Remote fibre laser welding as a comparative joining method for body in white applications.

Transcription

1 Remote fibre laser welding as a comparative joining method for body in white applications. Richard Hewitt Industrial Laser Applications Symposium (ILAS) th July TWI (Cambridge) Joint Comparisons Business Case Cost Initial Investment Production Area Energy Process Application / Performance Strength Distortion / Fixturing Summary 1

2 Remote Laser Welding Opportunities Faster processing speed Single sided access Comparable Investment Costs Improved piece cost Reduced floorspace Improved energy utilisation Flexible Manufacturing Product Design Flange dimensions can be reduced, resulting in an overall vehicle weight reduction Vehicle rigidity and strength can be increased due to stronger laser welds dependant upon product design Higher strength materials can be welded resulting in lighter components with fewer reinforcements 3 Remote Laser Welding - Challenges Business case: The laser source and applicator is a significant investment, cost effective implementation has to make use of improved process speeds. Identification of all investment and operating cost drivers required to make a valid comparison proven to be around same level as comparative joining processes Panel fit-up important not suited to all assemblies Degassing of zinc vapour: Solution required in material selection, tooling or pre processing Tooling specification: Clamping and location solutions required to maintain optimum fit-up and welding access. 4 2

3 Remote Laser Welding - Challenges Quality Control Planning: Process monitoring - Not yet a proven production tool for real- time analysis, there is a need for robust Quality Control Planning Few system integrators offering turnkey full service supply Laser Safety: Stringent Laser Safety requirements Education & training for maintenance & operators Product Development: To maximise the opportunities of remote laser welding, product and process development is key. 5 The Facility at Warwick 6 3

4 RSW v RLW v SPR Cost Matrix INVESTMENT COSTS Engineering Incoming Services Cell Integration Hardware Process Quality Control Implementation OPERATING COSTS Production Area Services Consumables Process Consumables Spare Parts Maintenance Quality Process Parameters Operating Parameters COST PER HOUR COST PER JOINT 7 Courtesy Stadco Ltd RSW vs RLW vs SPR Joint Cost 4

5 Benchmarking Study Spotwelding Remote Laser Welding RH LH Robot Qty reduced by 80% Floorspace reduced by 50% Less Tooling 9 Courtesy Stadco Ltd Energy Efficiency 5

6 Process Window & Stability Evaluation PROCESS WINDOW Parameter Power Speed Focus Incident angle System Performance Envelope Repeatability Focus drift On/off test PROCESS STABILITY WELD OK/NOK Interface width Penetration Porosity Weld strength Surface Concavity Top Bead Width Top Surface Cut Through Spatter Burn Through PROCESS STABILITY Joint condition Gap - tooling Gap - degassing Stitch profiles Flange condition Material Stack-up Coating Material type Contamination PROCESS STABILITY Courtesy Stadco Ltd 1mm to 1mm AA5754 Comparison 6

7 1mm to 2mm AA5754 Comparison 2mm to 2mm AA5754 Comparison 7

8 DX54 - Weld speed 25mm Stitch Porosity and material ejection 3.8 m/min DX54 1mm 1mm with gap 0.2mm DX54 - Interface Gap 25mm Stitch Porosity and material ejection Excessive undercutting 0.18mm DX54 1mm 1mm with gap 0.4mm 8

9 Focus Position Stitch Length 9

10 Stitch Shape 20mm Stitch Impingement angle Unreliable or no weld 10

11 Process Distortion SPR (Current Production Solution) SPR Current Production Solution RFLW Proposed Production Solution Fixturing Solutions Courtesy Comau 11

12 Summary Evidence has shown that Remote Fibre Laser Welding is of comparable quasistatic joining strength to existing structural joining techniques. Business case has been demonstrated for simple cell. In steel, a number of OEMs, e.g. VW, BMW, Audi, Renault, Hyundi, Toyota & Mercedes have installed systems within their facilities. These are mainly the result of internal development with equipment suppliers, there are very few System Integrators currently supporting this development. The DTI funded project aims to answer the challenges faced, and to benchmark the Remote Laser Process against exisiting Turn Key System suitable for the OEM and the Tier 1 Supplier: mixed product, variable volume scenario. The project will enable OEMs and BIW Tier 1 Suppliers to specify and support the application of Remote Laser Welding, within the automotive industry; material suppliers to understand the material requirements and the equipment and system integrators to understand the specific requirements of this application. 23 Thank you for your attention Any Questions Richard Hewitt richard.hewitt@warwick.ac.uk Acknowledgements: Charles Marine Stadco Anil Mistry Jaguar Cars Nic Blundell Warwick Eduardo Izquierdo Warwick Martin Kinsella Comau Systems Brooke Ward - AILU Award Winner TSB sponsored by DIUS The Technology Strategy Board is a business-led executive nondepartmental public body, established by the government. Its mission is to promote and support research into, and development and exploitation of, technology and innovation for the benefit of UK business, in order to increase economic growth and improve the quality of life. It is sponsored by the Department for Innovation, Universities and Skills (DIUS). Please visit for further information