WO2024215536A1

WO2024215536A1 - In-line, laser-assisted hybrid welding process and system

Info

Publication number: WO2024215536A1
Application number: PCT/US2024/022790
Authority: WO
Inventors: Dechao Lin; Rahul Vilas KULKARNI; Dewei Zhu; Sean MILESKI; Joao Felipe CARVALHO DE MORAES; Conrad DENDE; Ganesh Bhaskaran; Mitchell Glenn ROUX; Patrick Sean LESTER; James R. FEKETE
Original assignee: Novelis Inc.
Priority date: 2023-04-14
Filing date: 2024-04-03
Publication date: 2024-10-17

Abstract

A hybrid welding system for welding a metal substrate includes an arc welder and a laser assembly. The arc welder is configured to generate an electric arc in a joint area, and the laser assembly is configured to generate two or more laser beams. At least one laser beam of the two or more laser beams is near or at a perimeter portion of the electric arc in the joint area. A method of joining metal substrates may include traversing the joint area with the hybrid welding system while generating a shared molten metal pool in the joint area from the electric arc and the two or more laser beams of the hybrid welding system that is capable of running at a welding speed greater than 8 m/min, such as up to 30 m/min.

Description

IN-LINE, LASER-ASSISTED HYBRID WELDING PROCESS AND SYSTEM

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63/496,172, filed on April 14, 2023, the content of which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

[0001] This application relates to joining processes generally and more specifically to systems and methods for enhancing welding quality and performance.

BACKGROUND

[0002] Certain industries, including but not limited to the automotive industry, may utilize various techniques for joining one or more work pieces. Such techniques may include welding with a single laser beam. However, traditional laser welding with a single laser beam may create welds with defects, such as cracks across the weld, particularly in metal substrates such as aluminum alloys, more particularly high strength aluminum alloys. Filler metal may be used with laser welding, but providing filler metal reduces the welding speed because the laser beam must melt both the filler metal and the base metal. As an example, to generate welds having an acceptable weld quality, traditional approaches of laser welding with filler metal have a welding speed of less than 12 m/min. under a 20kW laser power. In addition, a high energy density laser beam that hits the filler metal and base metal may generate spattering.

SUMMARY

[0003] Embodiments covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.

1

SUBSTITUTE SHEET (RULE 26) [0004] According to certain embodiments, a hybrid welding system includes an arc welder for generating an electric arc in a joint area on a metal substrate while delivering filler metals. The hybrid welding system also includes a laser assembly for generating two or more laser beams. At least one laser beam of the two or more laser beams is near or at a perimeter portion of the electric arc in the joint area.

[0005] According to various embodiments, a hybrid welding system includes an arc welder for generating an electric arc in a joint area on a metal substrate while delivering filler metals. The hybrid welding system also includes a laser assembly for generating a leading laser beam in a front portion of the electric arc and a side laser beam in a perimeter portion of the electric arc.

[0006] According to various embodiments, a method of joining metal substrates includes traversing a joint area with a hybrid welding system while generating a connected molten metal pool in the joint area from an electric arc and two or more laser beams of the hybrid welding system.

[0007] According to certain embodiments, a method of in-line processing a joint area of metal substrates includes welding the joint area at a welding speed that matches a roll-forming line speed.

[0008] According to some embodiments, a method of joining metal substrates includes traversing a joint area with a hybrid welding system at a welding speed of at least 15 m/min. while generating a molten metal pool in the joint area using the hybrid welding system.

[0009] According to certain embodiments, a method of joining metal substrates includes providing an adhesive between the metal substrates at a location offset from a joint area and welding the joint area using a hybrid welding system having at least an electric arc and two or more laser beams.

[0010] Various implementations described herein can include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.

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SUBSTITUTE SHEET (RULE 26) BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The specification refers to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.

[0012] FIG. 1 illustrates a metal processing system with a roll-forming system and a joining system according to embodiments.

[0013] FIG. 2 illustrates the hybrid welding system of FIG. 1 forming a joint according to embodiments.

