hybrid laser welding of aluminium
TRANSCRIPT
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127 april 2005Benelux Laser Event 2005
HYBRID LASER WELDINGof Aluminium
Jo VerwimpLasercentrum Vlaanderen
VITO
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OUTLINE
1. The process2. Synergies3. Process combination4. Process parameters5. Experimental process parameter determination6. Joint geometries7. Experimental setup LCV8. Applications9. Demonstration
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The process
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Synergies
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Process combination
+ =
Laser only MIG only Laser + MIGhybrid
Alu 6082 T6, thickness 4 mmWelding speed = 1.2 m/minNd:YAG Laser power = 3.8 KWMIG parameters: 90 A, 16 V, wire speed = 2.2 m/min
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Process parameters (1)
Arc:• Voltage • Current• Power source (DC, AC, pulse)• Pulse frequency• Stick out
Wire:• Speed• Diameter• Type
Other:• Torch orientation• Gas shielding• Edge preparation
Source:• Type (CO2 , Nd:YAG, ...)• Power• (Pulse frequency)
Optics:• Focal length• Spot size• Focal position• Single – double focus
Other:• Welding speed• Gas shielding• Edge preparation
MIG LASER
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Process parameters (2): interactions
Distance between laser focal point & impingement of the arc:• Determination of weld pool geometry• Bigger weld pool = easier outgassing• Small distance: interaction laser – MIG• Larger distance: interaction will become negligible
Geometrical formation of laser beam and arc torch• Angle between laser & MIG (normally fixed to 30°)• Laser leading or trailing (normally laser leading)
Shielding gas• CO2 laser: helium needed (to suppress plasma formation)• Nd:YAG: Ar pure or Ar/He (He gives higher penetration)
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Experimental process parameter determination1. Laser only: determination of laser power
- full weld penetration
2. Hybrid: determination of MIG parameters, based on:- visual inspection on weld appearance- no undercut, full penetration
3. Hybrid: interaction parameters- distance laser/MIG and gas shielding
4. Hybrid: fine tuning of laser & MIG parameters, based on- visual inspection, RX inspection- tensile tests, bend tests
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Joint geometries
Single: max. 5; double max. 8mm Fillet or Lap joint: max. 5 mm
Lap-joint: max. 4 mm T-joint: single 4, double max. 6mm
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Experimental setup LCV
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Applications
Audi A8: Neckersulm
AutomotiveVolkswagen: WolfsburgAudi: NeckersulmMitsubishi: alu space frameAviationAirbus GermanyResearchUniversity of AachenFraunhofer Laser InstituteForce Denmark, VitoCSIRO Melbourne, Institut de Soudure (FR)TWI Cambridge, JWRI OsakaOther businessesPiping, shipbuilding, construction, ...
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Demonstration: alu 6061 T4, 4mm thick, 1.2 m/min
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Continuation:Experimental results by W. Van Haver
Thank you