TRUMPF welding application BrightLine Weld

The challenge: spatter during laser welding

Hardly any other tool can be used in such a wide range of applications as the laser - even for producing meter-long, deep penetration welded seams. Very high power densities of around 1 megawatt per square centimeter are required for deep penetration welding.

Under certain circumstances, this can cause spatter due to the high heat input and steam formation. This impacts the weld seam quality negatively and can require time- and cost-intensive post-processing. TRUMPF has found the fitting solution with BrightLine Weld.

Why is spatter created during deep penetration welding?

TRUMPF laser welding without BrightLine Weld scheme

The laser beam heats the material up to evaporation. The emitted metal vapor sets the weld pool in motion and accelerates it - if the acceleration is too high, spatter comes off the keyhole rear wall.

This creates emissions in the weld seam and there is less material left to form the weld seam.

Effects on the weld result and the welding process

On the whole, not only is the quality of the seam impaired but additional precious time is also taken up: spatter can adhere to the component itself, the machine or the focusing optics, which then requires post-processing or cleaning. By implication, machine downtimes and more replacement procedures for the protective glass in optics create additional costs which are increased even more by a higher number of rejects due to insufficient weld seam quality.

The solution: BrightLine Weld for your TruDisk disk laser

TRUMPF 2in1 laser light cable for laser welding

You can weld materials such as mild or stainless steel or even copper and aluminum with almost no spatter thanks to the patented TRUMPF BrightLine Weld technology.

But how does it work exactly? Our patented TRUMPF 2in1 laser light cable (LLK) always contains an inner and an outer fiber core. This means that within the laser, the laser power can be flexibly distributed among the core, the ring of the 2in1 LLK and the application-specific optimum. Depending on the material, the power distribution can be set so that it is ideal for the desired result.

Welding with BrightLine Weld

TRUMPF application laser welding with BrightLine Weld

Due to an additional ring beam, the keyhole opening is enlarged and the metal vapor can escape more easily. The melt accelerated in the direction of the surface is then diverted by the ring beam in the direction of the weld pool and there is no spatter.

Your advantages

Highest quality

You can rely on BrightLine Weld for high-quality weld seams which ensure high strength with no pores, seam collapse, cracks or end scratches.

Increased productivity

Thanks to a higher feed rate, you will work very productively – while maintaining the same level of seam quality.

Lower operating costs

You will benefit from lower machine downtimes, less post-processing, fewer rejects and very high protective glass resistance.

Plug-in laser light cable

As the laser light cable is a plug-in cable, it is easy to replace. This helps to reduce machine downtimes to a minimum.

Maximum application flexibility

Thanks to BrightLine Weld, it is possible to weld in the core fiber and the ring fiber with hundred percent laser power. Flexible distribution of the laser power between the core and the ring fibers can be achieved.

Applications with BrightLine Weld

TRUMPF laser welding application powertrain component

Manufacturing powertrain components

The TRUMPF BrightLine Weld technology has many advantages in the area of powertrains, for example for laser welding gear wheels. They can be welded with the same welding depth at a significantly higher feed rate.

Welding of hairpins during production in the electromobility field

Hairpin welding

Hairpins are rectangular copper wires which are used in the keyways of electrical steels in electric motors and are welded at the front. TRUMPF lasers weld hairpins to the highest quality with almost no spatter or pores.

TRUMPF application aluminum welding

Welding of aluminum battery housings

As battery components of electric cars are very sensitive, the welding procedure must not affect the surrounding material if at all possible. Low-spatter laser welding with the BrightLine Weld option is particularly suited for this. High feed rates minimize the heat input in the process.

TRUMPF application copper components

Joining copper components

It is possible to weld copper in a highly stable and practically spatter-free process with the TruDisk and the BrightLine Weld option. It satisfies the toughest quality requirements for both the weld seam and the welded component itself, particularly in the area of e-mobility.

TRUMPF laser welding application aluminum 6000

Fillet seam welding of aluminum 6000 alloys

In contrast to wobbling, wedge seams for automobile body applications can now be welded with the BrightLine Weld AL 6000 in a linear process at a high feed rate and without hot crack formation.

Penetration welding of stainless steel

Even tubes and profiles can be welded with penetration welding with the BrightLine Weld technology to a high level of weld seam quality and with high productivity.

The complete package from TRUMPF

TRUMPF laser welding BrightLine Weld consulting

The TRUMPF BrightLine Weld technology consists of a new generation TruDisk disk laser, the BrightLine Weld option, the patented TRUMPF 2in1 laser light cable as well as standard focusing optics from the BEO or PFO series. This means that you receive everything from one source at TRUMPF and can simply retrofit your machine with the BrightLine Weld option onsite if needed at a later point.

With the support of the TRUMPF application experts, we can establish the individually required parameters together with you in our Laser Application Center (LAC) and adapt them precisely to your application.

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