LaserLine 0506 Distributors Welding
-
Upload
bogdan-dumitrascu -
Category
Documents
-
view
15 -
download
1
description
Transcript of LaserLine 0506 Distributors Welding
![Page 1: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/1.jpg)
Laserline GmbH, Germany 1
Metal WeldingMetal Welding
with Diode Lasers with Diode Lasers
June 2005June 2005
Laserline GmbH ! Mülheim-Kärlich !
Germany
www.laserline.de
![Page 2: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/2.jpg)
Laserline GmbH, Germany 2
Metal Metal WeldingWelding withwith Diode Laser Diode Laser
Direct diode laser on robot. Photo: Irepa, France
Advantages of Diode Lasers
High welding speeds
Smooth and even welds that are free from
pores and cavities
Ideal working distance
Less weld seam after-treatment
Applications
Sheets and foils, automotive industry,
consumer goods, boxes and housings, fine-
and spot welding
![Page 3: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/3.jpg)
Laserline GmbH, Germany 3
Metal Welding: Typical DataMetal Welding: Typical Data
Laser
Direct and fiber-coupled diode lasers
Power
90 W to 4000 W
Beam quality
40 - 150 mm mrad
Spot dimensions
0.4 to 1.5 mm
Material
- Stainless and other types of steel,
aluminum, others
- Thickness: 0.1 – 2.5 mm
Stainless steel kitchen sink
10
100
1000
10 100 1000 10000
Power [W]
Be
am
qu
ali
ty [
mm
mra
d]
Hartlöten
Schneiden Tiefschweißen
Schweißen
Hybridschweißen
Härten
Auftragsschweißen
10
100
1000
10 100 1000 10000
Power [W]
Be
am
qu
ali
ty [
mm
mra
d]
Welding
![Page 4: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/4.jpg)
Laserline GmbH, Germany 4
Diode Laser Diode Laser TypesTypes forfor Metal Metal WeldingWelding
Fiber-coupled diode laser
OEM Module LDM
Direct diode laser, LDL 240, LDL 160, LDL 80 and LDL 40
![Page 5: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/5.jpg)
Laserline GmbH, Germany 5
Diode Laser Diode Laser withwith assistassist Gas Gas NozzleNozzle
Welding with diode laser on robot
Coaxial assist gas nozzle
Photo: IWB, Munich
![Page 6: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/6.jpg)
Laserline GmbH, Germany 6
Optics with different beam dimensions and working distances
Beam switch for fiber-coupled diode laser
Shield gas nozzle, cross jet
Integrated welding sensor
CCD camera, cover slide cassette for
welding optics
Cover slide monitor
Mechanical shutter, stack management
Interfaces: Profibus-DP, Interbus,
Ethernet, PC-based control
WeldingWelding: : OptionsOptions
![Page 7: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/7.jpg)
Laserline GmbH, Germany 7
WeldingWelding of Metals: Joints of Metals: Joints
Butt joint
Lap joint
Parallel joint
T - joint
Cross joint
Corner joint
Angle joint
Multiple joint
Schweißtechnik, VDI Verlag, 1996
![Page 8: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/8.jpg)
Laserline GmbH, Germany 8
WeldingWelding of Metals: of Metals: WeldWeld SeamSeam GeometryGeometry
I - weld on
butt joint
V - weld Y - weld
Fillet - welds
Area - weld Spot - weldsDouble -
fillet - weld Schweißtechnik, VDI Verlag, 1996
![Page 9: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/9.jpg)
Laserline GmbH, Germany 9
Laser Welding & Conventional WeldingLaser Welding & Conventional Welding
12
10
8
6
4
2
Laser HPDL Plasma MIG/MAG TIG(CO2, YAG)
Welding speed for different materials
Parameters
Butt joint: 1 mm
Laser: 2,5 kW
Conventional welding
Suitable parameters
Austenitic steel
Construction steel
Aluminum
Source: HIGHYAG
![Page 10: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/10.jpg)
Laserline GmbH, Germany 10
Joint TolerancesJoint Tolerances
Laser HPDL Plasma MIG/MAG TIG(CO2, YAG)
1,25
1,00
0,75
0,50
0,25
0,00
Perm
