TRUMPF Laser Technology Center
LASER INNOVATIONS FOR AUTOMOTIVE LIGHTWEIGHTING Enabling Technologies
Rick Davis Key Account Management - Automotive GALM - Detroit, USA, 8/24/2016
LASER INNOVATIONS FOR AUTOMOTIVE LIGHTWEIGHTING, Rick Davis
8/24/2016
1
CARS – made by laser Established and prooven technology
§ Remote applications § Laser welding and brazing
§ Cutting hotforming parts § Softening § Inductive heating § 3D cutting tubes / sheets
Welding and Remote
Cutting and Hotforming
Lightweight Design
§ Flange reduction § Linear sheet metal design § Integrated functions § New materials
E Drives
§ Battery production § Electric engines § Fuel cells
Powertrain
§ Gear welding § Clutches § Differentials § Shifting forks
LASER INNOVATIONS FOR AUTOMOTIVE LIGHTWEIGHTING, Rick Davis
§ Day/Night designs § Marking § Drilling § Surface treatment 8/24/2016
Interior and assembly 2
Laser technology enables automotive innovations Evolutions are happening in different levels 1. New mechanical designs: Lightweight sheet metal construction Productivity rising
2. New materials: Lightweight material combinations Cost reduction
3. New process chains: Laser applications in hot forming Weight reduction
4. New processes: Additive manufacturing technologies
5. New production concepts: Intelligent optical manufacturing processes
LASER INNOVATIONS FOR AUTOMOTIVE LIGHTWEIGHTING, Rick Davis
8/24/2016
3
Examples of laser innovation in vehicle production
LASER INNOVATIONS FOR AUTOMOTIVE LIGHTWEIGHTING, Rick Davis
8/24/2016
4
Hotforming Innovation: laser softening
Laser Softening
Hardness [HV1]
3D Laser Cutting
Lateral
650 600 550 500 450 400 350 300 250 200 150 100 50 0
Softened Flap Transition Base Material 0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
Measuring Position [mm]
§ Extremely high wear of mechanical cutting tools force laser cutting § Consistent quality § No part deformation § No wear on tooling LASER INNOVATIONS FOR AUTOMOTIVE LIGHTWEIGHTING, Rick Davis
§ Softening of sectional areas for bending operations § Improved crash performance of flange area § Softening of belt at upper part of B-pillar § Hardness adjustable to requirements § Several optical concepts available 8/24/2016
5
Laser brazing Innovation: Trifocal laser brazing of hot dipped zinc coatings
Laser brazing
Trifocal laser brazing for hot dipped zinc coating
Beam propagation realized by § Triple fibers § Adaptive optical elements
§ Very good gap bridge ability § Tightness § Very good optical appearance (body shell) § High process speed § Low heat input LASER INNOVATIONS FOR AUTOMOTIVE LIGHTWEIGHTING, Rick Davis
§ Higher speed § Low pore and spatter rate § Smooth surface
8/24/2016
6
Laser Remote Welding Innovation: welding on the fly integrated
Remote welding
IPFO: Intelligent scanner system Robot Standard interface
Position data
Position
Scanner Optic + Laser (Master)
Trigger
Scanner Optic – Job SO P1
Home
Welding 8
Welding 7
Positioning 7
Welding 6
Process Start
Positioning 6
Welding 5
Positioning 5
Positioning 4
Welding 3
Welding 4
Positioning 3
Welding 2
Positiotning 2
Positioning 1
approach
Welding 1
unproductive travelling times
Process End
Laser Scanner Welding
Process Start
Home
Welding 8
Welding 7
Welding 6
Welding 5
Welding 4
Welding 3
Welding 2
Approach
Welding 1
§ §
Elimination of non-productive travelling times Maximization of beam-on share
Process End
LASER INNOVATIONS FOR AUTOMOTIVE LIGHTWEIGHTING, Rick Davis
SO P2
SO P3
§ Scanner optic, robot and work piece in one control system § Automatic welding in consideration of robot movement § Easy teaching and programming § Non influence of variation of robot path or speed to welding result 8/24/2016
7
Powertrain differential gear welding Innovation: Welding without filler wire
Without filler wire 1,5% C effect Härteverlauf [HV] Hardness
t
T
Bolted version Microsection of a welding
