includes a second base steel substrate 36.
  • the base steel substrates 34, 36 may be composed of any of a wide variety of steels including a low carbon steel (also referred to as mild steel) , an interstitial-free (IF) steel, a high-strength low-alloy (HSLA) steel, or an advanced high strength steel (AHSS) such as dual phase (DP) steel, transformation-induced plasticity (TRIP) steel, twinning-induced plasticity (TWIP) steel, complex-phase (CP) steel, martensitic (MART) steel, hot-formed (HF) steel, and press-hardened (PHS) steel.
  • DP dual phase
  • TRIP transformation-induced plasticity
  • TWIP twinning-induced plasticity
  • CP complex-phase
  • MART martensitic
  • HF hot-formed
  • PHS press-hardened
  • each of the first base steel substrate 34 and the second base steel substrate 36 may be in the form of a pre-fabricated (e.g., stamped, drawn, punched, etc. ) panel derived from hot-rolled or cold-rolled steel sheet metal or a plate blank.
  • Each of the base steel substrates 34, 36 may have also been heat-treated to obtain a particular set of mechanical properties.
  • a few common heat-treating processes that may be practiced include annealing, quenching, and/or tempering.
  • a zinc-coated steel workpiece is a base steel substrate that includes a layer of zinc on at least one of its major surfaces. Indeed, as shown in Figure 3, each of the first and second steel substrates 34, 36 is coated with a layer of zinc 38 that, in turn, provides the workpieces 12, 14 with their respective outer surfaces 18, 22 and their respective faying surfaces 20, 24.
  • These zinc layers 38 may be applied by hot-dip galvanizing, electro-galvanizing, or galvannealing, for example, and are typically 2 ⁇ m to 16 ⁇ m thick.
  • the first and second steel workpieces 12, 14 may have thicknesses in the range of 0.4 mm to 4.0 mm, and more specifically in the range of 0.5 mm to 2.0 mm at least at the weld site 32.
  • the thicknesses of the first and second steel workpieces 12, 14 may be the same as or different from each other.
  • Figures 1–3 illustrate an embodiment of the remote laser welding method in which the workpiece stack-up 10 includes two overlapping steel workpieces 12, 14 that have the single faying interface 30.
  • the workpiece stack-up 10 may include an additional third steel workpiece 40 situated between the first and second steel workpieces 12, 14.
  • the third steel workpiece 40 if present, includes a third base steel substrate 42 that may be bare or coated with a layer of zinc 44 (as shown) .
  • the third steel workpiece 40 is similar in many general respects to the first and second steel workpieces 12, 14 and, accordingly, the description of the first and second steel workpieces 12, 14 set forth above (in particular the composition of the base steel substrates and the thickness of the workpieces) applies fully to the third steel workpiece 40.
  • the third steel workpiece 40 may also be fabricated, shaped, and heat-treated in any suitable manner applicable to the first and second steel workpieces 12, 14 as previously discussed.
  • the third steel workpiece 40 has two faying surfaces 46, 48.
  • One of the faying surfaces 46 overlaps and confronts the faying surface 20 of the first steel workpiece 12 and the other faying surface 48 overlaps and confronts the faying surface 24 of the second steel workpiece 14, thus establishing two faying interfaces 50, 52 within the workpiece stack-up 10 at the weld site 32.
  • These faying interfaces 50, 52 are the same type and encompass the same attributes as the faying interface 30 already described with respect to Figures 1 and 3.
  • the exterior outer surfaces 18, 22 of the flanking first and second steel workpieces 12, 14 still generally face away from each other in opposite directions and constitute the top and bottom surfaces 26, 28 of the workpiece stack-up 10.
  • the remote laser welding method including the following disclosure directed to a workpiece stack-up that includes two steel workpieces, can be readily adapted and applied to a workpiece stack-up that includes three overlapping steel workpieces without undue difficulty.
  • the remote laser welding apparatus 16 includes a scanning optic laser head 54.
  • the scanning optic laser head 54 focuses and directs a laser beam 56 at the top surface 26 of the workpiece stack-up 10 which, here, is provided by the outer surface 18 of the first steel workpiece 12.
