Applications of fiber laser based deep penetration welding in

Transcription

Applications of fiber laser based deep
penetration welding in shipbuilding, rolling
stocks production and pipe as well as pipeline
welding
4th Intern. Symposium on High-Power Laser
and their Applications
Steffen Keitel, Duisburg
Jan Neubert, Halle (Saale)
Ulf Jasnau, Rostock
August 08
Content
• GSI – the company
• GSI – welding application in industry
• GSI – first high power fiber laser in use
• Fiber laser based welding in shipbuilding
• Fiber laser based welding in rail car industries
• Fiber laser based welding in pipe production and pipeline welding
• Conclusions
GSI – Gesellschaft für Schweißtechnik International mbH
2
GSI Gesellschaft für Schweißtechnik International mbH
branches in Germany
Hamburg
Rostock
Bielefeld
Hanover
Duisburg
Berlin
Halle
Düsseldorf
Headquarter
Fellbach
ÜbachPalenberg
Munich
Saarland
Shops / Offices
3
GSI - Facts and annual output
Holder / Owner
DVS - Deutscher Verband für Schweißen und verwandte Verfahren e.V.
employees
turnover
branches
additional workshops
intern. Companies
400
45 Mio €
9
10
3 (SVV Praha, SLV-GSI Polska,
cooperative partners
GEWC Egypt, …)
6 (SLV Halle, SLV M-V, TC Kleben,
SLV Nord, SLV Mannheim, …
international contacts 50
20.000 trainings and examinations in welding
1.000
6.000
2.500
1600
180
trainings for supervisor in welding
further education for managers
qualification of companies / certification
certification of damage and material
projects in research and development
4
Research and Development in GSI
Fusion Welding
Mechanical
Joining
Thermal
Cutting
Thermal
Spraying
Friction Welding
Resistant
Welding
Brazing
Small
Parts and
Micro
Welding
5
System of Quality Assurence
company
testing/valuation
personal
Quality claims
weld technique
weld processes
Safety in working
material
nach DVS 3208
6
R & D of GSI
Application of Shop Primer
7
R & D of GSI
Plasma Welding in Automotive Industry
8
R & D of GSI
Resistant Powder Surfacing
9
Historic Development of Fusion Welding Processes
90
80
Increase of density
70
60
50
40
30
20
Development of the weld metallurgy
10
0
1930
1940
1950
Gasschweißen
gas welding
1960
1970
1980
Lichtbogenschweißen
arc welding
1990
2000
2010
Strahlschweißen
beam welding
10
Laser Welding of Water Tubes in 2003
Implementing the two Laser Sources in
an existing Tube Welding Line
EUROPIPE
1. Weld (inside of tube): CO2-Laser 12 kW
2. Weld (outside of tube): Nd:YAG-Laser 4,4 kW
11
Laser Beam Welding under Real Industriel Conditions
Welding Process with Laser Beam Welding of Front Side and Opposite Side
Welding Head
Outside
second pass
Welding Head
Inside
First pass
Bending Beam
Equipment for
Tube Forming
12
Laser Welding of Water Pipe in 2003
Materials Testing and Parameter
G22_X4_5
Base Material:
StE 240
Thickness:
10 mm
Filler Material:
SG-Mo
Laser Power inside:
11,87 kW (95 %)
Laser Power outside:
4,2 kW (95 %)
Welding Speed:
2,5 m/min
Speed of Filler Wire:
2,0 m/min
Overlap:
1,03 mm
13
Laser Beam Welding of Tubes under Industrial
Conditions
Leak Test of Laser Welded Tubes, Pressure up to Break
14
Laser Beam Welding in Manufacturing
of Rolling Stock
• Overlapped Welding of Sheets and
Reinforcement using Laser Welding
• Short Step Welding
Side Wall of a Rolling Stock Body
15
Current developments of electrical arc high
performance welding
process combination
process coupling
torch
laser beam
separate action zone
no common welding pool
torch
laser beam
common welding pool
hybrid process
16
Fiber laser based welding in rail car industries
Laser-Arc-Hybrid Welding Process
Hybrid welding of base
frame components
T-joint welding
with full
penetration from
8 - 10 mm
Torch equipment developed by:
17
GSI – first high power fiber lasers in use
• First fiber laser at GSI: 4,5 kW source, installed at SLV Halle in July 2003
• First 10 kW fiber laser source worldwide, installed at SLV M-V in August 2004
4,5 kW fiber laser
10 kW fiber laser prepared for mobile use with
chiller in a transport frame
18
Current developments of electrical arc high
performance welding
Hybrid welding head especially developed for fillet weld on
plates with large thickness
19
Hybrid welding of base frame components
•
•
„Marschbahn“: regional train between Hamburg – Sylt,
Travel speed: 160 km/h
20
Hybrid welding of base frame components
T-joint welding with full penetration
from 8 - 10 mm
Base frame assembly
21
Fiber laser based welding in shipbuilding
First mobile laser welds with a 10 kW fiber laser and a tractor system on a
sun-deck from a river cruise ship in Rostock, December 2006
sources: Neptun Werft Rostock, Meyer Werft Papenburg, SLV M-V Rostock
22
Development work for a refitting of a welding gantry using a 10 kW fiber
laser source for hybrid welding – demonstration in Rostock in July 2005
23
The first outfitting of a welding gantry with a 10 kW fiber laser source for
hybrid welding in production at Fincantieri Shipyard in Monfalcone in 2007
After approval of first WPS the first production welds were made at the end of 2007
24
Fiber laser based pipe welding
Hybrid welding equipment for orbital pipe welding
Welding equipment contains:
• Tractor
• Hybrid welding head
• Sensor for positioning
25
Fiber laser based pipe welding
Welding results in different positions
26
Hand Held Laser Systems
Manuell Laser Beam Welding and Cutting – semi atomized Process
27
Examples for Laser Deep Penetration Welding
Industrial field of
applications
Welding Application
Welding Deep
Laser Source
Shipbuilding
Laser Hybrid Welding
Butt Joint
8 mm
10 kW Fiber Laser
Rolling Stock
Production
Filled Weld
6 – 8 mm
4,5 kW Fiber Laser
Tube Production
Laser Welding
Butt Joint (Double
Side, 2 Passes)
6 – 12 mm
12 kW CO2 Laser
4,4 kW Nd:YAG Laser
Pipeline Welding
Butt Joint, Orbital
Welding
10 – 15 mm
10 – 12 kW Fiber
Laser
Shipbuilding
Laser Welding
2 – 5 mm
Butt Joint+Filled Weld,
Hand Positioned
4,5 kW Fiber Laser
4,4 kW Nd:YAG Laser
28
Conclusions
After 6 years working with high power fiber lasers in different application fields:
• High Power Fiber Laser are characterised be simple handling and high availability
• High power fiber lasers are usable in shipbuilding industry and other branches
• Fiber laser sources can be integrated easily in production systems in shipbuilding,
Pipe Welding, Production of Rolling Stocks as well as Pipeline Welding
• The fiber lasers realised the breakthrough of solid state lasers in shipbuilding
29

Applications of fiber laser based deep penetration welding in

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