Laser welded version
Material 2 mit > 1,5 % C
% Kohlenstof f
Typical hardness curve
Pre Carbon
Mat2 > 1,5% C
GJS-600
Voraussetzung: Mat1 < 1,5% C Material 1 mit < 1,5 % C
d
D
16MnCr5
Differential gear with wire
In
Post
Ni
§ Cost reduction § Material savings and weight reduction § Large torques transmittable (weld depth) § Reduced noise emission
LASER INNOVATIONS FOR AUTOMOTIVE LIGHTWEIGHTING, Rick Davis
§ Cost reduction through not using filler wire and therefore higher cycle times (factor 2!) § Quality improvement through measurement of the weld gap and repositioning of the laser beam at every part without loss of cycle time (Online Measurement)
8/24/2016
8
Laser cutting of CFRP Innovation: High quality 3D cuts in each production status
Cutting of textiles with CO2
Light weight solutions
Cutting of biaxial fabrics
§ Simultaneous cutting + fusion of multiple layers § Fixed cut surface § Drapability is still assured § Fiber swelling depends on tooling concept
LASER INNOVATIONS FOR AUTOMOTIVE LIGHTWEIGHTING, Rick Davis
§ Remote-processing § Contact-free § Wear less cutting § High feed rate of max. 20m/min with P=5kW and s=2mm § Heat affected zone (HAZ) e.g. approx. 100-500µm 8/24/2016
9
Laser welding of aluminum and steel Innovation: Welding without filler wire thanks to beam oscillation
Brazing with filler wire
Welding with beam oscillation
filler material laser beam
welded brazed
§ Under melting point of steel (just melting aluminum) § Flux is mostly necessary § Small process window § Filler material necessary § Welding/brazing combination
LASER INNOVATIONS FOR AUTOMOTIVE LIGHTWEIGHTING, Rick Davis
§ No filler material § No flux § No sensitivity of geometries
8/24/2016
10
Laser joining of plastic material Innovation: Joining of mix joining (e.g. metal/plastic)
No established process today
Glue-free joining thanks to specific structuring solidified melt
structured surface
polished cut
§ No glue or other additives needed § No curing time § High strength thanks to form locking connection § High accuracy in joining (plastic is pressed to dead stop)
LASER INNOVATIONS FOR AUTOMOTIVE LIGHTWEIGHTING, Rick Davis
8/24/2016
11
E-mobility: Battery manufacturing Innovation: Joining of Copper with green lasers
Laser as a established tool
Tap welding
Packaging Filling
Welding with green laser
Assembly
Marking
§ Cutting and welding in each status of the process chain § Mostly aluminum and copper applications § From single mode low to high power all industrials lasers in use in a wide application range LASER INNOVATIONS FOR AUTOMOTIVE LIGHTWEIGHTING, Rick Davis
§ Due to different absorption mechanism better energy balance (melting bath and vapor) § Better seam quality § Repeatable results in non-ferrous metals § Less spatters to less short-circuit faults § No surface preparation needed § No welding gas needed 8/24/2016
12
TRUMPF Group – an attentive company… § …A worldwide leading high technology company for machine tools, lasers and electronics. § …A family company: with a long-term strategy, aware of it’s history and focused on the future. § …A medium-sized company – despite our 11.000 employees. § …with the promise for innovation, shaping the technological edge for years § …an international company with more than half of its employees outside of Germany.
LASER INNOVATIONS FOR AUTOMOTIVE LIGHTWEIGHTING, Rick Davis
8/24/2016
13
Our business divisions Share of sales in 2014/15
Laser technology / Electronics
Machine tools for flexible sheet metal processing Sales 2014/15
2,360 mill. €
Sales 2014/15
966 mill. €
Share of sales
70 %
Share of sales
30 %
LASER INNOVATIONS FOR AUTOMOTIVE LIGHTWEIGHTING, Rick Davis
8/24/2016
14
TRUMPF Laser Technology Center
THANK YOU,
Rick Davis, Key Account Management - Automotive GALM - Detroit, USA, 8/24/2016
LASER INNOVATIONS FOR AUTOMOTIVE LIGHTWEIGHTING, Rick Davis
8/24/2016
