weil technology 的激光焊接设备基于标准化的平台和模块，可针对组件、客户和项目特定的生产系统进行配置。激光焊接工艺对比其他焊接方法的优点主要在于焊接速度快 10 倍。结果是非常坚固且耐用的焊接连接件、在部件中产生更少的热量输入，以及几乎对工件不造成扭曲。
When selecting laser components, we consider not only customer requests for specific installations, but also the technical requirements applicable in laser cutting and welding tasks, to help ensure an optimal process.
If order processing has already been carried out in our TechCenter feasibility or process stability studies, the question of which laser sources to use has already been answered. We generally work with global laser system manufacturers such as Trumpf, Rofin-Sinar, IPG and Laserline, as well as with OTC Daihen and Fronius in the arc welding area.
The most frequently used type of high power solid-state laser used is the TruDisk by Trumpf Laser GmbH, which can be used in both laser cutting and laser welding processes. This unit is an optimal choice for meeting our requirements for precision and reproducibility in cutting and welding results. The advantage of using the laser here is in creating smooth and burr-free edges that require no reworking, and in very small heat affected zones (low warpage).
In some applications, this type of laser was useful as a beam source in combination with scanner optics, in which the movable mirror guides the focusing optics of the laser beam. The fast adjusting movements by the mirror provide highly dynamic and precise welding results.
An increasing number of applications require not only almost spatter-free laser welding, but also outstanding weld seam quality with no spatter. The “BrightLine Weld” option from the TruDisk laser gets us one step closer to this goal. Primarily developed to weld copper and reduce weld spatter, “BrightLine Weld” offers the ability to create high-quality weld seams without end craters or seam collapse. The system prevents spatter first by welding with a high feed rate, and second with a “2in1 fibre” patented by Trumpf – two fibre optics in a single fibre – where two laser beams with different power distribution act on the weld seam. The result is reduced energy input and no component distortion, faster feed speeds / welding speeds, 40% lower energy consumption and lower levels of contamination on components and protective equipment.
Diode lasers by Laserline (LDF, LDM) are also frequently used. In tasks with lower performance requirements, such as with sheet metal up to 0.8 mm thick, or lower requirements for the characteristics and appearance of the weld seam, the ease of integrating this option into welding machines and lower investment and operating cost make it possible to substitute diode lasers in laser applications.
weil technology uses laser sources from IPG primarily for applications in laser cutting systems.
Arc welding or electrode welding is a manual process. The electrode used melts, evaporating inert gases and forming slag that protects the weld seam from external influences.
Inert gases are also used in inert gas welding; these flow around the electrode and melt and replace atmospheric oxygen. Inert gas welding can be fully automated. If specifically requested by a customer, for instance, we can integrate a tungsten inert gas welding source (WIG) into a raw material production system. In this process, a non-melting tungsten electrode is used to achieve a high-quality seam with slower welding speeds than in gas metal arc welding (manual metal arc welding MMAW). Metal inert gas welding (MIG) also uses inert gases – gases that do not chemically react with the melt – and is best suited for non-ferrous metals and high alloy steels. If reactive gases are used that change the composition of the melt – such as in un- or non-alloyed steels – the process is called metal active gas welding (MAG).
Slags and an obvious weld bead are the external signs of MAG welding, while a lack of through-weld, joint defects or the formation of corrosive areas are underlying disadvantages. Another problem is obvious weld spatter, which requires manual reworking to remove and makes the overall process more expensive.
Another advantage of the laser are the 10x higher speeds that can be achieved over MIG or MAG welding. No additional materials are required, but they can be added if necessary. Other advantages of laser welding:
- Laser welding results in low warpage; faster process speeds allow for more beneficial welding strategies;
- A laser weld seam requires no seam preparation, since the single layer welding penetration depth (> 10 mm) eliminates the need for expensive weld preparations;
- Laser welded seams do not have to be reworked, since the width-depth ratio of 1:5 creates an aesthetically pleasing seam appearance that normally does not require reworking.
- Laser welding is not only technically impressive, but offers major economic advantages for users when applied correctly.
The laser beam, just a few µ in width, requires precise guidance to hit the welded sheet metal edges, melt and bond them. Automated clamping technology is required to clamp the weld seam perfectly and completely over its entire length, holding it in place for the entirety of the welding process.