Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Welding thick metal sheets quickly

08.07.2014

It is possible to weld thick pipelines and metal sheets made of aluminum alloys or steel at high speeds of 6 m/min. respectively 1.5 m/min. with a hybrid welding process developed at the Laser Zentrum Hannover e.V. (LZH). In the future, the laser-based process can be used to shorten processing times, and thus significantly reduce the processing costs of liquid gas tanks and pipelines

cientists of the Joining and Cutting of Metals Group at the LZH have developed a process that can be used to make single-sided, zero-defect welds for aluminum sheets up to a thickness of 12 mm. To do so, they have combined a laser beam with two gas metal arc welding (GMAW) torches. A scanner mirror can be used to oscillate the laser beam lengthwise or crosswise to the feed direction.


The laser-hybrid welding process combines the advantages of laser beam and GMAW welding.

Photo: LZH


In the future, the hybrid welding process developed at the LZH can reduce manufacturing costs for pipelines.

Photo: LZH

The joining process can reach feed speeds of 5 to 6 m/min, and gaps of up to 0.5 mm and edge misalignment of up to 2 mm can be bridged. The engineers have also been able to weld steel sheets with a thickness up to 23 mm at a speed of 1.5 m/mm for single layer welds.

Perfect welding seam
The innovative process is not only extremely fast: In comparison to conventional methods with multiple layer gas metal arc welding processes, the seam geometry is very narrow and filler material consumption is considerably lower. At the same time, the quality of the weld seam is very good: Welds for 12 mm thick metal sheets made of the aluminum alloy EN AW‑6082‑T6 could reach the highest evaluation group B for welding seam impurities according to DIN EN ISO 12932 and DIN EN ISO 13919‑2.

In comparison to conventional processes, a further advantage of the combined processes is reduced thermal input, and thus reduced component distortion. A solid-state disk laser with an output power of 16 kW is used for the hybrid welding process.

Twelve times faster than gas metal arc welding (GMAW)
In order to join steel sheets with a thickness of 30 mm, conventional gas metal arc welding requires a tack weld and around six filler layers. The hybrid process only needs two to three filler layers. The first layer is made using the laser-GMAW hybrid process. It also replaces the tack welds and the first four layers of the conventional gas metal arc weld. Subsequently the sheets are subject to one or two backing runs with the GMAW process. Thus, the hybrid welding process can be used to weld a component with a length of 1.5 meters in one minute, whereas conventional processes need twelve minutes.

Combining advantages and compensating disadvantages
The main advantages of hybrid welding are the synergy effects between the arc of the GMAW process and the laser beam. In the combined process, the laser is coupled into the melt pool of the filler material of the GMAW process: The filler material is melted by the arc and in the molten state it absorbs the energy of the laser beam and transfers the energy to the weld area between the sheets. The laser beam and the arc process stabilize each other, making relatively high welding speeds for arc processes possible and for high gap widths.

The joint project „HYBRILAS: Welding of thick metal sheets using brilliant laser beam sources“ was part of the „MABRILAS initiative: Material processing with brilliant laser beam sources” and was financially supported by the German Federal Ministry of Education and Research (BMBF), and supported by the Association of German Engineers (VDI-TZ).

Weitere Informationen:

http://www.lzh.de/en/publications/pressreleases/2014/welding-thick-metal-sheets-... Additional figure and video

Lena Bennefeld | Laser Zentrum Hannover e.V.

Further reports about: GMAW ISO Laser Metals Welding conventional effects geometry hybrid process processes

More articles from Process Engineering:

nachricht Gluing with the Laser
30.06.2015 | Laser Zentrum Hannover e.V.

nachricht Innovative Modular Process Makes Plastic Film Coating Highly Efficient
09.06.2015 | 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: Increasingly severe disturbances weaken world's temperate forests

Longer, more severe, and hotter droughts and a myriad of other threats, including diseases and more extensive and severe wildfires, are threatening to transform some of the world's temperate forests, a new study published in Science has found. Without informed management, some forests could convert to shrublands or grasslands within the coming decades.

"While we have been trying to manage for resilience of 20th century conditions, we realize now that we must prepare for transformations and attempt to ease...

Im Focus: OU astrophysicist and collaborators find supermassive black holes in quasar nearest Earth

A University of Oklahoma astrophysicist and his Chinese collaborator have found two supermassive black holes in Markarian 231, the nearest quasar to Earth, using observations from NASA's Hubble Space Telescope.

The discovery of two supermassive black holes--one larger one and a second, smaller one--are evidence of a binary black hole and suggests that supermassive...

Im Focus: What would a tsunami in the Mediterranean look like?

A team of European researchers have developed a model to simulate the impact of tsunamis generated by earthquakes and applied it to the Eastern Mediterranean. The results show how tsunami waves could hit and inundate coastal areas in southern Italy and Greece. The study is published today (27 August) in Ocean Science, an open access journal of the European Geosciences Union (EGU).

Though not as frequent as in the Pacific and Indian oceans, tsunamis also occur in the Mediterranean, mainly due to earthquakes generated when the African...

Im Focus: Self-healing landscape: landslides after earthquake

In mountainous regions earthquakes often cause strong landslides, which can be exacerbated by heavy rain. However, after an initial increase, the frequency of these mass wasting events, often enormous and dangerous, declines, in fact independently of meteorological events and aftershocks.

These new findings are presented by a German-Franco-Japanese team of geoscientists in the current issue of the journal Geology, under the lead of the GFZ...

Im Focus: FIC Proteins Send Bacteria Into Hibernation

Bacteria do not cease to amaze us with their survival strategies. A research team from the University of Basel's Biozentrum has now discovered how bacteria enter a sleep mode using a so-called FIC toxin. In the current issue of “Cell Reports”, the scientists describe the mechanism of action and also explain why their discovery provides new insights into the evolution of pathogens.

For many poisons there are antidotes which neutralize their toxic effect. Toxin-antitoxin systems in bacteria work in a similar manner: As long as a cell...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

Networking conference in Heidelberg for outstanding mathematicians and computer scientists

20.08.2015 | Event News

Scientists meet in Münster for the world’s largest Chitin und Chitosan Conference

20.08.2015 | Event News

Large agribusiness management strategies

19.08.2015 | Event News

 
Latest News

Time travel into the past of marginal seas: IOW expedition explores Canadian coastal waters

31.08.2015 | Earth Sciences

Using DNA origami to build nanodevices of the future

31.08.2015 | Health and Medicine

10. Workshop Magnetlagertechnik Zittau-Chemnitz

31.08.2015 | Seminars Workshops

VideoLinks
B2B-VideoLinks
More VideoLinks >>>