[0014] FIG. 3 is another view of the hybrid welding system of FIG. 1 forming the first joint of FIG. 2.

[0015] FIG. 4 illustrates the hybrid welding system of FIG. 1 forming another joint configuration according to embodiments.

[0016] FIG. 5 is a graph illustrating joint strength of joints formed by the hybrid welding system of FIG. 1 according to embodiments.

[0017] FIG. 6A-B are photographs of lap joints formed by the hybrid welding system of FIG. 1 after the strength testing of FIG. 5.

[0018] FIG. 7 is a graph illustrating joint strength of joints formed by the hybrid welding system of FIG. 1 according to embodiments.

DETAILED DESCRIPTION

[0019] Described herein are hybrid welding systems, apparatus, and methods for joining two or more metal substrates. The hybrid welding systems and methods described herein may be used to form various types of joints, such as but not limited to butt joints, lap joints, comer joints, T-joints, edge joints, and the like. The hybrid welding systems and methods described herein may allow for welding at a high welding speed compared to traditional approaches, and in certain embodiments, the hybrid welding systems and methods described herein may provide welding at a welding speed of greater than 8 m/min., such as a welding speed of at least 12 m/min., such as a welding speed of at least 15 m/min., such as a welding speed up to 30 m/min., while maintaining acceptable (e.g., stabilized and/or consistent) weld quality. In some embodiments, the hybrid welding systems and methods described herein may be provided as an in-line joining process in combination with another fabrication system, such as but not limited to a roll-forming line. In such embodiments, the welding speed optionally may match

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SUBSTITUTE SHEET (RULE 26) the line speed of the roll-forming system. The hybrid welding systems and methods described herein may be useful for joining various types of metal substrates as desired, and may be particularly useful for joining aluminum or aluminum alloy metal substrates. In various embodiments, the hybrid welding systems and methods described herein may form stabilized and/or consistent weld quality in a high strength aluminum metal substrate with minimized and/or reduced spattering and minimized and/or reduced crack formation (or other defects) in the weld compared to traditional approaches. Various other benefits and advantages may be realized with the systems and methods described herein, and the aforementioned benefits and advantages should not be considered limiting.

[0020] FIG. 1 illustrates an example of a metal processing system 100 according to embodiments. The metal processing system 100 includes a hybrid welding system 102 for forming a joint in one or more metal substrates or workpieces. In various embodiments, the metal processing system 100 optionally includes a forming processing system 104 for fabricating and/or forming the one or more metal substrates upstream from the hybrid welding system 102. In other optional embodiments, an additional forming processing system (in addition to or in place of the forming processing system 104) may be provided downstream for further fabricating and/or forming the one or more metal substrates with the joint from the hybrid welding system 102 into a final product. In one non-limiting example, the forming processing system 104 may be a roll-forming system for forming a shaped and/or otherwise formed product; however, in other embodiments, additional and/or alternative processing systems may be utilized as desired. As discussed in detail below, the hybrid welding system 102 may have a high welding speed of greater than or equal to 8 m/min., such as greater than or equal to 15 m/min. Optionally, the high welding speed may be up to 30 m/min. In some embodiments, the welding speed of the hybrid welding system 102 may match a line speed of the roll-forming system (or other additional processing system 104). In this aspect, the hybrid welding system 102 may be an in-line joining system that may provide improved processing of the metal substrate(s) into a final product that reduces the handling required by an operator while forming joints at high speeds.

[0021] FIGS. 2-4 illustrate the hybrid welding system 102 in greater detail. In certain embodiments, the hybrid welding system 102 may be used to join two or more metal substrates 101, although the hybrid welding system 102 may be used in any welding application as desired. When joining metal substrates 101, the metal substrates 101 may have various compositions as desired, and in certain embodiments, one or more of the metal substrates 101

4

SUBSTITUTE SHEET (RULE 26) optionally may be an aluminum or aluminum alloy, such as but not limited to a Ixxx aluminum alloy, a 2xxx aluminum alloy, a 3xxx aluminum alloy, a 4xxx aluminum alloy, a 5xxx aluminum alloy, a 6xxx aluminum alloy, a 7xxx aluminum alloy, and/or an 8xxx aluminum alloy. The hybrid welding system 102 may join the two or more metal substrates 101 in various joint configurations such as, but not limited to, a butt joint (see, e.g., FIGS. 2 and 3), a lap joint (see, e.g., FIG. 4), a corner joint, a T-joint, an edge joint, combinations thereof, and/or other joint configurations as desired.

