laser welding - a new tool for metal fabricators

Laser Welding – A New Tool for Metal Fabricators

Tim MorrisTechnical Sales ManagerTRUMPF Laser Technology Center

Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 20072

Overview

MotivationLaser WeldingLaser Welding in Sheet Metal ApplicationsKey’s to SuccessRobotic Cell ConfigurationSummary


Overview



Motivation

2. Weight Reduction1. Elimination of Post Processing Steps

COST SAVINGS


Overview



Laser – The Universal Tool for Welding

EB MIG Spot welding TIG TIG

Plasma

TIG

MIG

HF

Seam welding MIG

EBEB

MIG

Laser welding

Narrow weld seamMin. heat affected zoneLittle metallurgic effects on the material

Little distortionNo filler material requiredHigh process speedNon-contactNo wear


Laser Power Density

Deep Penetration / Key-Hole Welding: up to 90% absorption

Thermal Conduction Welding: up to 90% of the laser power is reflected by the metal surface

Power Density [W/cm2]

Pen

etra

tion

Dep

th [m

m]

Thre

shol

d In

tens

ity

plasmashielding


Principle of Laser Welding

Heat Conduction Welding Penetration Welding

Sheet Thickness < 0.080”

Penetration < 0.75”


Laser Welding in Sheet Metal Manufacturing


Overview



1. Weight Reduction: Cross Member

MaterialMild SteelThickness 0.120”

Laser Welding Strategy Wire FeedShield Gas He


2. Elimination of Post Processing : OLYMPUS – Display Enclosure

MaterialMild SteelThickness 0.060”

Laser Welding Strategy Edge Weld (30” linear weld)No Shield Gas

Courtesy of H.P. Kaysser



3 min2 min

3 min8 min

0

5

10

15

20

25

30

35

40

Laser welding MIG welding

Prod

uctio

n tim

e in

[min

]

3) Strainghtening

2)Grinding

1) Welding



39%Savings (%)

$5.87Savings ($)

NoneGrinding

NoneStraightening

Incl. Load and un-load

$9.103 MinWelding time (automated $182 /hour)

Laser welding

$14.97Sum

$2.092 MinStraightening

$3.153 MinGrinding (manual $63/hour)

$9.738 MinWelding time (manual $73/hour)

Manual welding


2. Elimination of Post Processing : HDM – Printing Press Enclosure

MaterialMild SteelThickness 0.060” / 0.080”

Laser Welding Strategy Edge Weld/ Fillet WeldNo Shield Gas




3 min

2 min8 min

0

5

10

15

20

25

30

35

40


Prod

uctio

n tim

e in

[min

]

1) Welding 2)Grinding



53%Savings (%)

$6.81Savings ($)

nonGrinding (manual)

$6.072 MinWelding time (automated $182/h)

Laser Welding

$12.88Sum


$9.738 MinWelding time (manual $73/h )

Manual Welding


2. Elimination of Post Processing : Register Enclosure

MaterialStainless SteelThickness 0.040”

Laser Welding Strategy Heat Conduction WeldingShield Gas He


2. Elimination of Post Processing : Register Enclosure

Example: Housing 16“x24“x10“

3 min 3 min4 min

10 min

24 min

2 min 2 min0

5

10

15

20

25

30

35

40


Prod

uctio

n tim

e in

[min

]

4) Grinding and cleaning3) Welding (with fixture)2) Bending1) Cutting out the blank

ca. 3

0 m

in.


2. Elimination of Post Processing : OLYMPUS –Display Enclosure

68%Savings (%)

$25.24Savings ($)

NonGrinding

NonStraightening

Incl. Load and un-load

$12.134 MinWelding time (automated $182/hour)

Laser welding

$37.37Sum


$12.1710 MinWelding time (manual $73/hour)

Manual welding


2. Elimination of Post Processing : TRUMPF – CO2Resonator Cover

MaterialAluminumThickness 0.080”

Laser Welding Strategy Edge Weld (~ 240”)Argon Shield Gas



2. Elimination of Post Processing : TRUMPF – CO2 Resonator Cover

9.35 € 11.23 €28.08 € 18.54 €

11.11 €

169.58 €219.31 €

27.25 €

110.41 €

27.25 €

48.86 €44.12 €

0

50

100

150

200

250

300

350

400

450

MIG welding Laser welding

Pro

duct

ion

time

in [m

in]

Post ProcessingManual Welding ( MIG)YAG-Laser Welding Fixture Costs (3 Years)BendingStraighteningPunching/Laser Cutting

-24%

Cost Reduction: $126.68 / Cover


1. Weight Reduction: Exhaust Case Turbo Prop

MaterialNi-Alloy90% Sheet Metal Construction

Laser Welding Strategy Argon Shield Gas

Courtesy of ARCOR


Overview



Keys to Success

1.Design Phase 2.Part Preparation 3.Fixturing


The First Key to Success - Laser-Friendly Design

Joint design



Use of joining aids

embossments



Compensation of manufacturing tolerances

Toler. compensat.

Tole

r. co

mpe

nsat

.


The Second Key to Success– Part Preparation

Machined, Laser cut , PunchedRight-angled Clean (no oil, scale, rust)Oxide free Dross and burr free


The Third Key to Success – Fixturing

Inexpensive sheet metal parts Light and sturdyAdjustableReusable Components


Overview



Robotic Cell Configuration - Layout


Overview



Summary

Laser welding is an established process suitable for both CO2 and solid-state lasers

Tight tolerance requirements can be met with modern laser cutting and punching machines and press brakes and is critical to the success of laser welding in sheet metal

Welding fixtures can be produced economically from laser cut sheets or, wherever possible, integrated into the part itself through designs suitable for laser welding

Laser welding in sheet metal manufacturing opens up great cost savings for the right applications


Target Applications

Look ForSheet metal applications < 0.080” thick, currently arc weldedSignificant amounts of post-weld processing (grinding, straightening, etc…)Precision laser cutting, bending capability, and precision tooling capability must be in placeStainless Steel components typically have the quickest payback

Thank you

Tim MorrisGeneral ManagerTRUMPF Laser Technology Center

laser welding - a new tool for metal fabricators

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