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Joining

BOOTH 16
E 100.ROB
Combi-processing Forgives Tolerances
Laser cutting and welding with one tool - combi-processing - leads to more flexibility in short process chains with less equipment and reduced clamping, positioning and handling operations. Since the tool center point (TCP) of the combi-head is identical for both processes, the accuracy in locating the subsequent process relative to the previous process track is significantly increased.

By measuring the workpiece position and geometry with the capacitive distance sensor - possibly during cutting operations, a dynamical coordinate correction of the path for subsequent welding and cutting processes can be accomplished. In this way, parts with huge tolerances such as deep-drawn parts, bent components or profiles or unprecisely clamped parts can nevertheless be produced with high accuracy of important geometrical features.

As an example, U-profiles are cut to length, simultaneously gauged and flange plates are joined to the profile by a stake-weld. The path of the weld seam and subsequent cutting operations are positioned according to the measured profile geometry.

Contact Person
Dr. Frank Schneider
Phone +49 241 8906-426
frank.schneider@ilt.fraunhofer.de
Fraunhofer Institute for Laser Technology ILT


BOOTH 69
E 032
Different Process Approaches of Laser Beam Microwelding
In recent years different process approaches and new laser types with high brightness have been developed for the field of laser beam microwelding. The use of SHADOW® with pulsed lasers and the adoption of disc and fiber lasers have rendered intermittent seam welding obsolete. The SHADOW® technology combines the use of pulsed lasers with high speed welding resulting in a low heat input. The heat input can be reduced further by narrowing the weld seam width which can be achieved by the application of disc and fiber lasers with low M². In case of lap joints, which are exposed to high mechanical strain, a small laser welded seam may not be able to provide sufficient area to withstand the resulting stress. Theses welds are carried out with a fiber laser using different spatial power modulation techniques. To the linear feed motion an oscillating motion (e.g. a circular path) is added. This significantly improves controllability of the weld depth and the supporting joint area.

Contact Person
Dipl.-Ing. Benjamin Mehlmann
Phone +49 241 8906-613
Benjamin.Mehlmann@ilt.fraunhofer.de
Fraunhofer Institute for Laser Technology ILT

BOOTH 34
E 100.MAHO
Fiber Coupled Laser-arc Hybrid Welding in Heavy Section Applications
Fiber coupling technology simplifies the implementation and operation of industrial laser-arc hybrid welding systems significantly. With the availability of double-digit kW powers, disk and fiber lasers have just been introduced e.g. in ship building for highly productive and distortion minimized welding of large steel panels. Compared to CO2 lasers hitherto established in this field, the shorter wavelength of fiber coupled lasers changes the dynamics of keyhole formation and laser-arc interaction. This leads to changes in process behavior and parameter rules. A simple take-over of CO2 laser hybrid welding parameters is not sufficient, if a robust process for single-pass heavy section welding is required. Fraunhofer ILT is engaged in various hybrid welding projects in order to improve the process understanding and to enhance the stable application range with the new types of laser sources.

Contact Person
Dipl.-Ing Norbert Wolf
Phone +49 241 8906-448
norbert.wolf@ilt.fraunhofer.de
Fraunhofer Institute for Laser Technology ILT

BOOTH 17
E 100.ROB
High Speed Cutting and Welding
Fiber-coupled 1? lasers achieve cutting speeds in thin sheet metal far above those possible with CO2 lasers. 1mm thick sheets can be cut with speeds in the range of 100m/min. Highly dynamical machines allow to apply these speeds also in contour cutting. The achievable productivity and quality is better than in remote cutting, considering typical automotive sheet applications. So laser cutting partly substitutes mechanical blanking, which suffers from difficulties in cutting high strength steel grades. Similarly, 2D welding applications profit from high-speed laser processing.

