Dr. Andreas Mootz Managing Director EMAG Automation Salach, Germany
www.emag.com
ADVANCED MANUFACTURING NOW Laser Welding for Lighter Parts and Reduced Energy Costs
E
xperts estimate that a weight reduction of 100 kg in a vehicle results in a fuel consumption reduction of 0.3 liters per 100 km. For this reason, lightweight construc- tion is becoming increasingly important for
the automotive industry, where every component is assessed for possible fuel-saving potential. Advanced laser welding machines offer an innovative approach in the manufacture of transmission components. The process offers savings not only in material, but a cor- responding reduction in component weight. Differential housing manufacturing advancements
clearly show the possibilities that laser welding technology offers the automotive industry. For some time now, vehicle manufacturers have been replac- ing the screw connections between the differential housing and crown gear with a welded joint. The removal of screws reduces the material requirement, an important cost factor, considering the substantial number of such parts required in the passenger car sector. The reduction in the material volume leads to a corresponding reduction in the weight of a dif- ferential housing by approximately 1.2 kg. In terms of advancing lightweight construction, such savings can be quite substantial for the OEM. The manufacture of differential housings is a textbook case. Laser welding technology is respon- sible for having generated high-tensile welding joints that easily replace the traditional connections used in many applications and, at the same time, ensure that material costs are reduced.
Integration Guarantees Process Effi ciency Gears with integrated synchronized wheels that must be produced effi ciently and with a high degree of accuracy are an excellent example of the laser joining process effi ciency. The components are fi rst manufactured separately and might comprise cast parts as well as case-hardened and machined steel. This is followed by a joining and welding process to integrate the components. Laser welding provides
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high accuracy and pinpoint direction of the laser beam. This provides a fast process with minimal material distortion. The construction of today’s laser machines guarantees a highly effective overall pro- cess. The two workpieces are clamped together using a joining press. The clamping technology used guar- antees highly accurate positioning of the two com- ponents, offering optimal conditions for the welding process. Depending on the workpiece confi guration or the material makeup, the parts can be preheated and, as a fi nal operation, brushed—all in a single setup. The whole joining and welding process for a gearwheel typically takes just 12 seconds, with the components for a differential housing welded in less than 35 seconds, on average, according to industry statistics. Accuracy also improves, as the reduction of clamping operations can be achieved in today’s laser workcells, where cleaning, preheating, joining, brushing, marking and process sensor measurement all occur in the same work envelope.
Energy Effi cient Processes Energy effi ciency is also an important factor.
Overall, the solid-state laser welding technology used today is exceptionally economical. Whereas the classical carbon dioxide laser has an effi ciency rating of just 8%, the technology used in many solid-state lasers (fi ber, disk) is rated at approximately 20%. Thus, it consumes less electricity, offers the same op- tical result and signifi cantly reduces production cost. Carbon dioxide lasers continue to have validity in certain applications, but the technology is evolving at light speed, so to speak.
Conclusion
When seeking to utilize the laser technology as part of a modern workcell concept, it is always advis- able to fi nd an integrator who has skill and experi- ence in both the laser and machining technologies. This will result in an effective workfl ow process and improved part quality, while simultaneously achiev- ing energy effi ciencies.
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