Interface suspension for alloy based laser welding

Abstract

An interface suspension is disclosed for facilitating the laser welding of a first metal having a first zinc coating and a second metal having a second zinc coating. The interface suspension includes a petrolatum base. The interface suspension also includes a plurality of metal spherules suspended in the petrolatum base. The interface suspension melts when the laser welding occurs and allows the plurality of metal spherules to absorb vapors released by the first and second zinc coatings when the first and second zinc coatings boil.

1 . An interface suspension for facilitating the laser welding of a first metal having a first zinc coating to a second metal having a second zinc coating, said interface suspension comprising: 
 a petrolatum base; and    a plurality of metal spherules suspended in said petrolatum base such that said interface suspension melts when laser welding to allow said plurality of metal spherules to absorb vapors released by the first and second zinc coatings when the first and second zinc coatings melt.    
   
   
       2 . An interface suspension as set forth in  claim 1  wherein said plurality of metal spherules define diameters in the range between 40 microns and 250 microns.  
   
   
       3 . An interface suspension as set forth in  claim 2  wherein said plurality of metal spherules are fabricated from copper.  
   
   
       4 . An interface suspension as set forth in  claim 2  wherein said plurality of metal spherules are fabricated from silver.  
   
   
       5 . An interface suspension as set forth in  claim 2  wherein said plurality of metal spherules are fabricated from nickel.  
   
   
       6 . An interface suspension as set forth in any of claims  3 ,  4  or  5  wherein said plurality of metal spherules have a purity level greater than 99%.  
   
   
       7 . An interface suspension as set forth in  claim 6  wherein said petrolatum base defines a viscosity between 100 USP and 300 USP.  
   
   
       8 . An interface suspension as set forth in  claim 7  wherein said petrolatum base melts at a temperature in a range between 122° F. and 160° F.  
   
   
       9 . An interface suspension for facilitating the laser welding of a first metal having a first zinc coating to a second metal having a second zinc coating, said interface suspension comprising: 
 a petrolatum base; and    a plurality of copper spherules suspended in said petrolatum base such that said interface suspension melts when laser welding to allow said plurality of copper spherules to absorb vapors released by the first and second zinc coating when the first and second zinc coatings melt.    
   
   
       10 . An interface suspension as set forth in  claim 9  wherein said petrolatum base defines a viscosity between 100 USP and 300 USP.  
   
   
       11 . An interface suspension as set forth in  claim 10  wherein said plurality of metal spherules define diameters in the range between 40 microns and 250 microns.  
   
   
       12 . An interface suspension as set forth in  claim 11  wherein said plurality of metal spherules have a purity level greater than 99%.  
   
   
       13 . An interface suspension as set forth in  claim 12  wherein said petrolatum base melts at a temperature in a range between 122° F. and 160° F.