초록 ▼

An improved method of weldbonding utilizing inclusion bodies, placed directly between materials to be bonded or included in a weldbonding adhesive. The inclusion bodies maintain a gap between the materials to be welded which provides a gas releasing egress route to disperse the gas and gaseous bypro

An improved method of weldbonding utilizing inclusion bodies, placed directly between materials to be bonded or included in a weldbonding adhesive. The inclusion bodies maintain a gap between the materials to be welded which provides a gas releasing egress route to disperse the gas and gaseous byproducts produced during welding. This egress route substantially prevents the gases and gaseous byproducts from being expelled through the weld pool and the resultant degradation of the quality of the weld pool, particularly with coated materials, partial penetration welds, and such materials as 6000 series aluminum. The method further comprises an optional step of including a crack-reducing additive, applied either directly to the materials to be welded or included in the adhesive. A laser weldbonding embodiment may use a plurality of phased heat cycles to reduce weld imperfections, and enhance the effects of the adhesive and optional crack-reducing additive.

대표청구항 ▼

1. A method of weldbonding a plurality of rigid material components, the method comprising:applying an adhesive between a first rigid material component and a second rigid material component; bringing the first rigid material and the second rigid material into close proximity and maintaining the rel

1. A method of weldbonding a plurality of rigid material components, the method comprising:applying an adhesive between a first rigid material component and a second rigid material component; bringing the first rigid material and the second rigid material into close proximity and maintaining the relative position of the first rigid material and the second rigid material with a retaining means; sweeping a weld area with a welding means causing melting, wherein the weld area includes a portion of the adhesive; and providing a plurality of gas release and gap sustaining inclusion bodies between the first rigid material component and the second rigid material component whereby at least one gas generated by vaporization of a plurality of materials during the melting of the plurality of rigid material components, the adhesive, and the plurality of gas release and gap sustaining inclusion bodies, create at least one passageway between the first rigid material component and the second rigid material component. 2. The method according to claim 1, wherein the welding means is a laser beam having a variable intensity.3. The method according to claim 1, further comprising the step of introducing a crack-reducing additive to the weld area.4. The method according to claim 3, wherein the crack-reducing additive is an integral additive that is integral to the adhesive designed to be liquefied by the welding means and incorporated into the weld area to slow down the solidification of the weld thereby reducing cracking in the weld area.5. The method according to claim 2, further comprising the step of varying the intensity of the laser beam to produce a plurality of heating phases on the weld area incorporating at least an ablating phase, a welding phase, and an annealing phase.6. The method according to claim 1, wherein the plurality of gas release and gap sustaining inclusion bodies are substantially spherical.7. The method according to claim 1, wherein the plurality of gas release and gap sustaining inclusion bodies maintain a separation distance between the first rigid material component and the second rigid material component of between approximately 0.001 inches and approximately 0.020 inches.8. The method according to claim 1, wherein the plurality of gas release and gap sustaining inclusion bodies are substantially constructed of silica.9. The method according to claim 1, wherein the plurality of gas release and gap sustaining inclusion bodies is integral to the adhesive whereby the at least one gas generated by vaporization can escape from between the plurality of rigid material components to a surrounding atmosphere by forcing the adhesive away from the at least one gas thus creating at least one gas escape passageway between the inclusion bodies.10. The method according to claim 2, wherein the adhesive is a rapid-curing adhesive that substantially cures around the weld area when exposed to the laser beam.11. The method according to claim 2, wherein the adhesive contains at least one one-part latent curing agent, at least one two-part curing agent, and at least one viscosity and flow modifier.12. The method according to claim 1, wherein the plurality of rigid material components, the first rigid material component, and the second rigid material component are composed of metal or metal alloys.13. The method according to claim 1, wherein the plurality of rigid material components, the first rigid material component, and the second rigid material component are composed of aluminum alloy.14. The method according to claim 13, wherein the plurality of rigid material components, the first rigid material component, and the second rigid material component are composed of 6000 series aluminum alloy.15. The method according to claim 1, wherein the retaining means comprises at least one clamping device.16. The method according to claim 1, wherein the retaining means is provided by the adhesive applied between the first rigid material component and the second rigid material component.17. A method of weldbonding a plurality of aluminum alloy components, the method comprising:applying an adhesive between a first aluminum alloy component and a second aluminum alloy component; bringing the first aluminum alloy component and the second aluminum alloy component into close proximity and maintaining the relative position of the first aluminum alloy component and the second aluminum alloy component with a retaining means; sweeping a weld area with a welding means causing melting, wherein the weld area includes a portion of the adhesive; and providing a plurality of gas release and gap sustaining inclusion bodies between the first aluminum alloy component and the second aluminum alloy component whereby at least one gas generated by vaporization of a plurality of materials during the melting of the first aluminum alloy component, the second aluminum alloy component, the adhesive, and the plurality of gas release and gap sustaining inclusion bodies, create at least one passageway between the first aluminum alloy component and the second aluminum alloy component. 