  • the scanning optic laser head 54 is preferably mounted to a robotic arm (not shown) that can quickly and accurately carry the laser head 54 to many different preselected weld sites on the workpiece stack-up 10 in rapid programmed succession.
  • the laser beam 56 used in conjunction with the scanning optic laser head 54 is preferably a solid-state laser beam and, in particular, a fiber laser beam or a disk laser beam operating with a wavelength in the near-infrared range (commonly considered to be 700 nm to 1400 nm) of the electromagnetic spectrum.
  • a preferred fiber laser beam is any laser beam in which the laser gain medium is either an optical fiber doped with rare-earth elements (e.g., erbium, ytterbium, neodymium, dysprosium, praseodymium, thulium, etc. ) or a semiconductor associated with a fiber resonator.
  • a preferred disk laser beam is any laser beam in which the gain medium is a thin disk of ytterbium-doped yttrium-aluminum Garnet crystal coated with a reflective surface and mounted to a heat sink
  • the scanning optic laser head 54 includes an arrangement of mirrors 58 that maneuver the laser beam 56 within a two-dimensional process envelope 60 that encompasses the weld site 32.
  • the arrangement of mirrors 58 includes a pair of tiltable scanning mirrors 62. Each of the tiltable scanning mirrors 62 is mounted on a galvanometer. The two tiltable scanning mirrors 62 can move the laser beam 56 anywhere in the x-y plane of the top surface 26 encompassed by the operating envelope 60 through precise coordinated tilting movements executed by the galvanometers.
  • the laser head 54 also includes a z-axis focal lens 64, which can move a focal point 66 ( Figure 3) of the laser beam 56 in a z-direction oriented perpendicular to the x-y plane. All of these optical components 62, 64 can be rapidly indexed in a matter of milliseconds or less to focus and direct the laser beam 56 precisely as intended at the workpiece stack-up 10 to form a laser weld joint 68 (shown from the top in Figures 1–2 and in cross-section in Figure 3) that autogenously fusion welds the first and second steel workpieces 12, 14 together.
  • a z-axis focal lens 64 can move a focal point 66 ( Figure 3) of the laser beam 56 in a z-direction oriented perpendicular to the x-y plane. All of these optical components 62, 64 can be rapidly indexed in a matter of milliseconds or less to focus and direct the laser beam 56 precisely as intended at the workpiece stack-up 10 to form a
  • a cover slide 70 may be situated below the scanning optic laser head 54.
  • the cover slide 70 protects the tiltable mirrors 62 and the z-axis focal lens 64 from the environment yet allows the laser beam 56 to pass out of the laser head 54 without substantial disruption.
  • a characteristic that differentiates remote laser welding (also sometimes referred to as “welding on the fly” ) from other more-conventional forms of laser welding is the focal length of the laser beam.
  • the laser beam 56 has a focal length 72, which is measured as the distance between the focal point 66 and the last tiltable scanning mirror 62 that intercepts and reflects the laser beam 56 prior to the laser beam 56 impinging the top surface 26 of the workpiece stack-up 10 (also the outer surface 18 of the first steel workpiece 12) .
  • the focal length 72 of the laser beam 56 is preferably in the range of 0.4 meters to 1.5 meters with a diameter of the focal point 66 typically ranging anywhere from 350 ⁇ m to 700 ⁇ m.
  • the scanning optic laser head 54 shown generally in Figure 1 and described above, as well as others that may be constructed somewhat differently, are commercially available from a variety of sources.
  • Some notable suppliers of scanning optic laser heads and lasers for use with the remote laser welding apparatus 16 include HIGHYAG (World headquarters in Kleinmachnow, Germany) and TRUMPF Inc. (North American headquarters in Farmington, Connecticut) .
