Laser Welding Process

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  1. Laser welding process devised for large-area protective layers

    Hannover, Germany -- A new laser development project in Germany is developing a process to to achieve up to 400% higher process speeds for deposition welding (cladding) of wear and corrosion protective layers on large work pieces. Current gas metal-arc welding uses a light art to simultaneously melt the wire electrode and workpiece. The materials' mixing rate is 30%, meaning the coating process must be repeated up to three times to ensure sufficient quality of the protective layer. In this method, deposition speeds top out at 5 kg/hr, or roughly 24 hrs to coat a 1 m 2 area, which translates to more overhead costs (energy and workers). Project HoDopp, began in June 2012, funded by the German Federal Ministry of Education and Research (BMBF) within a program for SME innovative production researching, aims to increase throughput by up to 400% -- up to 20kg/hr deposition rate -- as well as reduce welding depth and improve the mixing rate to <5% so that only a single layer is necessary. Participants include laser research association Laser Zentrum Hannover eV (LZH) and three industry firms: MERKLE, G+F Strate GmbH , and Druckguss Service Deutschland GmbH . The keys to their work are two new processes that separate the melting of the wire and workpiece. The light arc burns between two electrodes but does not contact the workpiece. Adapting the nozzle form and burner position, and reducing the amount of protective gas, eliminates sputter and ensures process stability. A second step utilizes a low-output diode laser (<0.5 kW) to achieve low but homogeneous penetration depth on the workpiece, melting it shortly before the wire contacts the surface (a deflector device controls temperature distribution). "High energy input is needed to melt the deposition material, and this is provided by the light arc," explains Jörg Hermsdorf, head of LZE's Machines and Controls group. "On the other hand, the laser uses a low output power and can be used for precise, guided control of joining the melted material to the base material." The HoDopp partners calculate that the process time can be reduced to 6 hr for a 1m 2 area, which would make laser deposition welding more attractive for areas larger than 1 × 2 meters. That speed, combined with inexpensive diode laser technology, opens up the process for a range of applications. While automakers have already adopted laser welding for conventional tool and moldmaking, this new process could be used in a number of other applications: protective layers on shafts, rollers, and clamping devices; repairs on transport systems; or adding protective layers onto stressed areas of oil drilling shafts.

    Online Articles

    Online Articles

    Mon, 6 Aug 2012

  2. Radiation monitoring of laser welding

    A new Laser Process Control System (LPCS) enables on-line detection of laser welding process features and defects.

    Magazine Articles

    Magazine Articles

    Tue, 14 Jul 2015

  3. Owning the process

    Johnson Controls gained ownership of the remote beam laser welding process through the use of DOEs, regression statistical models, and laser beam and weld quality monitoring

    Online Articles

    Online Articles

    Fri, 1 Sep 2006

  4. Laser welding facilitates order from e-mobility industry

    Manz Automation has received an order for a pilot system in which an innovative laser welding process will be used for manufacturing lithium-ion battery systems.

    Online Articles

    Online Articles

    Thu, 9 Apr 2015

  1. Hybrid laser welding of polymers

    Magazine Articles

    Magazine Articles

    Sun, 1 Jun 2008

  2. Sheet metal laser welding helps job shops compete globally

    When joining sheet metal, job shops have yet to fully embrace more of the benefits laser technology affords.

    Magazine Articles

    Magazine Articles

    Fri, 15 Jul 2016

  3. Beam profiling's role in laser process validation

    medical device manufacturers across the country. Early on, the company decided to learn about laser monitoring on a laser welding process that joins two dissimilar metals of the implantable device shown in FIGURE 1. For this joining process, they

    Magazine Articles

    Magazine Articles

    Tue, 1 Jan 2013

  4. Banding together improvises new product

    Many companies become complacent in the "old way" of doing things and have little interest in introducing new approaches and ideas.

    Magazine Articles

    Magazine Articles

    Fri, 1 Mar 2013

  5. In-bore, multi-positional laser welding emerges

    The so-called LaserPipe method of welding can be applied to remote, in situ pipe manufacture and repair scenarios by carrying out laser welding in-bore.

    Magazine Articles

    Magazine Articles

    Wed, 14 Sep 2016

  6. Laser welding in commercial furniture manufacturing

    Over the past few years, the aesthetic appeal of display furniture design for retail stores has increased exponentially as a consequence of visual merchandising strategies.

    Magazine Articles

    Magazine Articles

    Mon, 27 Jan 2014

  7. Keys to laser welding lap and edge joints

    As material selections in automotive manufacturing move further into the high-strength realm, along with the more prevalent usage of difficult-to-weld materials such as aluminum, developing robust processes for joining these materials becomes ever more critical.

    Magazine Articles

    Magazine Articles

    Wed, 3 Feb 2016

  8. Primoceler, ESA present functionality test results of glass welding stress

    Primoceler and the ESA have concluded a series of tests to prove the functionality of a laser glass welding technology.

    Online Articles

    Online Articles

    Fri, 15 Jan 2016

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