18. The method according to claim 17, wherein the welding means is a laser beam having a variable intensity.19. The method according to claim 17, further comprising the step of introducing a crack-reducing additive to the weld area.20. The method according to claim 19, wherein the crack-reducing additive is a silicon rich material.21. The method according to claim 19, wherein the crack-reducing additive is an integral additive that is integral to the adhesive designed to be liquefied by the welding means and incorporated into the weld area to slow down the solidification of the weld area thereby reducing cracking in the weld.22. The method according to claim 18, further comprising the step of varying the intensity of the laser beam to produce a plurality of heating phases on the weld area incorporating at least an ablating phase, a welding phase, and an annealing phase.23. The method according to claim 17, wherein the plurality of gas release and gap sustaining inclusion bodies are substantially spherical.24. The method according to claim 17, wherein the plurality of gas release and gap sustaining inclusion bodies maintain a separation distance between the first rigid aluminum alloy component and the second aluminum alloy component of between approximately 0.001 inches and approximately 0.020 inches.25. The method according to claim 17, wherein the plurality of gas release and gap sustaining inclusion bodies are substantially constructed of silica.26. The method according to claim 17, wherein the plurality of gas release and gap sustaining inclusion bodies is integral to the adhesive whereby the at least one gas generated by vaporization can escape from between the plurality of aluminum alloy components to a surrounding atmosphere by forcing the adhesive away from the at least one gas thus creating at least one gas escape passageway between the inclusion bodies.27. The method according to claim 17, wherein the adhesive is a rapid-curing adhesive that substantially cures around the weld area when exposed to the laser beam.28. The method according to claim 17, wherein the adhesive contains at least one one-part latent curing agent, at least one two-part curing agent, and at least one viscosity and flow modifier.29. The method according to claim 17, wherein the retaining means comprises at least one clamping device.30. The method according to claim 17, wherein the retaining means is provided by the adhesive applied between the first rigid aluminum alloy component and the second aluminum alloy component.31. A method of laser weldbonding a first aluminum alloy component and a second aluminum alloy component, having a finish surface and a working surface, whereby a weld fully penetrates the first aluminum alloy component and partially penetrates the second aluminum alloy component from the working surface, producing an unmarred finish on the finish surface of the second aluminum alloy component, the method comprising:applying an adhesive between the first aluminum alloy component and the second aluminum alloy component; bringing the first aluminum alloy component and the second aluminum alloy component into close proximity and maintaining the relative position of the first aluminum alloy component and the second aluminum alloy component with a retaining means; sweeping a weld area with a laser welding beam having variable intensity causing melting, wherein the weld area includes a portion of the adhesive; and providing a plurality of gas release and gap sustaining inclusion bodies between the first aluminum alloy component and the second aluminum alloy component whereby at least one gas generated by vaporization of a plurality of materials during the melting of the first aluminum alloy component, the second aluminum alloy component, the adhesive, and the plurality of gas release and gap sustaining inclusion bodies, create at least one passageway between the first aluminum alloy component and the second aluminum alloy component, such that the weld fully penetrates the first aluminum alloy component and partially penetrates the second aluminum alloy component from the working surface, producing an unmarred finish on the finish surface of the second aluminum alloy component. 32. The method according to claim 31, further comprising the step of introducing a crack-reducing additive to the weld area.33. The method according to claim 32, wherein the crack-reducing additive is a silicon rich material.34. The method according to claim 32, wherein the crack-reducing additive is an integral additive that is integral to the adhesive designed to be liquefied by the welding means and incorporated into the weld area to slow down the solidification of the weld thereby reducing cracking in the weld area.35. The method according to claim 31, further comprising the step of varying the intensity of the laser beam to produce a plurality of heating phases on the weld area incorporating at least an ablating phase, a welding phase, and an annealing phase.36. The method according to claim 31, wherein the plurality of gas release and gap sustaining inclusion bodies are substantially spherical.37. The method according to claim 31, wherein the plurality of gas release and gap sustaining inclusion bodies maintain a separation distance between the first rigid aluminum alloy component and the second aluminum alloy component of between approximately 0.001 inches and approximately 0.020 inches.38. The method according to claim 31, wherein the plurality of gas release and gap sustaining inclusion bodies are substantially constructed of silica.39. The method according to claim 31, wherein the plurality of gas release and gap sustaining inclusion bodies is integral to the adhesive whereby the at least one gas generated by vaporization can escape from between the plurality of aluminum alloy components to a surrounding atmosphere by forcing the adhesive away from the at least one gas thus creating at least one gas escape passageway between the inclusion bodies.40. The method according to claim 31, wherein the adhesive is a rapid-curing adhesive that substantially cures around the weld area when exposed to the laser beam.41. The method according to claim 31, wherein the adhesive contains at least one one-part latent curing agent, at least one two-part curing agent, and at least one viscosity and flow modifier.42. The method according to claim 31, wherein the retaining means comprises at least one clamping device.43. The method according to claim 31, wherein the retaining means is provided by the adhesive applied between the first rigid aluminum alloy component and the second aluminum alloy component.