CATL纯铝极柱&连接片振镜焊接

2020/2/8CATLConfidentialCATL电池极柱连接片振镜焊接试验大族激光-6kw光纤激光器振镜焊接1234试验目的试验设备与条件试验参数与结果试验结果分析目录content试验目的2020/2/8CATLConfidentialPage3通过试验，激光焊接纯铝连接片（上层1.5mm，下层3mm），获得满足以下条件的优化工艺参数：在较低的激光功率下焊接（=4kw）；通过调整振镜轨迹参数，获得焊缝深宽比接近1的焊缝；下层工件熔深在1.4-1.7之间，两层工件间焊缝结合面宽度在1.4-1.7之间；焊缝外观光滑平整。试验设备2020/2/8CATLConfidentialPage4激光器：IPG-YLS-6000光纤芯径：150um振镜：HANSLASER大功率振镜头（CF150460，与BlackBird振镜头同样光学配置）控制系统：HANSLASERScanWeldingSoftware试验参数与结果2020/2/8CATLConfidentialPage5功率离焦量线宽步长二层熔深结合面宽度外观13.600.80.40.841.77OK23.6-310.60.621.2OK33.6-61.20.800OK43.8010.80.911.51飞溅、咬边53.8-31.20.40.651.24OK63.8-60.80.60.861.34OK7401.20.60.91.65OK84-30.80.81.151.61OK94-610.41.121.42OK103.8-310.60.741.34OK114-61.20.80.571.08OK124-30.80.41.191.49OK13400.60.41.321.61焊缝不平整14400.80.41.41.92OK154-30.80.41.161.48OK164-60.80.40.971.48OK17420.80.41.291.5咬边183.620.80.41.081.5OK193.8210.80.911.5OK20421.20.61.041.54OK213.620.80.41.011.38焊缝不平整22421.20.61.051.75OK233.640.80.40.81.29OK243.8410.80.841.46OK25441.20.60.941.49焊缝不平整螺旋线型轨迹线宽步长试验参数与结果：（焊接速度80mm/s，保护气体：氩气）试验参数与结果2020/2/8CATLConfidentialPage6焊缝外观试验参数与结果2020/2/8CATLConfidentialPage7焊缝外观试验参数与结果2020/2/8CATLConfidentialPage8焊缝外观试验参数与结果2020/2/8CATLConfidentialPage9焊缝截面：12563478试验参数与结果2020/2/8CATLConfidentialPage10焊缝截面：910131411121516试验参数与结果2020/2/8CATLConfidentialPage11焊缝截面：1718212219202324试验参数与结果2020/2/8CATLConfidentialPage12焊缝截面25试验结果分析2020/2/8CATLConfidentialPage13序号功率离焦量线宽步长二层熔深结合面宽度外观13.600.80.40.841.77OK23.6-310.60.621.2OK33.6-61.20.800OK43.8010.80.911.51飞溅、咬边53.8-31.20.40.651.24OK63.8-60.80.60.861.34OK7401.20.60.91.65孔、飞溅84-30.80.81.151.61OK94-610.41.121.42OK103.8-310.60.741.34OK114-61.20.80.571.08OK124-30.80.41.191.49OK13400.60.41.321.61飞溅、凸起14400.80.41.41.92OK154-30.80.41.161.48OK164-60.80.40.971.48OK17420.80.41.291.5咬边、凸起183.620.80.41.081.5OK193.8210.80.911.5OK20421.20.61.041.54OK213.620.80.41.011.38OK22421.20.61.051.75OK233.640.80.40.81.29凸起243.8410.80.841.46OK25441.20.60.941.49焊缝不平整试验参数与结果：（焊接速度80mm/s，保护气体：氩气）试验结果分析2020/2/8CATLConfidentialPage14工艺参数对外观的影响：均值响应表水平功率离焦量线宽步长10.200000.000001.000000.3000020.166670.000000.222220.3333330.363640.600000.166670.1666740.250000.3333350.66667Delta0.19690.666670.833330.16667排秩3214视外观缺陷值为1，外观OK值为0，主效应分析结果可见：线宽对外观缺陷影响最大，其次为焦点位置。