Automotive joining of light-weight materials enabled by fiber lasers
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1 Automotive joining of light-weight materials enabled by fiber lasers 26 APR 2017, GALM, Birmingham, UK Mark Thompson Director of Sales & Service, UK T h e P o w e r t o T r a n s f o r m TM Nasdaq: IPG Photonics (IPGP)
2 Contents IPG Photonics - Company Overview Static Beam forming for automotive joining Dynamic beam forming for advanced joining Copyright IPG Photonics
3 IPG Photonics Overview History IPG Photonics Istanbul (Turkey) Oxford, Massachusetts (USA) Barcelona (Spain) Daejeon (Korea) Bristol (UK) Gliwice (Poland) Detroit (MI, USA) Burbach (Germany) Bangalore (India) Singapore Sao Paulo (Brasil) Moscow (Russia) Milan(Italy) Beijing (China) Praque (Czechia) Tokyo (Japan) California (USA) Strasbourg (France) Headquarter/Production Production/Sales/Service Sales/Service Copyright IPG Photonics
4 IPG Photonics Overview General data IPG Photonics 2016 Sales by Geography and End-Use Founded in % year-over-year increase > 4,360 employees Total Sales >1 Billion US$ in % 15% 54% Net Sales (millions) $769.8 $648.0 $562.5 $ $901.3 Asia Europe, CIS Americas 94 % Materials Processing Advanced Applications, Medical, Telecom Source: IPG Photonics Annual Report 2016 Copyright IPG Photonics
5 IPG Laser Products Overview Leadership in Automotive Low Power CW Fiber Lasers Mid Power CW Fiber Lasers High Power CW Fiber Lasers Quasi-CW Fiber Lasers Nanosecond Fiber Lasers Pico & Femtosecond Fiber Lasers Mid-IR Hybrid Lasers CW Fiber Amplifiers Diode Lasers Copyright IPG Photonics
6 IPG Complimentary Products Overview Components Fiber Beam Delivery Beam Switches & Fiber Couplers Process Heads Collimators Chillers Copyright IPG Photonics
7 Automotive Product Lines Products for mainstream automotive applications Welding Remote processing Brazing Ablation/Cleaning Micro machining Cutting
8 Static beam forming tri-focal fiber delivery Motivation/ Requirements! High Reliable Process stability! Increased Speed! Increased Strength! High quality seam appearance at Hot-Dipped Zn coated Materials! Inline Cleaning process! Dynamic power modulation Main spot Welding Trifocal Process fiber side spots Ablation
9 Tri-focal Fiber Laser 3 beams in a single cable with independent power control Ablation side spots (2x 150W) Welding centre spot (1500W) Trifocal process (1500W + 2x150W)
10 Welding of Zn-coated Zero Gap Monofocal welding galvanized + hot dipped Trifocal welding galvanized + hot dipped
11 Car roof welding Aluminium Tri-focal welding Side Spot P L = 4,1 kw P Side = W V Rob = 4,0 m/min V Filler Wire = 4,2 m/min
12 Tri-focal - Brazing of hot dipped Zn coated steel Key Applications: ROOF JOINING & Trunk/Boot-lid joining P = 2,4 kw + 2 x 340 W v = 3,6 m/min Brazing of Hot-Dipped Zn coated
13 Welding of Aluminium Roof - Comparison Mono-focal welding of Al Real part from production Tri-focal welding of Al Real part from production Standard Cross section Improved Cross section
14 Dynamic beam forming with fiber laser Principle of a wobbling head Mirror General Specifications Max Wobble frequency 300 khz Laser Power up to 8 kw Max focal length 500 mm Full Scanning Range +/- 7,5 mm 72 Focal Lens Focal Length
15 Wobble Dynamic Beam Forming Optics for dynamic beam guidance Wobble head Scanner Delivering up to 2kW & High brightness lasers Arbitrary figures possible
16 Dynamic beam forming improves joint quality " Higher frequencies and low welding speed to generate large melting pool " Controlled thermal input " Intermetallic properties matched to need Circle Welding direction Wobble Welding direction Wobble Linear Example: 20 Hz 15mm/sec.
17 Copper and Aluminium Welding Technology Breakthrough Example: Fiber lasers for highly reflective material joining Challenge: Aluminium and copper are highly reflective materials, reducing the absorbed light in low brightness welding processes Historically gave poor weld strength and high spatter Unacceptable weld quality Requirements: Welding highly reflective materials requires: higher brightness lasers BUT with less excess heat input improved process stability compared to large spot welding Solution: Single mode, SM fiber lasers deliver significantly higher brightness Dynamic beam forming (or wobble welding) adds stability And distributes the thermal load to match with material properties
18 Approach Wobble (SM) Without wobbling: Power: 1kW Speed: 1m/min With wobbling: Power: 1kW Speed: 1m/min Frequency: 300 Hz Diameter: 0.4 mm
19 Approach Wobble (SM) Without wobbling: Power: 1kW Speed: 1m/min With wobbling: Power: 1kW Speed: 1m/min Frequency: 300 Hz Diameter: 0.4 mm
20 Approach Copper Welding with Wobble Welding and high brightness single mode fiber laser Power: 1 kw Speed: 1 m/min Spot diameter: 30µm Ø = 0,1 mm Ø = 0,2 mm Ø = 0,4 mm f = 300 Hz f = 600 Hz f = 900 Hz
21 Summary Tri-focal Fiber Laser shows for brazing:! Higher speed: +30% Higher strength: +30% Higher surface quality! Production Energy savings > 60% Tri-focal Fiber Laser shows for welding:! Higher speed for Aluminum Improved surface quality without cleaning! Welding of 6000 alloys without filler wire! Spatter free Overlap welding of Zn-coated zero gap Dynamic beam forming enables dissimilar materials welding! Wobble head welding matches laser brightness to materials properties! Single mode high brightness lasers weld highly reflective materials CHALLENGE US TO JOIN YOUR MATERIALS OF CHOICE:
22 Thank you for your attention! Mark Thompson MD, IPG Photonics (UK) Ltd Axis 1, Hawkfield B Pk, Bristol, BS14 0BY IPG Laser, Burbach Germany mthompson@ipgphotonics.com Thank you for your attention! Copyright IPG Photonics
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