  • the weld joint 68 is formed between the first and second steel workpieces 12, 14 by advancing the laser beam 56 along a predefined travel path relative to the top surface 26 of the workpiece stack-up 10 according to a programmed laser weld schedule. As shown best in Figures 2 and 3, the laser beam 56 is initially directed at, and impinges, the top surface 26 of the workpiece stack-up 10 within the weld site 32. The heat generated from absorption of the focused energy of the laser beam 56 initiates melting of the first and second steel workpieces 12, 14 to create a molten steel weld pool 74 that penetrates into the workpiece stack-up 10 from the top surface 26 towards the bottom surface 28 and intersects the faying interface 30.
  • the laser beam 56 also vaporizes the first and second steel workpieces 12, 14 directly beneath where it impinges the top surface 26 of the stack-up 10. This vaporizing action produces a keyhole 76, which is a column of vaporized steel that usually contains plasma.
  • the keyhole 76 is formed within the molten steel weld pool 74 and exerts an outwardly-directed vapor pressure sufficient to prevent the surrounding molten steel weld pool 74 from collapsing inward.
  • the keyhole 76 also penetrates into the workpiece stack-up 10 from the top surface 26 toward the bottom surface 28 and intersects the faying interface 30 of the two steel workpieces 12, 14.
  • the keyhole 76 provides a conduit for the laser beam 56 to deliver energy down into the workpiece stack-up 10, thus facilitating relatively deep and narrow penetration of the molten steel weld pool 74 into the workpiece stack-up 10 and a relatively small surrounding heat-affected zone.
  • the keyhole 76 may fully penetrate the workpiece stack-up 10, in which case it extends from the top surface 26 of the workpiece stack-up 10 (also outer surface 18) through the bottom surface 28 of the workpiece stack-up 10 (also outer surface 22) , as shown here in Figure 3. Or, alternatively, the keyhole 76 may partially penetrate the workpiece stack-up 10, in which case it extends into the stack-up 10 from the top surface 26 of the workpiece stack-up 10 and across the faying interface 30, but does not reach the bottom surface 28 of the workpiece stack-up 10.
  • the power level, travel velocity, and/or focal point position of the laser beam 56 may be controlled during the laser welding process so that the keyhole 76 penetrates the workpiece stack-up 10 to the desired depth.
  • the laser beam 56 is advanced from a start point to an end point relative to the top surface 26 of the workpiece stack-up 10 within the weld site 32. Such advancement of the laser beam 56 occurs along a programmed travel path by coordinating the movement of the tiltable scanning mirrors 62 in the scanning optic laser head 54.
  • the molten steel weld pool 74 is consequently translated along a corresponding course since it tracks the movement of the laser beam 56. Accordingly, as the laser beam 56 is advanced along its travel path, the molten steel weld pool 74 follows and leaves behind molten steel workpiece material in the wake of the progressing weld pool 74.
  • This molten steel workpiece material quickly cools and solidifies into the weld joint 68—the weld joint 68 being comprised of re-solidified coalesced steel derived from each of the steel workpieces 12, 14—that autogenously fusion welds the workpieces 12, 14 together.
  • the transmission of the laser beam 56 is ceased so that the laser beam 56 no longer impinges the top surface 26 of the workpiece stack-up 10.
  • the keyhole 76 collapses (if present) and the molten steel weld pool 74 solidifies to complete the formation of the weld joint 68.
  • More than one weld joint 68 may be formed within the weld site 32 in a similar manner if desired.
  • the laser beam 56 is advanced from a start point to an end point along a travel path 78 that promotes zinc vapor escape without necessarily requiring gaps or spaces between the faying surfaces 20, 24 of the first and second steel workpieces 12, 14.
  • the travel path 78 imposes movement of the laser beam 56 and, consequently, the molten steel weld pool 74, in two directions within the x-y plane of the top surface 26 of the workpiece stack-up 10: (1) a forward direction 80 and (2) back and forth in a lateral direction 82 oriented transverse to the forward direction 80.
  • the forward direction 80 is the directional component of the movement of the laser beam 56 occurring along a mean centerline 84 of the travel path 78 that extends from the start point to the end point and coincides with the overall direction in which weld joint 68 is growing lengthwise.
  • the lateral direction 82 is the directional component of the movement of the laser beam 56 representing purposeful deviations to either side of the mean centerline 84.