issib
le t
ole
ran
ce
in
mm
Position tolerance of weld source
Gap tolerance
Source: HIGHYAG
![Page 11: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/11.jpg)
Laserline GmbH, Germany 11
Comparison of Comparison of EnergyEnergy Density Density
0 101 102 103 104 105 106 107 108 109 [W/cm2]
Intensity
Welding Method
New application
for diode lasers
Gas Fusion Cutting
MIG/TIG Welding
Plasma Welding
Laser-/Electron Beam Welding
Diode Laser
Resistance Welding
Arc Welding
![Page 12: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/12.jpg)
Laserline GmbH, Germany 12
0
1000
2000
3000
4000
5000
6000
7000
0 1 2 3 4 5 6
Penetration [mm]
Sp
ee
d [
mm
/min
]
LPSS Spot = 0.3 mm
LDF Spot = 0.4 mm
ComparisonComparison LDF 400-850 LDF 400-850 withwith Nd:YAG Nd:YAG
LDF 400 - 850
1,8
mm
1,2 mm
0,70 mm
LPSS, 500 W
LPSS, 1000 W
![Page 13: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/13.jpg)
Laserline GmbH, Germany 13
Key Hole Key Hole WeldingWelding withwith Diode Laser Diode Laser
Fiber-coupled diode laser
LDF 1000-2000
Spot size: ! 0.8 mm
Working distance: 70 mm
Speed: 2 m/min
Material: 1.4301
1 m
m
![Page 14: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/14.jpg)
Laserline GmbH, Germany 14
Key Hole Key Hole WeldingWelding withwith Diode Laser Diode Laser
Fiber-coupled diode laser
LDF 1000-4000
Spot size: ! 1.0 mm
Working distance: 85 mm
Speed: 0.5 m/min
Material: 1.4301
6.4
mm
![Page 15: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/15.jpg)
Laserline GmbH, Germany 15
WeldingWelding withwith LDF 1000-4000 LDF 1000-4000
0,0
1,0
2,0
3,0
4,0
5,0
6,0
7,0
0,0 1,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0
weld speed [m/min]
pen
etr
ati
on
dep
th [
mm
]
3500 W
2800 W
2000 W
800 W
power at
workpiece
![Page 16: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/16.jpg)
Laserline GmbH, Germany 16
Workpiece preparation
Workpiece fixing
Welding
Further treatment*)
Weld seam quality
(TIG, MIG, MAG)
*) Grinding, polishing,
handling, production time
Workpiece preparation
Workpiece fixing
Welding
Weld seam quality
Diode laser
Conventional
Welding
Holistic evaluation necessary!
" Reproducibility
" Process stability
" Welding speed
" System downtime
(maintenance, random
failure, planned downtime)
" Gap tolerances
" Possibility of automation
" Product flexibility
Evaluation Method Evaluation Method
![Page 17: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/17.jpg)
Laserline GmbH, Germany 17
Diode Laser
Conventional
WeldingProduction Steps
(TIG
, M
IG, M
AG
)
CostCost Comparison Comparison
Workpiece preparation
Workpiece fixing
Welding
Further treatment
Weld seam quality
medium
medium
high
no
good
medium
medium
low
high
medium
![Page 18: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/18.jpg)
Laserline GmbH, Germany 18
Laser Welding of Metal HousingsLaser Welding of Metal Housings
Overall costs reduced by 70 %
compared to conventional welding
Relative Process Time
Process Conventional Diode laser
Welding 37 % 10 %
Grinding &
Polishing 30 % 9 %
Straightening 33 % 9 %
Total 100% 27 %
![Page 19: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/19.jpg)
Laserline GmbH, Germany 19
Laser Laser WeldingWelding of Metal of Metal HousingsHousings
2 kW fiber-coupled Diode Laser
Higher weld speed
Reduced treatment after welding
Overall costs reduced significantly
compared to conventional welding
Photo: Addmetal, NL
![Page 20: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/20.jpg)
Laserline GmbH, Germany 20
Overlap WeldingOverlap Welding
Overlap welding of car body metal sheets
(not zinc-coated) with diode laser
LDF 1000-2000
Optical power: 1800 W
Spot size: Ø 0,8 mm
Speed: 2,7 m/min.