[0022] As illustrated, the hybrid welding system 102 includes at least an arc welder 106 for generating an electric arc 110 (represented by a region of wavy lines in FIG. 2 and a dash-dot oval in FIG. 3). In addition to the arc welder 106, the hybrid welding system 102 includes a laser assembly 108 for generating two or more laser beams 107. Optionally, and as illustrated in FIG. 2, the hybrid welding system 102 includes a filler supply device 119 for supplying a filler material 121, such as but not limited to wire. During a welding process, as the hybrid welding system 102 moves in a welding direction (represented by arrow 120), the electric arc 110 and the laser beams 107 together form a shared molten metal pool 114 at a joint area 118 (see, e.g., FIG. 2) on one or more metal substrates 101 A-B that solidifies into a weld 116. In certain embodiments, one or more characteristics of the laser beams 107 may be controlled to create the stabilized and consistent molten metal pool 114 to achieve the weld 116 with an acceptable weld quality at a high welding speed of greater than or equal to 8 m/min., such as greater than or equal to 15 m/min.

[0023] The arc welder 106 may be various suitable devices for generating the electric arc 110. As non-limiting examples, the arc welder 106 may be a device suitable for generating the electric arc 110 via gas-shielded fusion arc processes such as those similar to gas metal arc welding, gas tungsten arc welding, flux-cored arc welding, combinations thereof, and/or other suitable processes as desired. In some embodiments, the arc welder 106 optionally may deliver a filler metal to the molten metal pool 114; however, in other embodiments, a filler metal need not be utilized. In some embodiments, the arc welder 106 may supply the filler metal only without generating an electric arc 110. In some embodiments, the arc welder 106 may be provided at an oblique angle relative to the joint area 118, although in other embodiments the arc welder 106 may be provided at any angle as desired relative to the joint area 118 and/or the surface(s) of the metal substrates 101 A-B. In various embodiments, the electric arc 110 generated by the arc welder 106 may cover the molten metal pool 114, which may minimize spattering during the welding process.

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SUBSTITUTE SHEET (RULE 26) [0024] The laser assembly 108 may include one or more devices 112 for generating the two or more laser beams 107. In certain embodiments, a single device 112 may generate two or more laser beams 107 and/or a single laser beam 107 of the two or more laser beams 107 as desired. In the embodiment illustrated, the laser assembly 108 generates three laser beams 107A-C (represented by arrows in FIG. 2 and circles in FIG. 3); however, in other embodiments, the laser assembly 108 may generate any number of laser beams 107 as desired, such as two laser beams 107, three laser beams 107, four laser beams 107, or more than four laser beams 107. In some embodiments, the number of laser beams 107 generated by the laser assembly 108 may be a characteristic that is controlled to create the stabilized and consistent molten metal pool 114 to achieve the weld 116 with an acceptable weld quality at a high welding speed of greater than or equal to 8 m/min., such as greater than or equal to 15 m/min. As discussed in detail below, various other characteristics or combinations of characteristics of the laser beams 107 may be controlled, such as but not limited to a location of the laser beams 107 relative to the electric arc 110, an angle of the laser beams 107, an intensity of the laser beams 107, combinations thereof, and/or other characteristics as desired.

[0025] In some embodiments, a location of one or more laser beams 107 relative to the electric arc 110 and/or the molten metal pool 114 may be controlled. As best illustrated in FIG. 3, in certain embodiments, at least one laser beam (e.g., laser beam 107A) may be provided in a front portion 122 of the electric arc 110 in the welding direction 120. The at least one laser beam 107A in the front portion 122 of the electric arc 110 may create a cavity (or “keyhole”) that is subsequently filled by the molten material surrounding the cavity, which may improve the penetration of the weld 116 in the metal substrates 101 A-B. In various embodiments, the at least one laser beam 107A in the front portion 122 of the electric arc 110 may promote stabilization of the electric arc 110 in its front portion 122.