  • These purposeful deviations in the lateral direction 82 may be of any form or profile that are intentionally induced and, for that reason, do not encompass minor unspecified deviations of a laser beam tracking an otherwise unidirectional travel path.
  • the deviations in the lateral direction 82 extend away from the mean centerline 84 by 0.05 mm to 3.0 mm on each side of the mean centerline 84.
  • the exact shape and profile of the travel path 78 of the laser beam 56 can assume any of a wide variety of profiles while still experiencing movement in the forward direction 80 and movement back and forth in the lateral direction 82.
  • One particularly effective type of bidirectional movement involves periodic oscillation of the laser beam 56 in the lateral direction 82 while moving the laser beam 56 in the forward direction 80.
  • the travel path 78 embodies a sinusoidal pattern that includes repeating waves 86 as viewed from above as the travel path 78 is projected on the x-y plane of the top surface 26 of the workpiece stack-up 10 within the weld site 32.
  • the laser beam 56 is oscillated back and forth in the lateral direction 82 between wave peaks 92 while moving in the forward direction 80. Such oscillation can render the repeating waves 86 continuous.
  • the laser beam 56 is oscillated at a relatively constant frequency to induce repeating waves 86 characterized by peak-to-peak amplitudes 94 and wavelengths 96 ranging from 0.1 mm to 6.0 mm and from 0.1 mm to 6.0 mm, respectively.
  • FIG. 6 A few alternative examples of a travel path in which the laser beam 56 can experience movement in the forward direction 80 and movement back and forth in the lateral direction 82 are depicted in Figures 6–8.
  • the travel path illustrated in Figure 6, which is denoted by reference numeral 78′ embodies a zig-zag wave pattern that includes repeating triangles 98.
  • Advancing the laser beam 56 along this type of travel path involves linearly oscillating the laser beam 56 back and forth in the lateral direction 82 between alternating vertices 100 while moving the laser beam 56 in the forward direction 80.
  • the travel path illustrated in Figure 7, which is denoted by reference numeral 78′′ embodies a rectangular wave pattern that includes repeating plateaus 102.
  • Advancing the laser beam 56 along this type of travel path involves linearly oscillating the laser beam 56 back and forth in the lateral direction 82 between alternating linear stages 104 while also moving the laser beam 56 in the forward direction 80.
  • the triangles 98 and plateaus 102 shown in Figures 6–7 may be sized similarly to the repeating waves 86 shown in Figure 5 and, as such, may be characterized by peak-to-peak amplitudes 106, 108 (between vertices 100 or linear stages 104) and wavelengths 110, 112 ranging from 0.1 mm to 6.0 mm and from 0.1 mm to 6.0 mm, respectively.
  • Another suitable travel path which is denoted by reference numeral 78′′′ , embodies a continuous loop pattern that includes a series of interconnected and overlapping loops 114, as shown in Figure 8.
  • This travel path of the laser beam 56 is somewhat different from the previously-discussed travel paths 78, 78′ , 78′′ ; indeed, the present travel path 78′′′ having continuous loops 114 as projected in the x-y plane of the top surface 26 of the workpiece stack-up 10 does not emulate a periodic waveform like the travel paths 78, 78′ , 78′′ illustrated in Figures 5–7.
  • the loops 114 of the present travel path 78′′′ are continuously curved in trajectory and spaced close enough together that each loop 114 intersects its preceding loop 114 when completing the aft portion of its trajectory.
  • the laser beam 56 is gyrated to produce the continuous and intersecting loops 114, which involves repeated rotational movement in the lateral direction 82, while moving in the forward direction 80.
  • the loops 114 tracked by the laser beam 56 may vary in size and spacing, although in many instances the loops 114 are characterized by radii 116 that range from 0.1 mm to 6.0 mm and midpoint distances 118 (measured between the centers of adjacent loops 114) that range from 0.1 mm to 6.0 mm.
