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Why waste valuable time and effort and stretch your nerves? Rely on joining with the laser tool and reduce your component costs sustainably. Smooth, visually high-quality visible seams up to metre-long, deep-welded and extremely stable connections. You can produce all of this effortlessly using laser welding. The result is narrow seam geometries with minimal distortion.
Produce high-tensile or tight seams with top visual quality.
High process speeds when it comes to laser welding reduce your component costs to a minimum.
Benefit from more design freedom due to a large variety of new seam geometries.
Achieve reproducible results thanks to automation. This is because robots do not forget.
Welding is fascinating In a number of ways. Bring new shapes to light. One aspect is essential here: the seam must hold. That is the basis for everything to come. Of course, there are a range of additional aspects that you can optimise to enable flexible sheet metal processing. Efficient use of time and labour resources is part of this. And, of course, part quality – both visual and technical. Inevitably, when it comes to classic arc welding, you keep on having to do something particularly unpopular – reworking. The good news is that laser welding results in parts that do not require reworking the majority of the time.
Tests in the material testing institute prove: a weld seam created with a laser is as stable as the welded material. Observers are amazed and impressed: if the mating parts are welded with the laser, the material tears – but the seam holds. Conventionally welded sheets invariably tear in the area of the weld seam in tests on the tension test bench at a material testing institute.
The fact is that the longer the welding time and the larger the outlay for reworking, the faster laser welding pays off. Even in the case of a lot size of one. If there are requirements when it comes to the seam quality, lots of reworking has to be carried out. Laser welding impresses here with visible seams of top visual quality – often without any reworking, such as grinding. Since less heat penetrates into the component during laser welding, there is barely any distortion and therefore no subsequent straightening. The significantly higher welding speed also saves time and therefore money.
The conventional welding processes create lots of seams, but do not have anywhere near the diversity of a laser. For example, the laser can weld materials of different thicknesses together and create lap seams/a concealed T-joint. With laser welding, all conceivable seam forms are possible; many of them are also accessible on one side. Heat conduction welding creates seams with excellent surface quality here. In the case of deep penetration welding, a high-tensile, narrow, and deep seam is created. Both processes – heat conduction welding and deep penetration welding – also enable a significantly higher process speed.
Expensive fixtures are only required in very complex, exceptional cases. The clamping system can often also be produced with sheet metal constructions and standard parts. Variants can then be constructed quickly later from the already available fixtures. TRUMPF provides start-up support with fixture construction with the seminar on fixture design. In two days, the experts enable the participants to construct fixtures from sheet metal so that they can process laser welding parts even more efficiently. Welding without a fixture is also possible. To do so, you have to pre-fix the component; you simply have to fix it in the machine for welding.
It is easy to get started with laser welding. The TruLaser Weld 5000 with FusionLine allows you to compensate for inaccuracies in components during the welding process and even to close gaps of up to one millimetre in width. The results from FusionLine when it comes to weld seam quality and process speed are significantly better here than those of conventionally welded components, even if they are not quite as good as in the case of a pure laser seam. This means that users can laser weld cost efficiently, even if their component range is not optimised to laser welding.
Laser welding with TRUMPF stands for top-quality seams, often without any reworking, such as grinding or polishing, at all. Distortion is also minimal, meaning that straightening work is eliminated. In addition, you also save on consumables, such as grinding wheels. Combined with the laser, which welds quickly and highly productively, you can achieve enormous time benefits. It can generally be said that the longer the welding time and the more reworking you have to do, the quicker laser welding pays off.
Numbers don't lie. We would therefore like to present you with a financial comparison of TIG manual welding and laser welding. The workpiece is a bonnet made of mild steel which has to meet high visual requirements. The result is that, with automated laser welding, you can reduce time required by up to 90% and reduce costs per part by 65% in the case of joining. Catapult your sheet metal processing into a new league. If you utilise up to 50% of your system in a shift with these types of components, it pays off in around two years.
This calculation is based on average values typical for Germany and a quantity of 500 bonnets that are produced in 10 units of 50 pieces each. In the case of TIG manual welding, the welding time per part is approx. 45 minutes; when using automated laser welding, it is only approx. 2 minutes. Reworking is also eliminated when laser welding this bonnet. In the case of a conventional welding process, this adds another 10 minutes to each part. This gain in time per part more than compensates for time spent programming the order, the costs for the fixture and the setup time per lot, which are comparatively higher in the case of laser welding.
Two mild steel sheets of 60 cm in length and 1 mm in thickness are welded. The differences in distortion that the sheets exhibit after processing can be seen quickly. Based on the low heat input into the component, which is characteristic for laser welding, subsequent straightening is not required. The higher process speed alone reduces time required by around 93%. The elimination of the straightening process therefore increases productivity.
Heat conduction welding, deep penetration welding or FusionLine: depending on the component, you can choose the right welding process with flexibility – without having to retool. This applies to all common materials, such as mild steel, stainless steel or aluminium.
Various material thicknesses
Lap seam
Concealed T-joint
Butt joint in the event of a tube flange
Heat conduction seam in the event of a corner joint
Butt joint in the event of a flange joint
Fillet seam in the event of a T-joint
Butt joint
Butt joint in the event of a tube
Whether it's in mechanical engineering, kitchen building and furniture building, in installation, design, medical and lamp technology, the food industry, container and apparatus construction, or the electronics sector – weld seams are present in lots of different places. Deep, stable and tight seams are a must in water tanks, among other things. On the other hand, in the case of a counter segment, beautiful visible seams with a smooth, rounded surface are what counts. The requirements can be very various. Yet, the same thing applies everywhere: the quality of the seam is what counts.
The right machine for laser welding in a modern sheet metal processing system Robots, lasers, processing optics, safety cabin and positioning units: the turnkey system can be individually adjusted to your needs for automated welding with the laser.
