Welding aluminum and galvanized steel in the automotive industry can be much easier and faster if you do it with a completely new type of process head along with the advanced Coherent ARM fiber laser technology.

Welding some of the more challenging materials such as aluminium and galvanised steel can be faster, easier and better quality than ever before with a solution that combines the latest technology from Coherent and German manufacturing company thyssenkrupp Automotive Body Solutions. Specifically, this new product combines Coherent's HighLight ARM (Adjustable Ring Mode) laser and thyssenkrupp's LSK 06 advanced process head to deliver key benefits in terms of weld quality, practicality and safety.

GO WITH THE FLOW

One of the biggest innovations of the LSK 06 process head is a completely new approach to gas flow. Traditional welding process heads use a strong cross flow of gas to prevent spatter forming on the shielding glass. However, this does not help the welding process itself. In fact, it creates unwanted gas turbulence that destabilizes the melt.

In contrast, the LSK 06 process head is designed to mechanically surround and enclose the entire weld area; in fact, it clamps around the workpiece and forms a relatively tight connection. A system of tubes in the process head then creates a laminar flow to extract the fume directly from the area around the welding process itself. This increases the efficiency of smoke removal and also stabilises and improves the dynamics of the melt.

Combined with the precise spatial control of laser power distribution provided by ARM's unique coaxial laser, the result is spatter and crack free welding, improved process consistency and shorter process times

A FORCE TO BE RECKONED WITH

The physical clamping of the LSK 06 process head also eliminates the need for costly and complex fixtures. It simply clamps parts together with a force that can range from 100 N to 1000 N to achieve the precise fit of parts needed for optimum welding results. This force is maintained and adjusted on the fly as needed as the process head moves along the weld joint. The result is better fits and reduced cycle times by eliminating the need to place parts in a complex fixture and then accurately adjust the fit.

PREMIUM LASER SYSTEM

By completely enclosing the weld area with the process head, you gain some other important practical advantages. Above all, this results in a Class I laser system. This, together with the fact that all process fumes are enclosed and exhausted, significantly increases the safety of the system.

The Class I laser system also means that you don't need a protective cabin around the welder. This saves production space and costs and improves accessibility for routine use and maintenance. It even makes it easier to retrofit the system to an existing production line.

The use of difficult-to-weld materials such as aluminium, high-strength steel and galvanised steel is becoming more common as car manufacturers strive to produce lighter, more efficient and safer cars. The thyssenkrupp LSK 06 process head and Coherent ARM fiber laser can work together to tackle the toughest of these welding challenges and achieve better results while simplifying the process. And Coherent's tests even show that the larger process window this welding system allows reduces the amount of laser power required. And it also saves money.

Watch the video to see this revolutionary laser system in action welding a high-strength aluminum casting to an automotive body.

Source: coherent.com