  • the programmed laser welding schedule that controls the overall laser welding method can execute instructions that dictate the profile of the travel path 78 of the laser beam 56, which can be any of the specific travel paths 78, 78′ , 78′′ , 78′′′ shown here as well as variations not shown. It can also execute instructions detailing other parameters of the laser beam 56 including (1) the power level, (2) the travel velocity, and (3) the focal point location relative to the top surface 26 of the workpiece stack-up 10 in the z-direction. Each of these three laser welding parameters may be varied to ensure the laser beam 56 creates the molten steel weld pool 74 (and preferably produces the keyhole 76 to the desired penetration depth) and acceptably forms the weld joint 68 while being advanced along its predetermined travel path 78.
  • the power level of the laser beam 56 is typically between 0.2 kW and 50 kW, and more narrowly between 2.0 kW and 10.0 kW
  • the travel velocity of the laser beam 56 is typically between 0.5 meters per minute and 100.0 meters per minute, and more narrowly between 1.5 meters per minute and 8.0 meters per minute
  • the focal point location of the laser beam 56 is typically set somewhere between the bottom surface 28 of the workpiece stack-up 10 and 40 mm above the top surface 26.
  • the bidirectional movement of the laser beam 56 helps minimize the entrapment of zinc vapors within the molten steel weld pool 74, especially in instances where intentionally imposed gaps or spaces are not present between the workpiece faying surfaces 20, 24 at the faying interface 30. This may be true for several reasons.
  • the back and forth movement of the laser beam 56 in the lateral direction 82 induces constant changes in the molten metal fluid velocity field within the molten steel weld pool 74, which disturbs entrained zinc vapors and consequently promotes zinc vapor evolution from the weld pool 74.
  • Having a keyhole 76 that fully penetrates the workpiece stack-up 10 makes it easier to vent zinc vapors in many instances by providing a conduit for zinc vapor escape that is less resistive to gas transport than the surrounding molten steel weld pool 74.
  • the back and forth movement of the laser beam 56 in the lateral direction 82 heats up a larger portion of the steel workpieces 12, 14—as compared to a conventional laser beam that moves unidirectionally—and results in more zinc being converted into high melting-temperature zinc oxides in the surrounding proximity of the molten steel weld pool 74.
  • the conversion of zinc to zinc oxides along the travel path of the laser beam 56 reduces the amount of zinc vapors that can be produced since zinc oxides have relatively high melting points and are therefore not readily vaporizable.
  • Examples set forth several specific implementations of the disclosed method. These Examples demonstrate laser weld joints of three different overall shapes—namely, a circular weld joint, a staple weld joint, and a stitch weld joint—as applied to different workpiece stack-ups comprised of two or three overlapping steel workpieces.
  • the workpiece stack-ups were laser welded with a remote laser welding apparatus that utilized a solid-state laser beam characterized by a near-infrared wavelength.
  • the focal length of the laser beam was set to 600 mm, with the actual location of the focal point being set somewhere between the bottom surface of the workpiece stack-up and 20.0 mm above the top surface.
  • a keyhole was formed in each Example that is believed to have minimized the entrapment of zinc vapors in the molten steel weld pool created by the laser beam.
  • the laser welding method involved advancing the laser beam along a sinusoidal travel path, which is plotted in Figure 9 and represented by reference numeral 120, to form a circle laser weld joint (the weld joint not being shown here) that fusion welded three overlapping steel workpieces together.
  • the three steel workpieces employed here were a 1.4 mm thick zinc-coated dual-phase steel workpiece (tensile strength of 900 MPa) sandwiched between another 1.4 mm thick zinc-coated dual-phase steel workpiece (tensile strength of 900 MPa) , which provided the top surface of the workpiece stack-up, and a 1.0 mm thick zinc-coated low carbon steel workpiece, which provided the bottom surface of the workpiece stack-up.
  • the sinusoidal travel path of the laser beam included repetitive waves characterized by peak-to-peak amplitudes of 0.5 mm and wavelengths of 0.4 mm. Additionally, the laser beam had a power level of 5500 W, a travel velocity of 3.6 m/min, and a focal point location of 16.2 mm above the top surface of the workpiece stack-up. The entire circle weld joint took 1.366 seconds to complete.
  • a similar welding method was also performed to form a circle laser weld joint (the weld joint not being shown here) that fusion welded two overlapping steel workpieces together.
