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
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 20073
Overview
MotivationLaser WeldingLaser Welding in Sheet Metal ApplicationsKey’s to SuccessRobotic Cell ConfigurationSummary
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 20074
Motivation
2. Weight Reduction1. Elimination of Post Processing Steps
COST SAVINGS
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 20075
Overview
MotivationLaser WeldingLaser Welding in Sheet Metal ApplicationsKey’s to SuccessRobotic Cell ConfigurationSummary
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 20076
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 Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 20077
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
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 20078
Principle of Laser Welding
Heat Conduction Welding Penetration Welding
Sheet Thickness < 0.080”
Penetration < 0.75”
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 20079
Laser Welding in Sheet Metal Manufacturing
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200710
Overview
MotivationLaser WeldingLaser Welding in Sheet Metal ApplicationsKey’s to SuccessRobotic Cell ConfigurationSummary
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200711
1. Weight Reduction: Cross Member
MaterialMild SteelThickness 0.120”
Laser Welding Strategy Wire FeedShield Gas He
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200712
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
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200713
2. Elimination of Post Processing : OLYMPUS – Display Enclosure
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
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200714
2. Elimination of Post Processing : OLYMPUS – Display Enclosure
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
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200715
2. Elimination of Post Processing : HDM – Printing Press Enclosure
MaterialMild SteelThickness 0.060” / 0.080”
Laser Welding Strategy Edge Weld/ Fillet WeldNo Shield Gas
Courtesy of H.P. Kaysser
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200716
2. Elimination of Post Processing : HDM – Printing Press Enclosure
3 min
2 min8 min
0
5
10
15
20
25
30
35
40
Laser welding MIG welding
Prod
uctio
n tim
e in
[min
]
1) Welding 2)Grinding
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200717
2. Elimination of Post Processing : HDM – Printing Press Enclosure
53%Savings (%)
$6.81Savings ($)
nonGrinding (manual)
$6.072 MinWelding time (automated $182/h)
Laser Welding
$12.88Sum
$3.153 MinGrinding (manual $63/hour)
$9.738 MinWelding time (manual $73/h )
Manual Welding
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200718
2. Elimination of Post Processing : Register Enclosure
MaterialStainless SteelThickness 0.040”
Laser Welding Strategy Heat Conduction WeldingShield Gas He
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200719
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
Laser welding MIG welding
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.
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200720
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
$25.2024 MinGrinding (manual $63/hour)
$12.1710 MinWelding time (manual $73/hour)
Manual welding
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200721
2. Elimination of Post Processing : TRUMPF – CO2Resonator Cover
MaterialAluminumThickness 0.080”
Laser Welding Strategy Edge Weld (~ 240”)Argon Shield Gas
Courtesy of H.P. Kaysser
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200722
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
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200723
1. Weight Reduction: Exhaust Case Turbo Prop
MaterialNi-Alloy90% Sheet Metal Construction
Laser Welding Strategy Argon Shield Gas
Courtesy of ARCOR
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200724
Overview
MotivationLaser WeldingLaser Welding in Sheet Metal ApplicationsKey’s to SuccessRobotic Cell ConfigurationSummary
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200725
Keys to Success
1.Design Phase 2.Part Preparation 3.Fixturing
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200726
The First Key to Success - Laser-Friendly Design
Joint design
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200727
The First Key to Success - Laser-Friendly Design
Use of joining aids
embossments
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200728
The First Key to Success - Laser-Friendly Design
Compensation of manufacturing tolerances
Toler. compensat.
Tole
r. co
mpe
nsat
.
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200729
The Second Key to Success– Part Preparation
Machined, Laser cut , PunchedRight-angled Clean (no oil, scale, rust)Oxide free Dross and burr free
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200730
The Third Key to Success – Fixturing
Inexpensive sheet metal parts Light and sturdyAdjustableReusable Components
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200731
The Third Key to Success – Fixturing
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200732
The Third Key to Success – Fixturing
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200733
Overview
MotivationLaser WeldingLaser Welding in Sheet Metal ApplicationsKey’s to SuccessRobotic Cell ConfigurationSummary
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200734
Robotic Cell Configuration - Layout
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200735
Robotic Cell Configuration - Layout
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200736
Overview
MotivationLaser WeldingLaser Welding in Sheet Metal ApplicationsKey’s to SuccessRobotic Cell ConfigurationSummary
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200737
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
Laser Welding in Sheet Metal Manufacturing TRUMPF Laser Technology Center, 280tm 200738
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