Laser welding machine and laser welding system: Efficient joining technology and laser welding solutions for industry (TIG welding)

Laser technology has made remarkable progress in recent decades, enabling a multitude of applications across various industries. Laser welding, in particular, has established itself as one of the most efficient and precise joining methods. Laser welding machines and systems play a crucial role in the production of goods in sectors such as automotive, aerospace, electronics, medical technology, and many more.

Functioning and technology

Laser welding machines use high-energy laser beams to join metals, plastics, or other materials. The process is based on the precise concentration of laser light, which is focused onto the parts to be welded. This generates an extremely high energy density that melts and bonds the material.

Modern laser welding systems offer various types of lasers, including fiber lasers, CO₂ lasers, and diode lasers. Each type has specific advantages and disadvantages that must be considered depending on the application. Fiber lasers, for example, are known for their high beam quality and energy efficiency, while CO₂ lasers offer greater penetration depth.

Advantages of laser welding

1. Precision and quality

Laser welding machines enable extremely precise welds with minimal distortion or deformation of the workpiece. This results in high-quality welded joints.

2. Speed ​​and efficiency

The welding process is often faster compared to conventional methods. Automated laser systems can accelerate the production process and increase efficiency.

3. Versatility

Laser welding can join a wide variety of materials, including different metals, plastics, and even mixed materials.

4. Minimal material consumption

Because the laser beam is so focused, only a limited amount of material is melted, which reduces material consumption.

5. No additives

Unlike some conventional welding processes, laser welding generally does not require additional fillers, minimizing costs and post-processing.

Industrial applications

1. Automotive industry

Laser welding machines are used in automotive manufacturing for the production of body parts, seat frames, exhaust systems, and more. The high-precision welds contribute to the safety and longevity of the vehicles.

2. Aerospace

In the aerospace industry, the weight of components is of crucial importance. Laser welding machines offer lightweight yet strong connections for structural elements of aircraft and spacecraft.

3. Electronics industry

The miniaturization of electronic components requires precise and reliable joining techniques. Laser welding systems enable the production of tiny connections in electronic components.

4. Medical technology

In medical technology, laser welding machines are used for the production of implants, medical instruments and devices where hygiene and precision are of utmost importance.

News and current developments

1. Additive manufacturing (3D printing) and laser welding

The integration of laser welding technologies into the 3D printing process has opened up new possibilities. This enables the production of complex components with high-strength welded joints.

2. Collaborative Robotics

Automation and robotics: Advances in robotics have led to collaborative laser welding systems where robots and human workers can work together safely. This flexibility enables more efficient manufacturing and makes the systems suitable for use in small and medium-sized enterprises.

3. Higher-power fiber lasers

The development of higher-powered fiber lasers has further increased welding speeds and enabled the processing of thicker materials.

4. Inline quality control

Modern laser welding systems are often equipped with inline quality controls that monitor the welds in real time and can detect possible defects, thus increasing production quality.

5. Innovative materials

Advances in materials science and technology have enabled the development of new materials specifically optimized for certain joining processes. These materials offer improved strength, flexibility, and resistance to environmental influences.

6. Lightweight construction and hybrid construction

Lightweight structures are important in many industries for reducing product weight and improving energy efficiency. Hybrid processes, which combine different joining techniques, offer diverse possibilities for innovative lightweight construction concepts.

outlook

Laser welding machines and systems have revolutionized joining technology, offering a wide range of advantages in terms of precision, speed, versatility, and quality. With continuous research and innovation, these technologies are expected to evolve further, conquering even more industries and improving industrial manufacturing.

Joining technology plays a crucial role in the modern manufacturing industry, and welding and cutting are two of the most important processes in this field. The precision and quality of these techniques are essential for the production of high-quality products in various industries such as automotive, aerospace, shipbuilding, mechanical engineering, and many others. In this text, we will examine welding and cutting technologies in more detail, highlighting their significance and current developments.

Welding: Creating connections that last

The importance of welding

Welding is a process in which two or more workpieces are permanently joined together by a weld seam. It is one of the oldest joining techniques and has evolved considerably over time. Welding is used in a wide variety of industries to produce complex structures and components that must withstand high loads.

