Laser Welding – A New Tool for Metal Fabricators
Tim Morris Technical Sales Manager TRUMPF Laser Technology Center
Overview Motivation Laser Welding Laser Welding in Sheet Metal Applications Key’s to Success Robotic Cell Configuration Summary
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 2
Overview Motivation Laser Welding Laser Welding in Sheet Metal Applications Key’s to Success Robotic Cell Configuration Summary
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 3
Motivation 1. Elimination of Post Processing Steps
2. Weight Reduction
COST SAVINGS
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 4
Overview Motivation Laser Welding Laser Welding in Sheet Metal Applications Key’s to Success Robotic Cell Configuration Summary
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 5
Laser – The Universal Tool for Welding
HF MIG TIG
EB
EB
Plasma
Seam welding
MIG
MIG
Spot welding
TIG
TIG
EB
MIG
Laser welding
Narrow weld seam
Little distortion
Min. heat affected
No filler material required
zone Little metallurgic effects on the material
High process speed
Laser Welding in Sheet Metal Manufacturing
Non-contact No wear TRUMPF Laser Technology Center, 280tm 2007 6
Thermal Conduction Welding: up to 90% of the laser power is reflected by the metal surface
Threshold Intensity
Penetration Depth [mm]
Laser Power Density
plasma shielding
Deep Penetration / Key-Hole Welding: up to 90% absorption
Power Density [W/cm2]
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 7
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 2007 8
Laser Welding in Sheet Metal Manufacturing
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 9
Overview Motivation Laser Welding Laser Welding in Sheet Metal Applications Key’s to Success Robotic Cell Configuration Summary
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 10
1. Weight Reduction: Cross Member
Material
Mild Steel Thickness 0.120” Laser Welding Strategy Wire Feed Shield Gas He
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 11
2. Elimination of Post Processing : OLYMPUS – Display Enclosure
Material
Mild Steel Thickness 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 2007 12
2. Elimination of Post Processing : OLYMPUS – Display Enclosure
Production time in [min]
40 35 30 25 20 15 2 min 3 min
10 5
8 min 3 min
0 Laser welding
MIG welding
3) Strainghtening 2)Grinding 1) Welding
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 13
2. Elimination of Post Processing : OLYMPUS – Display Enclosure
Manual welding Welding time (manual $73/hour)
8 Min
$9.73
Grinding (manual $63/hour)
3 Min
$3.15
Straightening
2 Min
$2.09
Sum
$14.97
Laser welding Welding time (automated $182 /hour)
3 Min
$9.10
Incl. Load and un-load Straightening
None
Grinding
None
Savings ($)
$5.87
Savings (%)
Laser Welding in Sheet Metal Manufacturing
39%
TRUMPF Laser Technology Center, 280tm 2007 14
2. Elimination of Post Processing : HDM – Printing Press Enclosure Material
Mild Steel Thickness 0.060” / 0.080” Laser Welding Strategy Edge Weld/ Fillet Weld No Shield Gas
Courtesy of H.P. Kaysser
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 15
2. Elimination of Post Processing : HDM – Printing Press Enclosure Production time in [min]
40 35 30 25 20 15 10
3 min
5
8 min
0
2 min
Laser welding
MIG welding
1) Welding
2)Grinding
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 16
2. Elimination of Post Processing : HDM – Printing Press Enclosure Manual Welding Welding time (manual $73/h )
8 Min
$9.73
Grinding (manual $63/hour)
3 Min
$3.15
Sum
$12.88
Laser Welding Welding time (automated $182/h)
2 Min
$6.07
Grinding (manual)
non
Savings ($)
$6.81
Savings (%)
Laser Welding in Sheet Metal Manufacturing
53%
TRUMPF Laser Technology Center, 280tm 2007 17
2. Elimination of Post Processing : Register Enclosure
Material
Stainless Steel Thickness 0.040” Laser Welding Strategy Heat Conduction Welding Shield Gas He
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 18
2. Elimination of Post Processing : Register Enclosure
35 30
ca. 30 min.
