structures to workpieces manufactured with other techniques. This adds flexibility to production processes in regard to the placement, geometry and size of the supplementary structure. And since additional material is attached only wherever it is really necessary, this technique once against saves weight in the finished part.
Perspectives for Novel Concepts But even the processes introduced up to this point by no means exhaust the options for using laser technology in vehicle engineering. Rather, they form the basis for numerous novel concepts. Only a single example is described at this juncture.
Remote fillet welding makes it possible to weld two workpieces at an overlapped seam. When compared with the laser welding normally used today, the amount of material can be further reduced by shortening the flanges in the overlapping zone. The seam is then welded by the laser beam direct in the fillet created
here, requiring no additional filler material. One example of an application is welding seams in the frames for vehicle doors.
This process does, however, require the highest positioning accuracy for the laser beam. This can be achieved by using appropriate sensors to register the orientation of the workpiece and continuously re-regulate the position of the laser beam.
To summarize, laser-based processes make it possible to produce vehicle bodies with lower weights and to do so in different ways. This makes laser processing an important advance along the way to reducing emission levels, increasing cruising ranges and beyond this, to speed up, reduce the costs for, and add flexibility to automotive production.
Ralf Kimmel is with TRUMPF Laser- und Systemtechnik GmbH.
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