当功率密度过大，焊缝温度过高，易产生飞溅，造成焊缝凸起、咬边、飞溅孔等缺陷。线宽应该控制在0.8-1.2试验结果分析2020/2/8CATLConfidentialPage15工艺参数对下层工件焊缝熔深的影响：由主效应图可以观察到，线宽和功率对熔深影响最大。在焦点附近，熔深变化不大。均值响应表水平功率离焦量线宽步长10.66100.70401.32001.061020.81830.86701.05890.850831.08001.07400.85670.730041.07250.684250.8600Delta0.4190.37000.63580.3310排秩2314试验结果分析2020/2/8CATLConfidentialPage16工艺参数对结合面宽度的影响：由主效应图可以观察到，离焦量和线宽对结合面宽度的影响较大步长和线宽应该选择小值，利于加大结合面宽度；功率应该尽可能大均值响应表水平功率离焦量线宽步长11.1401.0641.6101.51621.3981.3751.5371.44431.5351.6921.4051.19341.5211.18451.413Delta0.3950.6280.4260.322排秩3124试验结果分析2020/2/8CATLConfidentialPage17螺旋线参数、焦点位置对焊缝形貌的影响：功率离焦量线宽步长下层熔深结合面熔宽233.640.80.40.81.29183.620.80.41.081.513.600.80.40.841.77均值0.901.52243.8410.80.841.46193.8210.80.911.543.8010.80.911.51均值0.891.4925441.20.60.941.4920421.20.61.041.5425401.20.60.91.65均值0.961.56对比左侧表格可见，通过调整线宽和步长，在不同功率下（3.6kw、3.8kw、4.0kw），可得到的焊缝熔深、熔宽几乎相同的焊缝（熔深0.9左右，熔宽1.5左右）在3.8kw，4kw功率下，焦点0-4范围内，熔深熔宽变化不大。试验结果分析2020/2/8CATLConfidentialPage18不同焦点位置的焊缝变化：功率离焦量线宽步长二层熔深结合面宽度17420.80.41.291.514400.80.41.41.92154-30.80.41.161.48164-60.80.40.971.481.291.41.160.971.51.921.481.4820-3-6熔深&熔宽变化二层熔深结合面宽度试验结果分析2020/2/8CATLConfidentialPage19优选参数：试验中，第8、14、15号参数最为接近焊缝要求，结合面宽度均能符合要求，但熔深稍浅。根据之前的分析，可获得优选参数：激光功率4kw或更大离焦量：-2mm左右线宽：0.8mm步长：0.4mm或更小序号功率离焦量线宽步长二层熔深结合面宽度深宽比外观13.600.80.40.841.770.47OK23.6-310.60.621.20.52OK33.6-61.20.800-OK43.8010.80.911.510.60飞溅、咬边53.8-31.20.40.651.240.52OK63.8-60.80.60.861.340.64OK7401.20.60.91.650.55孔、飞溅84-30.80.81.151.610.71OK94-610.41.121.420.79OK103.8-310.60.741.340.55OK114-61.20.80.571.080.53OK124-30.80.41.191.490.80OK13400.60.41.321.610.82飞溅、凸起14400.80.41.41.920.73OK154-30.80.41.161.480.78OK164-60.80.40.971.480.66OK17420.80.41.291.50.86咬边、凸起183.620.80.41.081.50.72OK193.8210.80.911.50.61OK20421.20.61.041.540.68OK213.620.80.41.011.380.73OK22421.20.61.051.750.60OK233.640.80.40.81.290.62凸起243.8410.80.841.460.58OK25441.20.60.941.490.63焊缝不平整感谢聆听E-mail:[e-mail]——大族激光精密焊接事业部刘昊、胡勇、李博、李淼2016-1-29