[0026] Additionally, or alternatively, to the at least one laser beam 107 A in the front portion 122, one or more laser beams (e.g., laser beams 107B-C) may be provided at one or more perimeter portions of the electric arc 110. The one or more laser beams 107 in perimeter portions of the electric arc 110 may create molten metal to allow more metal deposition to form the weld 116. The one or more laser beams 107 in perimeter portions of the electric arc 110 may also provide welds 116 with clearer or more well-defined edges in the welding direction 120. The one or more laser beams 107 in perimeter portions of the electric arc 110 may further stabilize the profile of the electric arc 110. While FIG. 3 illustrates two laser beams 107B-C at two perimeter portions 124A-B, the number and location of the laser beams and/or perimeter

6

SUBSTITUTE SHEET (RULE 26) portions should not be considered limiting. As non-limiting examples, the laser assembly 108 may provide additional laser beams 107 surrounding additional perimeter portions of the electric arc 110 and/or may provide a single laser beam 107 at a particular perimeter portion of the electric arc 110. When two or more laser beams 107 are provided in perimeter portions of the electric arc 110, they may be provided symmetrically about the electric arc 110 in the welding direction 120 or asymmetrically as desired. In certain embodiments, the laser beams 107 in perimeter portions of the electric arc 110 may be offset or aligned along the direction of travel. In various embodiments, and as illustrated in FIG. 3, the laser beams 107 in the perimeter portions optionally may be offset both along the welding direction 120 and outwards relative to the laser beam 107A in the front portion 122. Various other patterns or configurations of locations of the laser beams 107 relative to the electric arc 110 may be utilized as desired, and the aforementioned examples should not be considered limiting.

[0027] In certain embodiments, the angle of one or more laser beams 107 may be controlled to create the stabilized and consistent molten metal pool 114 to achieve the weld 116 with an acceptable weld quality at a high welding speed of greater than or equal to 8 m/min., such as greater than or equal to 9 m/min., such as greater than or equal to 10 m/min., such as greater than or equal to 11 m/min., such as greater than or equal to 12 m/min., such as greater than or equal to 13 m/min., such as greater than or equal to 14 m/min., such as greater than or equal to 15 m/min. In various embodiments, the angle of one laser beam 107 relative to the electric arc 110 may be the same as the angle of another laser beam 107 relative to the electric arc 110. In other embodiments, each of the two or more laser beams 107 need not be at a same angle. Controlling the angle of one or more laser beams 107 may stabilize the electric arc 110 at various angles. In certain embodiments, controlling the angle of one or more laser beams 107 in addition to controlling the location of one or more laser beams 107 may provide improved stabilization of the profile of the electric arc 110 from various angles and locations, which may provide profile of the molten metal pool 114 that is has improved stability and consistency.

[0028] In some embodiments, the intensity of one or more laser beams 107 may be controlled. As non-limiting examples, the one or more laser beams 107 may be controlled such that the two or more laser beams 107 have a same intensity or at least one laser beam 107 has an intensity that is different compared to another laser beam 107. As a non-limiting example, the laser beam 107 A may have a higher intensity compared to the intensity of the laser beams 107B-C.

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SUBSTITUTE SHEET (RULE 26) [0029] As mentioned, various other characteristics of the two or more laser beams 107 may be controlled. In certain embodiments, controlling a plurality of characteristics of the laser beams 107 create the stabilized and consistent molten metal pool 114 to achieve the weld 116 with an acceptable weld quality at a high welding speed of greater than or equal to 8 m/min., such as greater than or equal to 15 m/min. As a non-limiting example, controlling the number of laser beams 107, the location of the laser beams 107 relative to the electric arc 110, and/or the angle of the laser beams 107 may provide an improved molten metal pool 114 to achieve the weld 116 with an acceptable weld quality at a high welding speed of greater than or equal to 8 m/min., such as greater than or equal to 15 m/min. In addition to welding at high welding speeds, the hybrid welding system 102 with the electrical arc 110 and the two or more laser beams 107 may provide improved processing in the presence of lubricants. As an example, while traditional welding processes require joint cleaning prior to welding, the hybrid welding system 102 allows for welding in the presence of a vaporous lubricant at the joint area 118.