0,7 mm
0,7 mm
![Page 21: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/21.jpg)
Laserline GmbH, Germany 21
Diode Laser Metal Diode Laser Metal WeldingWelding
Twin diode laser
2 x 700 W
Welding of instrument housings
Substitution of pulsed Nd:YAG
Diode Laser with Cross Jet
and CCD-Camera
Photo: RJ Lasertechnik
![Page 22: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/22.jpg)
Laserline GmbH, Germany 22
Laser Laser WeldingWelding of of StainlessStainless Steel Steel
Reduced production time
1 kW Diode Laser
Homogenous welding result
No further treatment required
Large tolerances in gaps
![Page 23: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/23.jpg)
Laserline GmbH, Germany 23
Laser Laser WeldingWelding of of StainlessStainless Steel Steel
Photo: IREPA
Direct diode laser and robot:
welding of kitchen sinks
Stainless steel welding samples
![Page 24: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/24.jpg)
Laserline GmbH, Germany 24
WeldingWelding of of KitchenKitchen SinksSinks
Direct diode laser on robot
Very smooth surface
No finishing process needed
Laser power: 1 – 4 kW
Welding speed up to 5 m/min
![Page 25: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/25.jpg)
Laserline GmbH, Germany 25
Photo: Addmetal, NL
Step-Seam Welding of ProfilesStep-Seam Welding of Profiles
Fiber-coupled diode laseron robot
Very smooth surface
High-quality welds
No distortion of parts
![Page 26: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/26.jpg)
Laserline GmbH, Germany 26
0,3 mm stainless steel
200 Watt Diode Laser
Weld speed: 1,5 m/min.
Advantages:
Small heat affected zone
High process speed
Even weld surface
Gas proof weld
WeldingWelding of of BatteryBattery HousingHousing
weld seam
![Page 27: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/27.jpg)
Laserline GmbH, Germany 27
0,5 mm stainless steel
Tolerance in heigth: 1 mm
800 Watt diode laser
Weld speed: 2 m/min.
Advantages:
Even weld seam
No Adaptation of heigth
High reproducibility
High process speed
Laser Laser WeldingWelding of of StainlessStainless Steel Steel
![Page 28: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/28.jpg)
Laserline GmbH, Germany 28
Substitution of Substitution of PulsedPulsed Nd:YAG Nd:YAG
Welding of transformer plates
Multi diode laser system with 3
diode laser heads, each 500 W
Results:
Better weld seam
Shorter cycle time
Reduced production costs
![Page 29: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/29.jpg)
Laserline GmbH, Germany 29
Direct diode laser, LDL 80-1000
1000 W
Multi-shift operation in production
Multi-diode laser system
WeldingWelding of of TransformerTransformer PlatesPlates
![Page 30: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/30.jpg)
Laserline GmbH, Germany 30
WeldingWelding of of SawSaw Blades Blades
Direct Diode Laser LDL 80-1000
Optical power: 400 Watt
Material thickness: 1,5 mm
Weld
![Page 31: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/31.jpg)
Laserline GmbH, Germany 31
WeldingWelding withwith Diode Laser: Diode Laser: ExamplesExamples
Micro welding and fine welding
butt joint welding
![Page 32: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/32.jpg)
Laserline GmbH, Germany 32
WeldingWelding withwith Diode Laser: Diode Laser: ExamplesExamples
2 mm deep weld
fine welding
![Page 33: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/33.jpg)
Laserline GmbH, Germany 33
WeldingWelding withwith Diode Laser Diode Laser
stainless steel welding
Welding with diode laser on robot: Erlas
![Page 34: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/34.jpg)
Laserline GmbH, Germany 34
WeldingWelding of of stainless steel tubesstainless steel tubes
Fiber-coupled diode laser
LDF 600-1000
Optical power: 1000 W