  • That particular stack-up included a 1.4 mm thick zinc-coated dual-phase steel workpiece (tensile strength of 900 MPa) , which provided the top surface of the workpiece stack-up, and a 1.0 mm thick zinc-coated low carbon steel workpiece, which provided the bottom surface of the workpiece stack-up.
  • the travel path followed by the laser beam in that instance was also a sinusoidal travel path, albeit with some differences in the laser welding parameters.
  • the sinusoidal travel path of the laser beam included repetitive waves characterized by peak-to-peak amplitudes of 0.5 mm and wavelengths of 0.4 mm.
  • the laser beam had a power level of 4600 W, a travel velocity of 3.0 m/min, and a focal point location of 17.6 mm above the top surface of the workpiece stack-up.
  • the laser welding method involved advancing the laser beam along a sinusoidal travel path, which is plotted in Figure 10 and represented by reference numeral 130, to form a staple laser weld joint (the weld joint not being shown here) that fusion welded three overlapping steel workpieces together.
  • the three steel workpieces employed here were a 1.4 mm thick zinc-coated dual-phase steel workpiece (tensile strength of 900 MPa) sandwiched between another 1.4 mm thick zinc-coated dual-phase steel workpiece (tensile strength of 900 MPa) , which provided the top surface of the workpiece stack-up, and a 1.0 mm thick zinc-coated low carbon steel workpiece, which provided the bottom surface of the workpiece stack-up.
  • the sinusoidal travel path of the laser beam included repetitive waves characterized by peak-to-peak amplitudes of 0.5 mm and wavelengths of 0.4 mm. Additionally, the laser beam had a power level of 5500 W, a travel velocity of 3.6 m/min, and a focal point location of 16.2 mm above the top surface of the workpiece stack-up. The entire staple weld joint took 2.149 seconds to complete.
  • a similar welding method was also performed to form a staple laser weld joint (not depicted) that fusion welded two overlapping steel workpieces together.
  • That particular stack-up included a 1.4 mm thick zinc-coated dual-phase steel workpiece (tensile strength of 900 MPa) , which provided the top surface of the workpiece stack-up, and a 1.0 mm thick zinc-coated low carbon steel workpiece, which provided the bottom surface of the workpiece stack-up.
  • the travel path followed by the laser beam in that instance was also a sinusoidal travel path, albeit with some differences in the laser welding parameters.
  • the sinusoidal travel path of the laser beam included repetitive waves characterized by peak-to-peak amplitudes of 0.5 mm and wavelengths of 1.0 mm.
  • the laser beam had a power level of 4600 W, a travel velocity of 3.0 m/min, and a focal point location of 17.6 mm above the top surface of the workpiece stack-up.
  • the laser welding method involved advancing the laser beam along a sinusoidal travel path, which is plotted in Figure 11 and represented by reference numeral 140, to form a stitch laser weld joint (not depicted) that fusion welded three overlapping steel workpieces together.
  • the three steel workpieces employed here were a 1.4 mm thick zinc-coated dual-phase steel workpiece (tensile strength of 900 MPa) sandwiched between another 1.4 mm thick zinc-coated dual-phase steel workpiece (tensile strength of 900 MPa) , which provided the top surface of the workpiece stack-up, and a 0.8 mm thick zinc-coated low carbon steel workpiece, which provided the bottom surface of the workpiece stack-up.
  • the sinusoidal travel path of the laser beam included repetitive waves characterized by peak-to-peak amplitudes of 0.5 mm and wavelengths of 0.5 mm. Additionally, the laser beam had a power level of 5500 W during most of the travel path and a reduced power level of 4500 W during the very early and late stages of the travel path.
  • the travel velocity of the laser beam was 3.0 m/min and a focal point location was set at the bottom surface of the workpiece stack-up. The entire stitch weld joint took 1.143 seconds to complete.
  • a similar welding method was also performed to form a staple laser weld joint (not depicted) that fusion welded two overlapping steel workpieces together.