[0030] When the filler supply device 119 and/or filler material 121 is included with the hybrid welding system 102, the filler material 121 may be supplied into the common molten pool. Optionally, the filler material 121 is supplied ahead of the laser 107A, although in other embodiments it may be provided at other locations relative to other components of the hybrid welding system 102 as desired. Moreover, while a single filler supply device 119 and single supply of filler material 121 is illustrated, in other embodiments, the hybrid welding system 102 may include any number of filler supply devices 119 and/or supplies of filler material 121 may be utilized as desired.

[0031] As mentioned, the hybrid welding system 102 may be used to form various types of joints as desired and at high welding speeds. FIGS. 2-3 illustrate a butt joint 126 joining the metal substrates 101A-B and formed by the hybrid welding system 102, and FIG. 4 illustrates a lap joint 128 joining the metal substrates 101 A-B and formed by the hybrid welding system 102.

[0032] Referring to FIG. 4, in certain embodiments, the hybrid welding system 102 optionally allows for an adhesive 429 to be provided between the metal substrates 101 A-B in the lap joint 128. In such embodiments, the adhesive 429 may be provided a predetermined distance 430 from the location where the weld 116 is formed. In some embodiments, the predetermined distance 430 may be at least 2 mm, although in other embodiments, the predetermined distance 430 may be closer to or farther from the weld 116. When the adhesive 429 is included, the resulting lap joint 128 may have an improved strength, providing a further improved joint

8

SUBSTITUTE SHEET (RULE 26) compared to traditional approaches. In other embodiments, the adhesive 429 need not be included to form a joint using the hybrid welding system 102.

[0033] FIGS. 5 and 6A-B illustrate examples of the improved strength of lap joints 528A-B formed using the hybrid welding system 102 and with the adhesive 429 compared to lap joints 528C-D formed using the hybrid welding system 102 without the adhesive 429. In FIGS. 5 and 6A-B, two metal substrates 101A-B were joined by the lap joints 528A-D, and both metal substrates 101A-B were the same 6xxx aluminum alloy metal substrate. The various joints 528A-D were formed using the same technique and configuration of the hybrid welding system 102 except that the lap joints 528A-B had an extra heat treatment of 180 °C for 30 minutes.

[0034] As illustrated in the graph of FIG. 5, the lap joints 528 A-B formed with the adhesive 429 had a higher strength compared to the lap joints 528C-D without the adhesive 429. In particular, the lap joints 528 A-B had about twice the strength of the lap joints 528C-D. The improved strength is further illustrated by comparing FIG. 6A, which illustrates lap joint 528 A, with FIG. 6B, which illustrates lap joint 528C. As illustrated in FIG. 6 A, the lap joint 528 A separated and formed a fracture 551 A at the weld 116, and in FIG. 6B, the lap joint 528C separated and formed a fracture 55 IB at the top sheet 101 A. The difference in location of the separation (e.g., weld 116 vs. top sheet 101 A) illustrates the improved ability of the adhesive 429 to keep the metal substrates 101 A-B together.

[0035] Referring back to FIGS. 2-3, a method of forming a joint includes traversing the joint area 118 with the hybrid welding system 102 while generating the molten metal pool 114 in the joint area 118 from the electric arc 110 and the two or more laser beams 107 of the hybrid welding system 102. Forming the joint may include forming various joints such as but not limited to a butt joint, a lap joint, a T-joint, a comer joint, an edge joint, and/or other joints as desired.