Spot : ! 0.6 mm
Welding speed: up to 7.5 m/min
![Page 35: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/35.jpg)
Laserline GmbH, Germany 35
WeldingWelding of of flat heating tubesflat heating tubes
Fiber-coupled diode laser
LDF 1000-2000
Optical power: 2000 W
Spot : ! 1 mm
Welding speed: up to 2.5 m/min
![Page 36: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/36.jpg)
Laserline GmbH, Germany 36
WeldingWelding of of bellows bellows II
Fiber-coupled diode laser
LDF 600-1000
Optical power: 1000 W
Spot : ! 0.6 mm
Welding speed: up to 5 m/min
![Page 37: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/37.jpg)
Laserline GmbH, Germany 37
WeldingWelding of of bellows bellows IIII
Three shift production
Different diametres are possible
Each length is possible
![Page 38: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/38.jpg)
Laserline GmbH, Germany 38
WeldingWelding of of pressure sensorspressure sensors
Fiber-coupled or direct diode laser
Even weld seam
No Adaptation of heigth
High reproducability
High process speed
Stable welding process
![Page 39: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/39.jpg)
Laserline GmbH, Germany 39
Influence of Process GasesInfluence of Process Gases
MünchenTU
Prof. Reinhart
Shield gas: Ar (100 %) Ar CO2 (80 %, 20
%)
Optical power: 3000 W
Welding speed: 0,5 m/min
Material: St 37
Thickness: 3 mm
![Page 40: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/40.jpg)
Laserline GmbH, Germany 40
StepStep WeldingWelding of Zn-coated of Zn-coated PlatesPlates
Fiber-coupled diode laser
LDF 1000-2000
Optical power: 1800 W
Speed: 2.5 m/min
Thickness: 2 x 0.8 mm
Bottom
Top
![Page 41: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/41.jpg)
Laserline GmbH, Germany 41
Substitution of Substitution of cwcw Nd:YAG Laser Nd:YAG Laser
Welding of electromechanical
components
500 W, 600 !m fiber
Material X5 CrNi 18 - 9
Welding speed: 18,9 mm/s
Depth of weld: 0,6 mm
Result:
Comparable welding results
with lower production costs
![Page 42: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/42.jpg)
Laserline GmbH, Germany 42
Hybrid Hybrid WeldingWelding: Nd:YAG & Diode Laser: Nd:YAG & Diode Laser
System set-up:
wavelength coupling
MünchenTU
Prof. Reinhart
Spot geometry
1
2
0,6
![Page 43: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/43.jpg)
Laserline GmbH, Germany 43
Hybrid Hybrid WeldingWelding: Nd:YAG & Diode Laser: Nd:YAG & Diode Laser
Tailored Blanks
Material: AlMg3
Thickness: 1.5 / 1.2 mm
PNd:YAG = 3 kW, pHPDL = 3 kW
Speed = 8 m/min
Fillet Weld
Material: AlMgSi1
Thickness: 2 mm
PNd:YAG = 3 kW, pHPDL = 3 kW
Speed = 5 m/min
MünchenTU
Prof. Reinhart
![Page 44: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/44.jpg)
Laserline GmbH, Germany 44
1 m/min
2 m/min
4 m/min
3 kW
Nd:YAG
3 kW Nd:YAG
and
3 kW diode laser
Hybrid Hybrid WeldingWelding, Cross , Cross Section Section
5 mm5 mm
MünchenTU
Prof. Reinhart
![Page 45: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/45.jpg)
Laserline GmbH, Germany 45
Hybrid Hybrid WeldingWelding of of StainlessStainless Steel Steel
Weld seam surface:
Border seam AlMg3
Weld seam surface:
overlapping sheets AlMg3
MünchenTU
Prof. Reinhart
![Page 46: LaserLine 0506 Distributors Welding](https://reader034.fdocuments.in/reader034/viewer/2022050908/55cf8dee550346703b8ccc22/html5/thumbnails/46.jpg)
Laserline GmbH, Germany 46
Performance of Welding ProcessesPerformance of Welding Processes
Welding of thin aluminum alloy sheets at high speed
DC pulsed MIG X ! X
Laser beam X " "
DC MIG and laser hybrid ! ! !
AC pulsed MIG " X !
Thickness: less than 2 mm
Weld speed: over 2 m/min
Joint
gap
Proper
heat input
Beam
stability
Laser AC pulsed MIG hybrid " " "
" good
! not good enough
X bad
Source: DAIHEN