Laser beam welding-cutting

Laser beam welding (LBW) is a welding technique used to join multiple pieces of metal through the use of a
laser. The beam provides a concentrated heat source, allowing for narrow, deep welds and high welding
rates.
The laser beam welding has high power density (on the order of 1 MW/cm2)
resulting in small heat-affected zones and high heating and cooling rates. The spot
size of the laser can vary between 0.2 mm and 13 mm, though only smaller sizes
are used for welding. The depth of penetration is proportional to the amount of
power supplied, but is also dependent on the location of the focal point:
penetration is maximized when the focal point is slightly below the surface of the
work piece.
A continuous or pulsed laser beam may be used depending upon the application.
Millisecond-long pulses are used to weld thin materials such as razor blades while
continuous laser systems are employed for deep welds.
LBW is a versatile process, capable of welding carbon steels, HSLA steels, stainless
steel, aluminum, and titanium. Due to high cooling rates, cracking is a concern
when welding high-carbon steels. The weld quality is high, similar to that of
electron beam welding. The speed of welding is proportional to the amount of
power supplied but also depends on the type and thickness of the work pieces.
The high power capability of gas lasers makes them especially suitable for high volume applications. LBW is
particularly dominant in the automotive industry.

LBW machine's characteristics at CEWAC

Characteristics of Cabin:
Brand and Type :
TruLaser Cell 3010
Dimensions of cabin
1000 x 500 x 400 mm
Max length (X):
600 mm
Max length (Y):
300 mm
Max length (Z):
200 mm
Working speed X ,Y and Z axis:
150 mm/s
Accuracy:
20 m
Laser source characteristics:
Brand and Type:
TRUMPF TRUPULSE 203
Type of laser :
Pulsed YAG
Average power:
200W
Max. pulse power:
8 kW
Max. pulse energy:
90 J
Pulse duration:
0,3 - 50 ms
Beam quality:
12 mmmrad
Min. diameter laser light cable:
300 m
Cooling water temperature range: 6 - 28 C
Photos :

Cabine laser TruLaser Cell 3010

Source TruPulse
203

Hybrid laser welding

The combination of laser welding with another weld process is called a "hybrid welding process". This means
that a laser beam and an electrical arc act simultaneously in one welding zone, influencing and supporting
each other.
There are three main types of hybrid welding process, depending on the arc used: TIG, plasma arc or MIG
augmented laser welding. While TIG-augmented laser welding was the first to be researched, MIG/MAG is the
first to go into industry and is commonly known as hybrid laser welding.

For welding metallic objects, the laser beam is focused to obtain intensities of more than 1 MW/cm2. When
the laser beam hits the surface of the material, this spot is heated up to vaporization temperature, and a
vapor cavity is formed in the weld metal due to the escaping metal vapor. This is known as a keyhole. The
extraordinary feature of the weld seam is its high depth-to-width ratio. The energy-flow density of the freely
burning arc is slightly more than 100 kW/cm2. Unlike a dual process where two separate weld processes act
in succession, hybrid welding may be viewed as a combination of both weld processes acting simultaneously
in one and the same process zone. Depending on the kind of arc or laser process used, and depending on the
process parameters, the two systems will influence each other in different ways.
The combination of the laser process and the arc process results in an increase in both weld penetration
depth and welding speed (as compared to each process alone).
Laser provide:
- Deep penetration
- High welding speed
- Low distortion
- High welding speed
Arc provide:
- Wider weld pool
- Gap-brinding capability
- Shield gas

GMAW

LBW

Comparison between gas, laser and hybrid

welding

HLW machine's characteristics at CEWAC

Laser source characteristics:
Brand and Type:
Type of laser :
Power:
Fiber optic :

TRUMPF HL3006 D
Nd-YAG continu.
3 kW
600 m

Characteristics of robot:
Brand and Type :

KUKA KR-30-HA 6 axes + Table DKP-400 2 axes

Characteristics of laser head:

Brand and Type :
Focusing optics:

HLW

TRUMPF BEO 70 F150

150 mm

Characteristics of hybrid head:

Laser :
MIG :
Focusing optics:

TRUMPF BEO 70 F200

FRONIUS LASER HYBRIDE
200 mm

Source characteristics MIG

Brand and Type :
Wire diameters:

FRONIUS TPS4000 (400 A)

1mm or 1.2 mm

Photos :

Source laser

Hybrid head

Robot KUKA 6 Axes + table 2 axes

Electron Beam Welding (EBW)

Electron Beam Welding is a welding process utilizing a heat generated by a beam of high-energy electrons.
The electrons strike the work piece and their kinetic energy converts into thermal energy heating the metal
so that the edges of work piece are fused and joined together forming a weld after Solidification.
The process is carried out in a vacuum chamber at a pressure of about 2*10-7 to 2*10-6 psi (0.00013 to
0.0013 Pa). Such high vacuum is required in order to prevent loss of the electrons energy in collisions with air
molecules.
The electrons are emitted by a cathode (electron gun). Due to a high voltage (about 150 kV) applied between
the cathode and the anode the electrons are accelerated up to 30% - 60% of the speed of light. Kinetic
energy of the electrons becomes sufficient for melting the targeted weld. Some of the electrons energy
transforms into X-ray irradiation.
Electrons accelerated by electric field are then focused into a thin beam in the focusing coil. Deflection coil
moves the electron beam along the weld.
Electron Beam is capable to weld work pieces with thickness from 0.0004 (0.01 mm) up to 6 (150 mm) of
steel and up to 20 (500 mm) of aluminum. Electron Beam Welding may be used for joining any metals
including metals, which are hardly weldable by other welding methods: refractory metals (tungsten,
molybdenum, niobium) and chemically active metals (titanium, zirconium, beryllium). Electron Beam Welding
is also able to join dissimilar metals.

