Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Quick and safe laser joining of steel-aluminum mixed connections

05.06.2018

For the automotive industry of the future, load-adapted and lightweight components made from steel-aluminum mixed joints are required. Within the LaserLeichter project, the Laser Zentrum Hannover e.V. (LZH) has developed a laser welding process for the quick and safe joining of three-dimensional structures made of steel and aluminum.

Robust and lightweight steel-aluminum composite components are ideal for reducing vehicle weight and can help reducing pollutant emissions. In order to optimize the joining of mixed compounds for series production in the automotive industry, the scientists at the LZH have developed processes for joining two- and three-sheet metal joints with high welding speeds of up to seven meters per minute.


Quick and safe joining of steel and aluminum using remote laser welding

Photo: LZH


Remote laser welding of steel-aluminum mixed joints.

Photo: LZH

The basis for the remote laser beam welding process is a 3D scanner optic, newly developed by the TRUMPF Laser GmbH. With this, complex three-dimensional seam geometries are possible even with large structures. Thus, the process is particularly interesting for car body construction and can replace complex robot movements.

Stable joint in the event of a crash

The weld joint achieves a shear tensile strength of approximately 67 percent of the aluminum alloy. Due to the parallel arrangement of three welds, this can even be increased to about 95 percent. The process was developed for battery cases of electric cars, seat structures and car body parts. The Volkswagen AG (VW) has quasi-statically and dynamically tested the validation components for car body applications. The joined mixed compounds have an advantageous crash behavior, since the joining partners remain safely connected.

Use of the laser minimizes intermetallic phases

One of the challenges in welding steel and aluminum is to avoid hard and brittle intermetallic phases in the welding seam, which cannot be completely avoided. During laser welding, a low amount of heat is introduced into the workpiece in a well targeted manner. Therefore, these phases are formed to a reduced extent and the dissimilar materials are melted as defined. Thus, it is possible to control the mixing of the joint.

About LaserLeichter

In the joint project "Development of Laser-Based Joining Technologies for Similar Lightweight Constructions" (LaserLeichter) the partners LZH, VW, inpro Innovationsgesellschaft für fortgeschrittene Produktionssysteme in der Fahrzeugindustrie mbH, Precitec GmbH & Co. KG, MATFEM Partnerschaft Dr. Gese & Oberhofer, LUNOVU GmbH, Scherdel Marienberg GmbH, InfraTec GmbH, Brandenburgische Technische Universität Cottbus-Senftenberg and the Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS worked together under the coordination of the Robert Bosch GmbH.

Associated partners were TRUMPF Laser GmbH, ASTOR Schneidwerkzeuge GmbH, ThyssenKrupp Steel Europe AG, Bond-Laminates GmbH and Hydro Extrusion Offenburg GmbH (formerly SAPA Aluminium Profile GmbH). LaserLeichter was funded by the Federal Ministry of Education and Research (BMBF) within the scope of the funding initiative “Photonic Processes and Tools for Resource-Efficient Lightweight Construction“.The consortium was coordinated by the LZH.

Weitere Informationen:

https://www.lzh.de/en/publications/pressreleases/2018/quick-and-safe-laser-joini... Press release with video

Lena Bennefeld | Laser Zentrum Hannover e.V.

More articles from Process Engineering:

nachricht Diamond watch components
18.06.2018 | Schweizerischer Nationalfonds SNF

nachricht Coating free-form surfaces on large optical components
05.06.2018 | Fraunhofer-Institut für Organische Elektronik, Elektronenstrahl- und Plasmatechnik FEP

All articles from Process Engineering >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Overdosing on Calcium

Nano crystals impact stem cell fate during bone formation

Scientists from the University of Freiburg and the University of Basel identified a master regulator for bone regeneration. Prasad Shastri, Professor of...

Im Focus: AchemAsia 2019 will take place in Shanghai

Moving into its fourth decade, AchemAsia is setting out for new horizons: The International Expo and Innovation Forum for Sustainable Chemical Production will take place from 21-23 May 2019 in Shanghai, China. With an updated event profile, the eleventh edition focusses on topics that are especially relevant for the Chinese process industry, putting a strong emphasis on sustainability and innovation.

Founded in 1989 as a spin-off of ACHEMA to cater to the needs of China’s then developing industry, AchemAsia has since grown into a platform where the latest...

Im Focus: First real-time test of Li-Fi utilization for the industrial Internet of Things

The BMBF-funded OWICELLS project was successfully completed with a final presentation at the BMW plant in Munich. The presentation demonstrated a Li-Fi communication with a mobile robot, while the robot carried out usual production processes (welding, moving and testing parts) in a 5x5m² production cell. The robust, optical wireless transmission is based on spatial diversity; in other words, data is sent and received simultaneously by several LEDs and several photodiodes. The system can transmit data at more than 100 Mbit/s and five milliseconds latency.

Modern production technologies in the automobile industry must become more flexible in order to fulfil individual customer requirements.

Im Focus: Sharp images with flexible fibers

An international team of scientists has discovered a new way to transfer image information through multimodal fibers with almost no distortion - even if the fiber is bent. The results of the study, to which scientist from the Leibniz-Institute of Photonic Technology Jena (Leibniz IPHT) contributed, were published on 6thJune in the highly-cited journal Physical Review Letters.

Endoscopes allow doctors to see into a patient’s body like through a keyhole. Typically, the images are transmitted via a bundle of several hundreds of optical...

Im Focus: Photoexcited graphene puzzle solved

A boost for graphene-based light detectors

Light detection and control lies at the heart of many modern device applications, such as smartphone cameras. Using graphene as a light-sensitive material for...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

VideoLinks
Industry & Economy
Event News

Munich conference on asteroid detection, tracking and defense

13.06.2018 | Event News

2nd International Baltic Earth Conference in Denmark: “The Baltic Sea region in Transition”

08.06.2018 | Event News

ISEKI_Food 2018: Conference with Holistic View of Food Production

05.06.2018 | Event News

 
Latest News

Carbon nanotube optics provide optical-based quantum cryptography and quantum computing

19.06.2018 | Physics and Astronomy

How to track and trace a protein: Nanosensors monitor intracellular deliveries

19.06.2018 | Life Sciences

New material for splitting water

19.06.2018 | Physics and Astronomy

VideoLinks
Science & Research
Overview of more VideoLinks >>>