[0036] In some embodiments, the method includes traversing the joint area 118 at a welding speed of at least 8 m/min., such as at least 15 m/min. In various embodiments, the method includes traversing the joint area 118 at a welding speed that matches the line speed of the additional processing system 104, such as but not limited to the line speed of a roll-forming system.

[0037] In various embodiments, generating the molten metal pool 114 includes directing at least one laser beam 107B-C of the two or more laser beams 107 in a perimeter portion of the electric arc 110. In certain embodiments, generating the molten metal pool 114 includes

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SUBSTITUTE SHEET (RULE 26) directing at least one laser beam 107 A of the two or more laser beams 107 in a front portion of the electric arc 110. The method may include controlling one or more of a number of laser beams 107, a location of the laser beams 107 relative to the electric arc 110, an angle of the laser beams 107, and/or an intensity of the laser beams 107.

[0038] In some embodiments, the method optionally includes providing a filler metal to the joint area 118 using the arc welder 106.

[0039] Optionally, the method includes providing the adhesive 429 between the metal substrates 101 A-B at a location offset from the joint area 118.

[0040] FIG. 7 illustrates examples of lap joints formed using the hybrid welding system 102 compared to traditional lap joints. In FIG. 7, lap joint 701A was formed using the hybrid welding system 102 and with the adhesive 429, and the adhesive 429 was an acrylic foam adhesive tape. Comparative lap joint 70 IB was formed using traditional laser welding and with the same adhesive 429 as the lap joint 701A. Lap joint 701C was formed using the hybrid welding system 102 and with the adhesive 429, and the adhesive 429 was a second acrylic foam adhesive tape different from that of the lap joints 701A-B. Comparative lap joint 701D was formed using traditional laser welding and with the same adhesive 429 as the lap joint 701C. In FIG. 7, two metal substrates 101 A-B were joined by the lap joints 701 A-D, and both metal substrates 101 A-B were the same 6xxx aluminum alloy metal substrate.

[0041] As illustrated in FIG. 7, for a given adhesive, the lap joints formed using the hybrid welding system 102 had both an improved joint strength and increased maximum load compared to lap joints formed via traditional laser welding. As an example, the lap joint 701 A formed using the hybrid welding system 102 had a joint strength of 161.6 MPa while the comparative lap joint 701B had a joint strength of 132.8 MPa. Similarly, the lap joint 701C formed using the hybrid welding system 102 had a joint strength of 127.4 while the comparative lap joint 70 ID had a joint strength of 95.2 MPa.

[0042] The above method is for illustrative purposes, and in other embodiments, additional and/or fewer steps may be implemented as desired. Moreover, other benefits and advantages may be realized with the systems and methods described herein, and the aforementioned benefits and advantages should not be considered limiting.

[0043] A collection of exemplary embodiments is provided below, including at least some explicitly enumerated as an “Illustration” providing additional description of a variety of example embodiments in accordance with the concepts described herein. These illustrations

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SUBSTITUTE SHEET (RULE 26) are not meant to be mutually exclusive, exhaustive, or restrictive; and the disclosure not limited to these example illustrations but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0044] Illustration 1. A hybrid welding system comprising: an arc welder for generating an electric arc in a joint area on a metal substrate; and a laser assembly for generating two or more laser beams, wherein at least one laser beam of the two or more laser beams is near or at a perimeter portion of the electric arc in the joint area.

[0045] Illustration 2. The hybrid welding system of any preceding or subsequent illustration or combination of illustrations, wherein the perimeter portion is a first perimeter portion, and wherein at least a second laser beam of the two or more laser beams is a corresponding perimeter portion.

[0046] Illustration 3. The hybrid welding system of any preceding or subsequent illustration or combination of illustrations, wherein the arc welder is further configured to provide a filler metal.

[0047] Illustration 4. The hybrid welding system of any preceding or subsequent illustration or combination of illustrations, wherein at least one laser beam of the two or more laser beams is near a front portion of the electric arc.

[0048] Illustration 5. The hybrid welding system of any preceding or subsequent illustration or combination of illustrations, wherein the two or more laser beams are provided at a plurality of angles relative to the joint area and relative to each other.