Fraunhofer ILT is building a laboratory machine for enhanced process development and diagnostics of high speed applications. The machine has an acceleration of 4g for processing speeds of up to 300m/min at excellent accuracy. To allow visual access from various perspectives, the processing head remains in a fixed position while the work piece is moved in X and Y direction on double gantry axes. Thus diagnostics equipment as high speed cameras and detectors can be installed stationary without dynamic load.

Contact Person
Dr. Frank Schneider
Phone +49 241 8906-426
frank.schneider@ilt.fraunhofer.de
Fraunhofer Institute for Laser Technology ILT

BOOTH 20
E 100.ROB
Laser Processing Heads for Cutting and Welding
Laserfact GmbH develops, produces and delivers beam tools for flexible manufacturing with lasers. The aim of Laserfact is the provision of laser processing heads which perform extremely reliably, efficiently and flexibly in industrial laser applications. By using sophisticated optics and nozzle design combined with solid engineering the products of Laserfact achieve optimum performance with striking simplicity in construction, operation and application. Laserfact supplies beam tools for laser cutting and laser welding with CO2 lasers and solid-state lasers. Specialties of Laserfact are combi-heads for flexible laser cutting and laser welding of sheet metal components without changing heads. A combi-head allows software-controlled process change on demand and with it significant cost savings regarding investment and operation. Among other Laserfact products a new version of the laser combi-head, being specially developed for coaxial mounting on robots and gantries with integrated beam guiding, is presented within a 3D laser gantry of Reis Robotics.

Contact Person
Harald Dickler
Phone +49 241 8906-438
dickler@laserfact.de
Laserfact GmbH

BOOTH 04
Entrance
Mercedes E-Class BR212: Joining Technologies
Body in White of the new Mercedes Benz E-Class, BR212, demonstrating the application of different joining technologies in volume production, e.g. laser brazing, laser welding and remote laser welding.

Contact Person
Dr. Markus Beck
Phone +49 7308 505 2930
markus.mb.beck@daimler.com
Daimler AG

BOOTH 06
Hallway in front of E 100.CPC
Multi-Point Contour Control
Advancing laser sources enable manufacturers to weld seams of high quality and at high process velocities. These processes require high degrees of precision and their parameters have to be kept in close limits. The welding velocity is the most important parameter among laser power which has to be held constantly in order to achieve a stable quality of the manufactured products. Only a stable energy input per unit length may ensure a steady quality of the welded seam.

Multi-Point Contour Control enables the user to measure the real velocity, its direction and the resulting contour directly at the Tool Center Point. The Computer Vision System may also indicate the rotation of the welding head and defocused areas. By comparing the desired contour and welding velocity with the measured data, inaccurate programming can be detected. The awareness of the actual contour helps to adapt the machine’s settings and empowers the manufacturer to increase the quality of welded seams.

Contact Person
Dipl.-Ing. Christoph Franz
Phone +49 241 8906-621
christoph.franz@ilt.fraunhofer.de
Fraunhofer Institute for Laser Technology ILT

BOOTH 70
E 032
Vision Assisted Laser Beam Welding of Electrical Components
Assembly and joining of micro electrical devices implies high positioning accuracy what normally places great demands on handling and clamping of the parts. In order to provide a flexible production technology for such parts the effort for clamping and handling devices must be reduced. Therefore an adaptable production system for different joining tasks is presented. The production system is based on a vision assisted laser welding tool. A CMOS camera is used for work piece observation through a galvanometric scanner. This enables position recognition within a working area of 25mm2 with an accuracy < 10?m and real-time process supervision. The processing head is integrated in a conveyor system to enable combination with other processes. For demonstration of the system capabilities leadframes are welded to DCB substrates which are used for assembly of high power electronic devices. The welds are carried out with a fiber laser using different spatial power modulation techniques. Compared to spot welds the controllability of the weld depth is significantly improved.

Contact Person
Dipl.-Ing. Jens Gedicke
Phone +49 241 8906-145
Jens.Gedicke@ilt.fraunhofer.de
Fraunhofer Institute for Laser Technology ILT
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