Welding processes and their characteristics

• Arc welding: Arc welding is one of the most frequently used welding processes. An electric arc is generated between an electrode and the workpiece, melting the material and creating a joint. There are various subcategories such as metal active gas (MAG) welding and tungsten inert gas (TIG) welding.
• Laser welding: Laser welding is known for its exceptional precision and quality. It uses high-energy laser beams to join materials together. The small heat-affected zone minimizes deformation and allows its use on delicate workpieces.
• Electron beam welding: In electron beam welding, a focused beam of electrons is directed at the workpiece, melting and welding the material. This process is used for high-density materials and in a vacuum.

Cutting: precise shaping for efficient manufacturing

The importance of cutting

Cutting is an essential step in manufacturing, bringing raw materials into the desired shape and size. Precise cuts are crucial for producing parts and components with tight tolerances.

Cutting technologies and their properties

• Laser beam cutting: Laser beam cutting is known for its high precision and speed. A high-energy laser beam is directed at the material, causing it to melt or vaporize. This allows for the cutting of thin and thick materials with great accuracy.
• Plasma cutting: Plasma cutting is mainly used for cutting metals. A plasma jet, generated by ionized gas, melts the material, thus enabling the cutting of thicker sheets.
• Water cutting: Water cutting uses a fine jet of water mixed with abrasive particles to cut materials. This method is ideal for soft materials or those that could be damaged by high temperatures.

News and current developments

Industry 4.0 and Automation

Joining technology has benefited from advances in automation and Industry 4.0. Robot-based welding and cutting systems are increasingly being used to increase productivity and make manufacturing processes more efficient.

Artificial Intelligence and Machine Learning

The integration of artificial intelligence into welding and cutting systems enables improved process control and error detection. The technology can automatically adjust parameters to achieve optimal results and minimize scrap.

Material innovations

Advances in materials science and technology have led to the development of new materials specifically optimized for welding and cutting. These materials offer improved strength, corrosion resistance, and other properties important for specific applications.

Hybrid systems

The combination of different joining and cutting technologies makes it possible to leverage the advantages of multiple processes and meet specific requirements. Hybrid welding and cutting systems are increasingly used in industry.

The two pillars of joining technology

Welding and cutting are two essential pillars of joining technology and play a crucial role in the modern manufacturing industry. The precision and quality of these processes are indispensable for the production of high-quality products. Through continuous research and innovation, welding and cutting technologies are expected to be further improved to meet the increasing demands of industry and unlock new manufacturing possibilities.

Joining technology is an important area in manufacturing and deals with joining workpieces to produce finished products. Various methods are used to join the workpieces permanently or temporarily, depending on the requirements of the specific application. The quality and reliability of the joining technology are crucial for the performance and functionality of the final product. In this text, we will look at the fundamentals of joining technology and provide some examples of different joining processes.

Types of joining technology

There are a variety of joining processes that can be selected depending on the materials, applications, and specific requirements. Here are some of the most common types of joining techniques:

• Welding: Welding is one of the oldest and most widely used joining processes. It encompasses various techniques such as arc welding, laser welding, electron beam welding, and more. In welding, workpieces are permanently joined together by a weld seam, with the material being melted at the joint.
• Soldering: Soldering is a process in which a solder is applied to the workpieces to be joined. When heated, the solder melts and joins the workpieces. Unlike welding, soldering does not melt the base material.
• Gluing: In gluing, the workpieces are joined together by a layer of adhesive. Gluing is particularly suitable for materials that are difficult to weld or sensitive to high temperatures.
• Riveting: In riveting, rivets or pins are inserted through the workpieces to be joined and then deformed or welded at the ends. This creates a permanent connection.
• Mechanical connections: Mechanical connections include techniques such as bolting, clamping, or press fits. These methods do not require permanent changes to the material and allow for non-destructive disassembly.

Examples of the application of joining technology

• Automotive industry: Joining technology plays a central role in vehicle manufacturing in the automotive industry. Welding is used for body assembly, while bonding is used in vehicle glazing or with composite materials.
• Aerospace: In the aerospace industry, high-strength and reliable connections are required. Welding and bonding are used here for structural parts, engines, and aircraft components.
• Electronics industry: Soldering processes are used in the electronics industry to manufacture printed circuit boards and electronic components. Adhesive bonding is used in the assembly of displays, touchscreens, and housings.
• Medical technology: In medical technology, adhesives and welding processes are used to manufacture medical devices, implants, and prostheses. Precise and reliable connections are of paramount importance in this field.
• Shipbuilding: In shipbuilding, welding techniques are used for the production of ship hulls and components, while riveting has traditionally been used for joining plates and sheets.

