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Laser Welding in Automotive Industry

Dynamic Processes Open Up New Possibilities

Today, there is no modern vehicle on the streets, in which laser was not applied. Whether laser welded tailored blanks, gear components or car keys – the applications are manifold. In the process the employment of modern scanner technology plays an increasingly important role besides the already known advantages of laser technology. Such scanners allow for maximal efficiency of the beam sources and thus increase productivity. With up to 200 welded joints per minute and with insignificant welding downtime the large capacity remote welding, for instance, took root mainly in the production of automobile rear car seats.

Dynamic Beam Welding

Dynamic Beam Welding

Within the shortest possible time multi spot welds of any geometry can be generated with Dynamic Beam Welding Systems in a very large work space. This system technology is applied amongst others in the production of automobile seats and mountings.

For this application we recommend the: HighLight FL Series

Laser Welding of Battery Housings

Laser Welding of Battery Housings

Helium-tight seam welding with laser and galvanometric scanner. For this application high reflective materials such as copper or aluminum are welded with a fiber laser. Besides many other industries, the batteries are used for example within the automotive industry.

 

For this application we recommend: HighLight FL Series, StarFiber, StarPulse

Laser Welding for the Connection of Battery Cells

Laser Welding for the Connection of Battery Cells

Single battery cells are connected in series or parallel within a battery module. This is realized by the electrical connection of the contact tabs/arrestors. During the welding process for contacting, the heat input must be kept at a minimum, making the laser the ideal tool. Because high reflecting materials such as copper or aluminum have to be joined, the fiber laser in combination with a 2D scanner solution is the right choice for this application. Usually for this application output powers of up to 2 kW are used.

 

Together with further peripheral components, several battery modules are assembled to one battery pack for use e.g. in electric cars.

 

For this application we recommend: HighLight FL Series

Spot Welding of Copper Conductors for Electric Motors

Spot Welding of Copper Conductors for Electric Motors

For this application a high number of welds per part have to be realized. With scanner and fiber laser, the laser beam can be positioned from weld to weld within milliseconds. Adjusted scanner movements melt the copper so that broad welding gaps can be bridged. Due to their high absorption into highly reflective materials such as copper, the fiber laser is the right tool for this application. Another advantage of laser welding with the fiber laser is the low heat input due to very short process times. Therefore damaging the isolations because of high temperatures can be avoided.

For this application we recommend: HighLight FL Series

Laser Welding of Gears and Powertrain Components

Laser Welding of Gears and Powertrain Components

Using lasers, gear components made from high-strength steels can be welded without cracking. The welding of gear components using laser could be established already a long time ago due to its advantages such as low maintenance costs, low distortions at the work piece, high flexibility and simple automation.


For this application we recommend the: DC Series, HighLight FL Series

Laser Welding of Tailored Blanks

Laser Welding of Tailored Blanks

Tailored blanks consist of laser joined flat sheets of different material thicknesses and alloys. Linear as well as non-linear joints are generated. Due to the strength and ductility of the laser-welded seams, the tailored blanks can be subsequently stamped into components such as car doors. For this application we recommend: DC Series, HighLight FL Series

 

As part of the preparation of high strength tailored blanks out of manganese-boron steel prior to laser-welding, q-switched solid-state lasers can be used for decoating the aluminum-silica layer. 

For this application we recommend: DQ SeriesHighLight FL1000P

Laser Welding of Air Conditioning Cooling Pipes

Laser Welding of Air Conditioning Cooling Pipes

For welding the aluminum of this air conditioning part, our fiber lasers are the ideal choice. The shorter 1um wavelength is much better absorbed by high reflective materials such as copper, aluminum or brass, compared to longer wavelengths.

For this application we recommend: HighLight FL Series

Laser Welding of Brake Sensors

Laser Welding of Brake Sensors

The steel of ABS brake sensors is welded with high-power fiber lasers. Besides the brake sensors also various other sensors like pressure sensors, force sensors and air-bag sensors are welded by laser.

 

For this application we recommend: HighLight FL Series

Laser Welding of Exhaust System Components

Laser Welding of Exhaust System Components

Stainless steel heat exchanger tubes are welded with laser scanner solutions in combination with our high power fiber lasers. Stainless steel exhaust couplings and sleeves can be either welded with fiber or CO2 lasers

For this application we recommend: HighLight FL Series, DC Series

Laser Welding of SCR Injectors

Laser Welding of SCR Injectors

To meet the emission standards, the harmful nitrogen oxides are converted into the air components nitrogen, water and carbon dioxide by selective catalytic reduction (SCR method). The selective Catalytic Reduction (SCR) Injectors are welded with Coherent-ROFIN fiber lasers and are used for AdBlue injection in large diesel engines.

 

For this application we recommend: HighLight FL Series

Welding of Safety Belt Pretensioner

Welding of Safety Belt Pretensioner

Pretensioners preemptively tighten the seat belt to prevent the occupant from jerking forward in a crash. In case of an accident, small bullets are shot into the shown component. The two parts of the pretensioner are laser joined with the help of a Coherent-ROFIN CO2 laser

 

For this application we recommend: DC Series

Welding of Fuel Filters

Welding of Fuel Filters

For welding of aluminum fuel filters, fiber lasers are the ideal choice due to their wavelength of 1µm. The shorter wavelength is much better absorbed by highly reflective materials such as aluminum, copper and brass, compared to the CO2 laser.

 

For this application we recommend: HighLight FL Series

Laser Welding of Carriages

Laser Welding of Carriages

Flexible fiber optics in connection with modern robots make fiber lasers a perfect tool in the highly automated welding of carriages – independent of applied material and metal gauge.

For this application we recommend the: HighLight FL Series

Fine Welding (Spot and Seam Welding)

Fine Welding (Spot and Seam Welding)

Spot and seam welding with the laser are primarily applied for particulate, mechanic and electro-mechanic work pieces, for example when contacting spark plug connectors and power electronics, for sensors and airbag detonators. Also heavily stressed screwed fastenings are replaced through fine welding. As in many cases copper or aluminum have to be processed high pulse peak capacities of up to 20 kW are applied.

For this applications we recommend the: StarPulse, StarFiber

 

Laser Welding of Polymers

Laser Welding of Polymers

The transmission welding entirely displaces the joints into the inner part of the join partner, works with minimal heat input and leaves perfect surfaces. This way, also sensitive components – for instance sensors – can be welded gas-proof. One of the most well-known fields of application for plastics welding using the laser is car keys that are common today. The laser welds all thermoplastic and thermoplastic elastomeric bonds, pressure-sealed and with high stability.


For this application we recommend: MPS Lasermachine for laserwelding of plastic