Laser Remote Welding of Aluminum without filler wire Laser Remote

Transcription

Laser Remote Welding of Aluminum without filler
wire
Laser Remote Schweißen ohne Zusatzmaterial
Dr. Rüdiger Brockmann
Industry Management Automotive
Corrado Bassi
Manager, Automotive Development Europe
TRUMPF Laser- und Systemtechnik GmbH
Novelis Switzerland SA
Ditzingen, Germany
Sierre, Switzerland
19.04.2012
Konferenz Fügen © TRUMPF
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Outline
 Remote Welding – State of the art
 Conventional laser welding of aluminum
 Issue with welding of 6xxx Aluminium Alloys
 Laser Remote Weldable Aluminium Alloy
 Technical Solution Fusion Novelis Alloy
 Remote welding test with Fusion Novelis Alloy
 Applications and perspectives
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TRUMPF Laser Applications in Automotive Industry
Rear Center
Component
Doors
Remote Laser Applications
IP Beam
Side Panel
Battery
Seat Rests, Tracks,
Recliners
Bumpers
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What makes remote welding more productive?
Process Start
Home
Welding 8
Positioning 7
Welding 7
Positioning 6
Welding 6
unproductive
travelling times
Positioning 5
Welding 5
Positioning 4
Welding 4
Positioning 3
Welding 3
Positiotning 2
Welding 2
Positioning 1
Welding 1
approach
Conventional Laser Welding
Process End
Process Start
Home
Welding 8
Welding 7
Welding 6
Welding 5
Welding 4
Welding 3
Welding 2
Welding 1
Approach
Laser Scanner Welding
 Elimination of non-productive travelling times
 Maximization of beam-on share
Process End
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Door welding station: RSW vs. Laser Remote
Resistant Spot
p Welding
g
- 7%
%
Jobs/year
Invest
Laser Remote Welding
g
- 37%
3 %
Floorspace
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Cycle time in s
RSW versus laser on the fly remote welding
Resistance Spot Welding:
 34
+ shift mark
 4 robots, 5 weld guns
 additional tool for shift mark
 processing time: 35 sec
Laser Scanner Welding:
 34
+ shift mark
 1 robot, 1 scanner optics
processing
g time: 13 sec ((with 4 kW))
 p
 processing time reduction: factor 3!
Laser shift mark:
Source: Volkswagen AG
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Comparison of Technologies in terms of
productivity
Resistance Weld
Cost = $$$
Disk Laser with PFO
Cost = $
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Outline
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Motivation: 6xxx alloys are known to be difficult
material for welding
 The columnar grain structure in the welded zone linked with the slight amount of Mg, Si and/or
Cu lead to high hot-cracking susceptibility (HCS)
 Welding can only be successfully performed with filler material and/or low welding speed
AA6014 Laser welded without filler
Barker etched
500m
 Limited possibilities for 6xxx Aluminum alloys in automotive industry
 High
Hi h costt and
d complexity
l it for
f laser
l
welding,
ldi
due
d to
t additional
dditi
l filler
fill material
t i l
 Draw back for remote laser welding
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Laser Welding of Aluminum Automotive Doors
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Outline
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Solution: Novelis FusionTM for (remote) laser welding
of 6xxx
 A 6xxx sheet cladded with eutectic Al
Al-Si
Si composition (or slightly hypo
hypo-eutectics)
eutectics) leads to good
weldability
- No hot-cracking in the weld
- Improved weldability and stabilization of molten pool oxide film by high Si
 Laser welding without filler metal becomes possible, even at high speed or near edge welding
 Maintains all advantages of 6xxx monolithic alloys
 (Remote) Laser welding - without filler - without gas protection
Si distribution
of fusioncost
remoteeffective
laser weld