 

ALPHA LASER, a leading provider of laser welding solutions, will present its latest 1200 W laser welding system at the Welding and Cutting trade fair in Essen (September 11-15, 2023). This system is specifically designed for welding large and delicate components where conventional welding methods reach their limits. The high-performance systems enable welding tasks previously only possible with TIG and MIG welding, but with the advantages of laser welding.

Advantages of the ALPHA LASER 1200 W laser welding system

• Due to the low heat input into the material, preheating is no longer necessary, which saves time and costs.
• Minimal deformation and cracking, making it possible to weld critical and sensitive metals without cracking.
• Flexible welding: The systems enable both pulsed and continuous welding depending on the application.

Application areas of the 1200 W laser welding systems

The powerful 1200 W laser welding systems are ideal for various applications, including:

• shaft repair
• Hardfacing welding with wire and powder
• Casting repairs in hydroelectric power plants
• Welding of large and sensitive components where TIG welding is problematic
• These systems can melt wires with a diameter of 1.6 mm.

Expansion options and automation

The ALPHA LASER 1200 W systems offer numerous expansion options, such as rotary axes, heavy-duty rotary axes, and tilt-swivel lenses for rapid laser beam positioning. The Mabotic software with scanner kit allows for the scanning, programming, and welding of complex component geometries, enabling the automation of welding tasks.

Innovative systems

The introduction of the high-performance ALPHA LASER 1200 W laser welding systems marks a significant step forward in welding technology for delicate components. These innovative systems enable demanding welding tasks to be performed precisely and efficiently, while avoiding the drawbacks of conventional welding processes.

For more information about ALPHA LASER laser welding systems and their application possibilities, please visit our booth 5C10 or www.alphalaser.eu

 

Source: Press release dated July 31, 2023

TIG welding (tungsten inert gas welding) is an arc welding process that uses a non-consumable tungsten electrode to create the weld. It is classified as a gas-shielded welding process because an inert gas, usually argon or helium, is used during the welding process to protect the molten metal from reacting with oxygen and nitrogen in the air.

TIG welding process

• Preparation: The workpieces to be welded are first cleaned and precisely positioned. The weld seam and electrode position are carefully determined.
• Setting up the welding machine: The welding machine is set up according to the requirements. The welding current, the gas flow rate, and other parameters are adjusted.
• Tungsten electrode and gas: The non-consumable tungsten electrode is inserted into the welding gun. The inert gas is supplied to protect the weld area from oxidation and impurities.
• Welding process: The welder starts the arc by bringing the tungsten electrode close to the workpiece and then removing it. The arc is created and the material is melted.
• Filler material: If additional welding material is required, it is manually introduced into the welding zone. The addition of filler material can be precisely controlled and is not necessary in some cases, depending on the welding task.
• Weld: The tungsten electrode and the weld pool create the weld. The quality of the weld depends on the welding speed, the welding current, and the welder's precision.

Characteristics of TIG welding

• TIG welding enables extremely precise and clean weld seams.
• Since the tungsten electrode does not melt, it is not incorporated into the weld and does not contribute to the welding material.
• The use of inert gas as a shield creates a clean welding zone with minimal risk of contamination.
• The process can be used on various metals such as aluminum, stainless steel, copper and nickel.
• Due to its precision and control requirements, TIG welding demands a certain level of experience and skill from the welder.

Applications of TIG welding

TIG welding is used in many industries, especially where high weld quality is required. Examples of applications include:

• Manufacturing of aircraft parts and spacecraft where high-strength and reliable welds are required.
• Food and pharmaceutical industries, where clean and uncontaminated welds are essential for hygiene and safety.
• Manufacturing of stainless steel tanks and pipelines where precise and tight welds are required.
• Artistic metalwork and metal processing, where precise welds are required for aesthetic and decorative purposes.

Precision and versatility

TIG welding is a widely used welding process due to its precision and versatility, employed in many demanding applications. It enables high-quality and durable welds and is valued by experienced welders in various industries.