  • That particular stack-up included a 1.2 mm thick zinc-coated dual-phase steel workpiece (tensile strength of 900 MPa) , which provided the top surface of the workpiece stack-up, and a 0.7 mm thick zinc-coated low carbon steel workpiece, which provided the bottom surface of the workpiece stack-up.
  • the travel path followed by the laser beam in that instance was also a sinusoidal travel path, albeit with some differences in the laser welding parameters.
  • the sinusoidal travel path of the laser beam included repetitive waves characterized by peak-to-peak amplitudes of 0.5 mm and wavelengths of 0.5 mm.
  • the laser beam had a power level of 3300 W, a travel velocity of 3.0 m/min, and a focal point location of 20.0 mm above the top surface of the stack-up.

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

Abstract

L'invention concerne un procédé pour souder au laser un empilement de pièces à travailler (10) qui comprend au moins deux pièces d'acier se chevauchant (12,14), dont au moins l'une est une pièce d'acier revêtue de zinc. Le procédé décrit met en œuvre le fait de faire avancer le faisceau de laser (56) par rapport à la surface supérieure (26) de l'empilement de pièces à travailler (10) d'une manière qui applique un mouvement bidirectionnel du faisceau de laser (56). En particulier, quand il avance par rapport à la surface supérieure (26) de l'empilement de pièces à travailler (10), le faisceau de laser (56) se déplace dans une direction vers l'avant (80) tout en se déplaçant également vers l'avant et vers l'arrière dans une direction latérale (82) orientée transversalement par rapport à la direction vers l'avant. Un tel mouvement bidirectionnel est censé réduire au minimum le piégeage de vapeurs de zinc dans le bain de soudure d'acier fondu (74), produisant ainsi un joint soudé au laser (68) qui contient moins de défauts de soudure provenant de vapeurs de zinc qui peuvent être générées par la chaleur du faisceau de laser (56).
PCT/CN2015/088563 2015-08-31 2015-08-31 Procédé pour souder au laser des pièces d'acier WO2017035728A1 (fr)

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CN110914014A (zh) * 2017-06-13 2020-03-24 通用汽车环球科技运作有限责任公司 用于使用焊接路径的组合激光焊接金属工件的方法
CN110936016A (zh) * 2018-09-25 2020-03-31 通用汽车环球科技运作有限责任公司 用于激光焊接的方法和设备
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WO2022005491A1 (fr) 2020-06-29 2022-01-06 Ipg (Beijing) Fiber Laser Technology Co., Ltd. Procédé et système d'ébavurage et de chanfreinage au laser

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US10953494B2 (en) 2016-03-16 2021-03-23 GM Global Technology Operations LLC Remote laser welding of overlapping metal workpieces at fast speeds
US10953497B2 (en) 2016-04-08 2021-03-23 GM Global Technology Operations LLC Method for laser welding steel workpieces
US10946479B2 (en) 2016-04-14 2021-03-16 GM Global Technology Operations LLC Laser spot welding of overlapping aluminum workpieces
US10195689B2 (en) 2016-07-11 2019-02-05 GM Global Technology Operations LLC Laser welding of overlapping metal workpieces assisted by varying laser beam parameters
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CN110914014A (zh) * 2017-06-13 2020-03-24 通用汽车环球科技运作有限责任公司 用于使用焊接路径的组合激光焊接金属工件的方法
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CN112601630A (zh) * 2018-09-05 2021-04-02 古河电气工业株式会社 焊接方法及焊接装置
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CN110936016B (zh) * 2018-09-25 2022-04-26 通用汽车环球科技运作有限责任公司 用于激光焊接的方法和设备
CN110936016A (zh) * 2018-09-25 2020-03-31 通用汽车环球科技运作有限责任公司 用于激光焊接的方法和设备
WO2022005491A1 (fr) 2020-06-29 2022-01-06 Ipg (Beijing) Fiber Laser Technology Co., Ltd. Procédé et système d'ébavurage et de chanfreinage au laser
EP4171863A4 (fr) * 2020-06-29 2024-08-14 IPG (Beijing) Fiber Laser Technology Co., Ltd. Procédé et système d'ébavurage et de chanfreinage au laser

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