[0049] Illustration 6. The hybrid welding system of any preceding or subsequent illustration or combination of illustrations, wherein the two or more laser beams comprises a first laser beam and the at least one laser beam in the perimeter portion as a second laser beam, and wherein the first laser beam and the second laser beam are offset along a direction of travel of the hybrid welding system.

[0050] Illustration 7. A joining system comprising the hybrid welding system of any preceding or subsequent illustration or combination of illustrations and a roll-forming system upstream from the hybrid welding system, wherein a welding speed of the hybrid welding system is at least 15 m/min.

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SUBSTITUTE SHEET (RULE 26) [0051] Illustration 8. The joining system of any preceding or subsequent illustration or combination of illustrations, wherein a line speed of the roll-forming system is substantially the same as the welding speed.

[0052] Illustration 9. A hybrid welding system comprising: an arc welder for generating an electric arc in a joint area on a metal substrate; and a laser assembly configured to generate (i) a leading laser beam in a front portion of the electric arc and (ii) a side laser beam in a perimeter portion of the electric arc.

[0053] Illustration 10. The hybrid welding system of any preceding or subsequent illustration or combination of illustrations, wherein the arc welder is further configured to deliver a filler metal to the joint area.

[0054] Illustration 11. The hybrid welding system of any preceding or subsequent illustration or combination of illustrations, wherein an angle of the leading laser beam is different from an angle of the side laser beam relative to the joint area.

[0055] Illustration 12. The hybrid welding system of any preceding or subsequent illustration or combination of illustrations, wherein the side laser beam is a first side laser beam, and wherein the hybrid welding system further comprises two or more side laser beams, each in a perimeter portion of the electric arc.

[0056] Illustration 13. A joining system comprising the hybrid welding system of any preceding or subsequent illustration or combination of illustrations and a roll-forming system upstream from the hybrid welding system, wherein a welding speed of the hybrid welding system is substantially the same as a line speed of the roll-forming system.

[0057] Illustration 14. A method of joining metal substrates, the method comprising traversing a joint area with a hybrid welding system while generating a shared molten metal pool in the joint area from an electric arc and two or more laser beams of the hybrid welding system.

[0058] Illustration 15. The method of any preceding or subsequent illustration or combination of illustrations, wherein traversing the joint area comprises welding at a welding speed of at least 15 m/min.

[0059] Illustration 16. The method of any preceding or subsequent illustration or combination of illustrations, wherein generating the molten metal pool comprises directing at least one laser beam of the two or more laser beams in a perimeter portion of the electric arc.

12

SUBSTITUTE SHEET (RULE 26) [0060] Illustration 17. The method of any preceding or subsequent illustration or combination of illustrations, wherein generating the molten metal pool comprises directing a first laser beam of the two or more laser beams in a front portion of the electric arc along a direction of travel and directing a second laser beam of the two or more laser beams in a perimeter portion of the electric arc.

[0061] Illustration 18. The method of any preceding or subsequent illustration or combination of illustrations, wherein generating the molten metal pool further comprises providing a filler metal to the joint area.

[0062] Illustration 19. The method of any preceding or subsequent illustration or combination of illustrations further comprising providing an adhesive between the metal substrates at a location offset from the joint area.

[0063] Illustration 20. The method of any preceding or subsequent illustration or combination of illustrations, wherein traversing the joint area comprises welding at a welding speed that is substantially the same as a line speed of an upstream roll-forming system.

[0064] Illustration 21. A weld formed by the method and/or system of any preceding or subsequent illustration or combination of illustrations.

[0065] Illustration 22. A method of in-line processing a joint area on a metal substrate, the method comprising welding the joint area at a welding speed that matches a subsequent rollforming line speed.

[0066] Illustration 23. A method of joining metal substrates, the method comprising: providing an adhesive between the metal substrates at a location offset from a joint area; and welding the joint area using a hybrid welding system comprising an electric arc and two or more laser beams.