Production time in [min]
40
25 20
24 min
15 10 5 0
10 min 4 min 3 min 2 min
3 min 2 min
Laser welding
MIG welding
4) Grinding and cleaning 3) Welding (with fixture) 2) Bending 1) Cutting out the blank
Laser Welding in Sheet Metal Manufacturing
Example:
Housing 16“x24“x10“
TRUMPF Laser Technology Center, 280tm 2007 19
2. Elimination of Post Processing : OLYMPUS – Display Enclosure Manual welding Welding time (manual $73/hour)
10 Min
$12.17
Grinding (manual $63/hour)
24 Min
$25.20
Sum
$37.37
Laser welding Welding time (automated $182/hour)
4 Min
$12.13
Incl. Load and un-load Straightening
Non
Grinding
Non
Savings ($)
$25.24
Savings (%)
Laser Welding in Sheet Metal Manufacturing
68%
TRUMPF Laser Technology Center, 280tm 2007 20
2. Elimination of Post Processing : TRUMPF – CO2 Resonator Cover
Material
Aluminum Thickness 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 2007 21
2. Elimination of Post Processing : TRUMPF – CO2 Resonator Cover 450
Production time in [min]
400 350
-24%
110.41 €
300
27.25 € 27.25 €
250 200
219.31 € 169.58 €
150 100 50
28.08 € 9.35 € 44.12 €
11.11 € 18.54 € 11.23 € 48.86 €
MIG welding
Laser welding
Post Processing Manual Welding ( MIG) YAG-Laser Welding Fixture Costs (3 Years) Bending Straightening Punching/Laser Cutting
0 Cost Reduction: $126.68 / Cover Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 22
1. Weight Reduction: Exhaust Case Turbo Prop
Material
Ni-Alloy 90% Sheet Metal Construction Laser Welding Strategy Argon Shield Gas
Courtesy of ARCOR
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 23
Overview Motivation Laser Welding Laser Welding in Sheet Metal Applications Key’s to Success Robotic Cell Configuration Summary
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 24
Keys to Success
1.Design Phase
2.Part Preparation
Laser Welding in Sheet Metal Manufacturing
3.Fixturing
TRUMPF Laser Technology Center, 280tm 2007 25
The First Key to Success - Laser-Friendly Design Joint design
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 26
The First Key to Success - Laser-Friendly Design Use of joining aids
embossments
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 27
The First Key to Success - Laser-Friendly Design Compensation of manufacturing
Toler. compensat.
Laser Welding in Sheet Metal Manufacturing
Toler. compensat.
tolerances
TRUMPF Laser Technology Center, 280tm 2007 28
The Second Key to Success– Part Preparation
Machined, Laser cut , Punched
Laser Welding in Sheet Metal Manufacturing
Right-angled Clean (no oil, scale, rust) Oxide free Dross and burr free
TRUMPF Laser Technology Center, 280tm 2007 29
The Third Key to Success – Fixturing Inexpensive sheet metal parts Light and sturdy Adjustable Reusable Components
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 30
The Third Key to Success – Fixturing
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 31
The Third Key to Success – Fixturing
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 32
Overview Motivation Laser Welding Laser Welding in Sheet Metal Applications Key’s to Success Robotic Cell Configuration Summary
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 33
Robotic Cell Configuration - Layout
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 34
Robotic Cell Configuration - Layout
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 35
Overview Motivation Laser Welding Laser Welding in Sheet Metal Applications Key’s to Success Robotic Cell Configuration Summary
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 36
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 2007 37
Target Applications
Look For Sheet metal applications < 0.080” thick, currently arc welded Significant amounts of post-weld processing (grinding,
straightening, etc…) Precision laser cutting, bending capability, and precision tooling
capability must be in place Stainless Steel components typically have the quickest payback
Laser Welding in Sheet Metal Manufacturing
TRUMPF Laser Technology Center, 280tm 2007 38
Thank you
Tim Morris General Manager TRUMPF Laser Technology Center