Versatile,
and simple welding procedure
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Technical Solution - Novelis Fusion 8840 has a
special Clad Alloy to help welding
A 6xxx clad layer alloy enables
welding without filler metal
• Alloy Novelis Fusion 8840
• Core Alloy : AA6016 (other core possible)
• Availability: for inner immediately
and for skin from march 2012
• Width : 1850 mm max (temporary)
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Remote welding of various geometry
Collaboration TRUMPF - Novelis: Tests of various geometries
I-Joint - overlap
Butt Weld
Edge Overlapp
Edge
T Joint
Extrusion-Sheet
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Kehl-Naht and Butt welding gives good welds with Fusion
New Fusion 6xxx
Monolithische Legierung- Normal 6xxx : Ac-170 / Ac-170
Kehl-Naht
New Fusion 6xxx
Monolithische Legierung- Normal 6xxx : Ac-170 / Ac-170
Butt-Welding
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T-Join and welding on extruded part are also possible with Fusion Alloy
Fusion / Fusion N°106
T-Joint
T
Joint
N°148
Welding on Extrusion
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Laser processing window
Minimum Flange Weld Distance & Alloy
Combination (Fusion
(Fusion, Monolithic)
Remote welding on various alloy
combination with reduced flange
width (middle weld to edge distance) :
►
Fusion/Fusion
►
Ac-170/Ac-170
►
Fusion/Ac-170 and Ac-170/Fusion
3 mm
6 mm
10 mm
Trials configuration:
II-Naht
Naht configuration with a fixed gap of 0
1mm
0.1mm
►
Constant power of 4kW, without defocusing
►
Speed adjusted for each alloy combination
►
No adjustment for start/end of the weld
botttom top
►
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20x5-pt_backside.jpg
20x5-pt
p _backside.jpg
jpg
Monolithic 6xxx : Ac-170 - 10 mm from edge
Monolithic Ac-170/Ac-170 is cracking at 10 mm from edge
DPI
Gap 0.1 mm – 4 kW – V= 6 m/min
Top
side
v
Struccture
Back
side
C k att grain
i b
d
 Cracks
boundary
 Columnar grain on the weld border
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Fusion/Fusion - 6 mm from edge  good weld
Fusion/Fusion – Gap 0.1 mm – 4 kW – V= 4.5 m/min
Top
side
DPI
v
Struccture
Back
side
6 mm
N cracks
k observed
b
d
 No
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Fusion / Ac-170 - 6 mm from flange - good weld
DPI
Fusion/Ac-170 – Gap 0.1 mm – 4 kW – V= 5.5 m/min
Top
side
v
Struccture
Back
side
6 mm
N cracks
k observed
b
d
 No
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Fusion / Fusion : 3 mm from edge – crack
DPI
Fusion/Fusion – Gap 0.1 mm – 4 kW – V= 4.5 m/min
Top
side
v
Struccture
Back
B
k
side
 Grain boundary liquation in the HAZ on the
edge side. This a heat flow issue not
material problem.
3 mm
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Novelis Fusion - Flange Remote Welding Possible >
5 mm
2.5
5
6
7.5
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Edge distance
10 mm
Laser processing window for Monolithic-Fusion
Sheet Combination
a
6 mm fl
ld iis possible
ibl with
ith F
i &F
i
M
lithi combination
bi ti
flange weld
Fusion
Fusion-Monolithic



bottom
m top

bottom
m top

bottom
m top



bottom
m top

Fus/
Fu
us


Fus/
617
70
a = 3 mm
6170/
Fus
a = 6 mm
617
70/
617
70
a =10 mm

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Fusion Novelis 8840 - Remote Laser Welding /
Process limitations
IInvestigation
ti ti off speed
d and
d jjoint
i t gap
Crack free weld with Fusion alloy can be achieved up to :
Welding Sp
peed [m/min
n]
22
 Speed of :
 Gaps of :
20
22 m/min
0.4 mm
This is not of direct use for production but shows the
potential robustness of weld in real environment or by
t h i l issues
technical
i
in
i assembly
bl
12
10
0
0.3
0.4
0.5
0.6
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0.7
Outline
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Applications for Aluminium Fusion 8840 - Laser &
Remote weldable alloy
 Replace steel panels by Aluminium
(Laser remote welded doors, decklid, side panels …)
 Make use of advantages of remote welding for new
panels
 shorter flanges
g
 stiffness increase or weight reduction
 Investigate mixed assembly : extrusion- casting sheet
 Investigate potential for roof assembly
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Perspectives for Aluminium Fusion 8840 - Laser &
Remote weldable alloy
 Investigate potential of reduced clamping
complexity and effort for remote welding
with Fusion Alloy
 Investigate potential for one side
assembly solution?
pp
for body
y in white assemblyy
In application
(modules)
 Objectives : flexibility, freedom of
assembly
assembly, cost?
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Und jetzt freue ich mich auf Ihre Fragen.
Dr. Rüdiger Brockmann
Dr
TRUMPF Laser- und Systemtechnik GmbH
Johann-Maus-Straße 2
71254 Ditzingen
[email protected]
di
b k
@d t
f
Corrado Bassi
Novelis Switzerland SA
Rte des Laminoirs 15
CH - 3960 Sierre, Switzerland
corrado bassi@novelis com
[email protected]
TLD261br - 2012/04/19

Laser Remote Welding of Aluminum without filler wire Laser Remote

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