[0067] The subject matter of embodiments of the present disclosure is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “vertical,” “horizontal,” “lateral,” “longitudinal,”

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SUBSTITUTE SHEET (RULE 26) “front,” and “back,” among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing. Throughout this disclosure, a reference numeral with a letter refers to a specific instance of an element and the reference numeral without an accompanying letter refers to the element generically or collectively. Thus, as an example (not shown in the drawings), device “12A” refers to an instance of a device class, which may be referred to collectively as devices “12” and any one of which may be referred to generically as a device “12”. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, or gradients thereof, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention, and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0068] The above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications can be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described embodiments, nor the claims that follow.

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SUBSTITUTE SHEET (RULE 26)

Claims

CLAIMS That which is claimed:

1. A hybrid welding system comprising: an arc welder for generating an electric arc in a joint area on a metal substrate; and a laser assembly for generating two or more laser beams, wherein at least one laser beam of the two or more laser beams is near a perimeter portion of the electric arc in the joint area.

2. The hybrid welding system of claim 1, wherein the perimeter portion is a first perimeter portion, and wherein at least a second laser beam of the two or more laser beams is a corresponding perimeter portion.

3. The hybrid welding system of claim 1, wherein the arc welder is further configured to provide a filler metal.

4. The hybrid welding system of claim 1, wherein at least one laser beam of the two or more laser beams is near a front portion of the electric arc.

5. The hybrid welding system of claim 1, wherein the two or more laser beams are provided at a plurality of angles relative to the joint area and relative to each other.

6. The hybrid welding system of claim 1, wherein the two or more laser beams comprises a first laser beam and the at least one laser beam in the perimeter portion as a second laser beam, and wherein the first laser beam and the second laser beam are offset along a direction of travel of the hybrid welding system.

7. A joining system comprising the hybrid welding system of claim 1 and a roll-forming system upstream from the hybrid welding system, wherein a welding speed of the hybrid welding system is at least 15 m/min.

8. The joining system of claim 7, wherein a line speed of the roll-forming system is substantially the same as the welding speed.

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SUBSTITUTE SHEET (RULE 26)

9. A hybrid welding system comprising: an arc welder for generating an electric arc in a joint area on a metal substrate; and a laser assembly configured to generate (i) a leading laser beam in a front portion of the electric arc and (ii) a side laser beam in a perimeter portion of the electric arc.

10. The hybrid welding system of claim 9, wherein the arc welder is further configured to deliver a filler metal to the joint area.

11. The hybrid welding system of claim 9, wherein an angle of the leading laser beam is different from an angle of the side laser beam relative to the joint area.

12. The hybrid welding system of claim 9, wherein the side laser beam is a first side laser beam, and wherein the hybrid welding system further comprises at least a second side laser beam, each in a perimeter portion of the electric arc.

13. A joining system comprising the hybrid welding system of claim 9 and a roll-forming system upstream from the hybrid welding system, wherein a welding speed of the hybrid welding system is substantially the same as a line speed of the roll-forming system.

14. A method of joining metal substrates, the method comprising traversing a joint area with a hybrid welding system while generating a shared molten metal pool in the joint area from an electric arc and two or more laser beams of the hybrid welding system.

15. The method of claim 14, wherein traversing the joint area comprises welding at a welding speed of at least 15 m/min.

16. The method of claim 14, wherein generating the molten metal pool comprises directing at least one laser beam of the two or more laser beams in a perimeter portion of the electric arc.

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SUBSTITUTE SHEET (RULE 26)

17. The method of claim 14, wherein generating the molten metal pool comprises directing a first laser beam of the two or more laser beams in a front portion of the electric arc along a direction of travel and directing a second laser beam of the two or more laser beams in a perimeter portion of the electric arc.

18. The method of claim 14, wherein generating the molten metal pool further comprises providing a filler metal to the joint area.

19. The method of claim 14, further comprising providing an adhesive between the metal substrates at a location offset from the joint area.

20. The method of claim 14, wherein traversing the joint area comprises welding at a welding speed that is substantially the same as a line speed of an upstream roll-forming system.

21. A weld formed by the method of claim 14.

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SUBSTITUTE SHEET (RULE 26)