Vacuum environment necessity

The emissive element and the electrodes are placed in the gun. The piece to be welded is located in the
welding chamber.
Since the collision of free electrons and gas molecule, which would induce beam dispersion and a decrease in
the carried power density, the gun and the piece to be welded are vacuum pumped.
The dimension of the welding chamber depends on the dimension of the parts to be welded with its
positioning equipment and can vary from few litres up to few ten m3.
Electron Beam process
The electrons are small particles of matter with small mass. When they are accelerated they hit the piece
transferring their kinetic energy into thermal energy ensuring metal melting creating plasma of metallic
vapours.
The E.B. welding process is a high energetic process allowing to use very high power up to ten's of kW
on small surfaces of 5/10 of mm diameter. However, the total heat input is actually much lower than that of
any arc welding process.

Principals advantages of the electron beam welding process:

very small deformations after welding,
very thick materials (exceeding 60 mm with steel) in one pass,
possibility to weld all the steel, copper, nickel materials, aluminium, metals sensitive to oxygen and
other gases as zirconium, titanium
no filler metal and no gas,
high welding quality. The welds obtained are exceptionally pure,
high reliability,
high reproducibility,
high productivity.
Disadvantages of Electron Beam Welding (EBW):

Expensive equipment;
High production expenses;
X-ray irradiation.

EBW machine's characteristics at CEWAC

Brand :
Type :
Photos :

TECHMETA
MEDARD 43

Chambers tubular extention :

200 mm x 500 mm

Characteristics :
Power :
Accelerating tension :
Beam current :
Chambers dimensions :
Movement :
Max length X and Y axis :
Max speed X and Y axis:
Max speed C axis (rotation) :
Chambers vacuum :
Beams deflection :
- Max angle :
- Frequency :

6 kW
20 to 60 kV
1 to 100 mA
500 x 500 x 500 mm
CNC
200 mm - accuracy 25 m
3 m/min
120 RPM
10-4 mbar
+/- 6
0.1 to 2000 Hz

Friction-Stir Welding (FSW)

Friction-stir welding (FSW) is a solid-state joining process (the metal is not melted) that uses a third body tool
to join two facing surfaces. Heat is generated between the tool and material which leads to a very soft region
near the FSW tool. It then mechanically intermixes the two pieces of metal at the place of the joint, then the
softened metal (due to the elevated temperature) can be joined using mechanical pressure (which is applied
by the tool), much like joining clay, or dough. It is primarily used on aluminum, and most often on extruded
aluminum (non-heat treatable alloys), and on structures which need superior weld strength without a post
weld heat treatment. Frictional heat is generated between the wear-resistant welding components and the
work pieces. This heat, along with that generated by the mechanical mixing process and the adiabatic heat
within the material, cause the stirred materials to soften without melting. As the pin is moved forward, a
special profile on its leading face forces plasticized material to the rear where clamping force assists in a
forged consolidation of the weld.

A number of potential advantages of FSW over conventional fusion-welding processes have been identified:

Good mechanical properties in the as-welded condition

Improved safety due to the absence of toxic fumes or the spatter of molten material.
No consumables A threaded pin made of conventional tool steel, e.g., hardened H13, can weld over
1 km (0.62 mi) of aluminium, and no filler or gas shield is required for aluminium.
Easily automated on simple milling machines lower setup costs and less training.
Can operate in all positions (horizontal, vertical, etc.), as there is no weld pool.
Generally good weld appearance and minimal thickness under/over-matching, thus reducing the need
for expensive machining after welding.
Low environmental impact.

However, some disadvantages of the process have been identified:

Exit hole left when tool is withdrawn.

Large down forces required with heavy-duty clamping necessary to hold the plates together.
Less flexible than manual and arc processes (difficulties with thickness variations and non-linear
welds).
Often slower traverse rate than some fusion welding techniques, although this may be offset if fewer
welding passes are required.

FSW machine's characteristics at CEWAC

Brand :
Type :
Photos :

ESAB
ESAB 53 UTL and STL

Characteristics :
Degree of freedom :
Max length X and Z axis :
Welding speed:
Forging force :
MAX thickness in one pass:

2D
6 m and 0.6 m
2 m/min
100 kN
30mm ALU

Robotic Friction-Stir Welding (RFSW)

Friction stir welding is a mechanical welding process, which is easily automated and monitored. Automatic
tool change, automated loading and unloading, and the possibility of extending the workspace by using
coupled linear axes and/or component positioners represent clear advantages in the field of automation. For
Friction Stir Welding of thin sections up to 6 mm modern industrial robots are also suited and represent an
alternative machine concept to specially designed FSW machines. They feature an enormous flexibility
combined with low invest costs compared to special machines.
The flexibility of the robot not only makes it possible to realize 3D weld contours, but also to generate other
tasks such as milling or positioning thanks to modular tool change. In this way, friction stir welding can be
integrated into automated manufacturing operations.

FSW machine's characteristics at CEWAC

Brand:
Type:
Robot:

Friction Stir Link

FSL robotic cell
ABB IRB 7600 + horizontal or vertical positioner

Characteristics :
Workspace hemisphere:
Welding speed:
Forging force :
MAX thickness in one pass:

2.5 m diameter
2 m/min
10.3 kN
6 mm ALU