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VERTICAL-DOWN HYBRID WELDING IN SHIP BUILDING
- THE NEXT INNOVATION STEP -
Univ.-Prof. Dr.-Ing. U. ReisgenDr.-Ing. S. OlschokDipl.-Ing. C. Turner
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History Hybrid Welding (in Shipbuilding)
1979 First mention in literatureSteen, W.M., Eboo, M.: „Arc augmented Laser beam welding”, Metal Construction, volume 11, issue 7, 1979
1994 – 1999 Work at ISF with CO2 lasers with different laser power
Till 1999 development of possible fileds of application for shipbuilding (butt joint, fillet joint)
Certification of hybrid welding by DNV for plates till 12 mm thickness
2000 Installation and bringing into service of first panel line world wide (20 m)
2000 – 2012 Development with solid state lasers
2009 First panel line with 30 m width with solid state laser
2011 Formulation of three ISO standards for hybrid welding
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New Standards for Hybrid WeldingComing Soon
ISO-TC44-SC10-WG9 „HYBRID WELDING“Secretariat: Torsten Diether, Deutsches Institut für Normung e.V. (DIN)Convenor: Simon Olschok, RWTH Aachen University (ISF)
ISO/DIS 12932: Welding — Laser-arc hybrid welding of steels, nickel and nickel alloys — Quality levels for imperfections
ISO/DIS 15609-6: Specification and qualification of welding procedures for metallic materials — Welding procedure specification — Part 6: Laser-arc hybrid welding
ISO/DIS 15614-14: Specification and qualification of welding procedures for metallic materials — Welding procedure test —Part 14: Laser beam arc hybrid welding
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Hybrid - Advantages
GMA Laser- cheap, conventional power source- directed influence of the
thermal cycle- Addition of filler material
> good gap bridging ability> metallurgical influence of
the grain structure
- high welding speed
- high welding in depth
- deep small weld seam
Hybrid process
- stabilisation of the process by interaction between the single processes- increase of the thermal efficiency- extended welding possibilities
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Source: FORCE Institute, Denmark
1. Forming Panels
2. Adding longitudinal stiffeners (bulb flats)
3. Adding transversal stiffeners (bulb flats)
Starting Situation 1995First Three Welds of a Ship
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CO2-Laser (TLF12000 turbo)Material: AH36; t = 12 mmEdge preparation: PlasmacutFiller wire: G3Si1; dFW = 1,2 mm
PL
vw
VFW
= 12 kW= 2 m/min= 12 m/min
Pictures: MEYER WERFT, Papenburg
CO2-Laser-GMA Hybrid Welding – Butt WeldApplication at a Shipyard (10 m length)
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CO2-Laser-GMA Hybrid Welding – Fillet WeldApplication at a Shipyard (10 m length)
>
Detail-scale 5:1
z
xy
Welding parameters:
ttPvv
Web
Flange
L
W
FW
7 mm6 mm6 kW1.25 m/min12.5 m/min
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CO2-Laser-GMA Hybrid WeldingPanel Production
Pictures: MEYER WERFT, Papenburg
900 km Weld Seam Length
450 km Hybrid Welds
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200 mm
Fillet Weld PB
Fillet Weld PG
Long
itudi
nal S
tiffe
ners
Tran
sver
sal S
tiffe
ners
Pan
el
Solid State Laser – Next GenerationWelding Task
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Nominal output power 10.0 kW(at the workpiece)Wavelength: 1070 nmFibre optics core: ø 200 µmBPP: < 12 mm x mrad Foot Print: 800 x 1.460 mmHeight: 1.500 mm Cooling capacity: 31 kWWPE (wt cooler ): > 27%
KuKa KR 60 Jet 60 kGCloos Robot Control Rotrol IICloos GMA Machine QuintoCloos Hybrid Head
Fiber Laser IPG Scanner Mirror ILV KuKa Robot, Cloos Control
Welding Equipment
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9 mm Web6 mm BeltvW = 1,5 m/minGMA Leading
6 mm Web6 mm BeltvW = 2,2 m/minGMA Leading
9 mm Web6 mm BeltvW = 1,5 m/minGMA Trailing
Fillet Weld PB
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For welding as far in the corner as possible(floor plate), the GMA torch is set in neutralposition, the laser beam irradiates at anangle of 13° from the top in leading direction.Biggest problem: molten pool is running ahead.Through adaptation of the GMA processduring welding operation, the molten poolis retained.
9 mm Web6 mm BeltvW = 1,2 m/minGMA Leading
6 mm Web6 mm BeltvW = 2,2 m/minGMA Leading
9 mm Web8 mm BeltvW = 1,2 m/minGMA LeadingAdjustment of tP
Fillet Weld PG (falling down)
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Without Gap7 mm WebvW = 1,5 m/minPL = 8 kWvf = 11,5 m/min
Gap 0,5 mm7 mm WebvW = 1,5 m/minPL = 8 kWvf = 13,0 m/min
Gap 1 mm7 mm WebvW = 1,5 m/minPL = 8 kWvf = 15,0 m/min
Gap Bridging Ability with Scanner Mirror
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side control hide control
GMA Sensoring- Problem -
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Synchronous Displacement of Robot and Scan Mirror
Hybrid Sensoring- Solution -
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Current
Mirror/Rob
Current Mean
Current
Mirror/Rob
Current Mean
Current
Mirror/Rob
Current Mean
Time [s]Time [s]Time [s]
Cu
rren
t [A
]
Cu
rren
t [A
]
Cu
rren
t [A
]
Current-/Mirror (Rob) Signalin Case of Position Misalignment – Part 1
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Position Misalignment, Not Readjusted
Position Misalignment, Readjusted
Time [s]
Cur
rent
[A]
CurrentMirror/RobCurrent Mean
Time [s]
Cur
rent
[A]
CurrentMirror/RobCurrent Mean
Current-/Mirror (Rob) Signalin Case of Position Misalignment – Part 2
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Video: MEYER WERFT, Papenburg
Testing on Shipyard
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Testing on Shipyard
Video: MEYER WERFT, Papenburg
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Welding Task Third Generation- In Future Possible? -
Wall Thickness: 4 – 12 mmSeam length: up to 5 mType of weld: Fillet- and Buttm WeldJoint gap: 0 – 3 mmClamping: Teckwelding
GMA (3Gd):Lack of PenetrationIncomplete Fusion
GMA (3Gu):Thermal Load
Welding Task
Panel
Supporting Beam Structures
Holland Profiles
PAGE 23www.wir-fuegen-alles.de© RWTH Aachen University
„FaSek“ Goal and Benefit„Fully Mechanized, Sensor Based Vertical Down Welding for the Section Fabrication in the Shipbuilding Industry“
2 process variants for vertical down weldingBoth sided, simultanous GMA weldingLaser-GMA Hybrid Welding with GMA process opposite
High welding speed compared to the commonly used vertical uphill welding
High degree of mechanisation
Welding in one molten pool -> reduction of distortion
Automatic seam tracing and measurement of the joint gap
Automatic selection of the welding parameters dependent on the joint gap
PAGE 24www.wir-fuegen-alles.de© RWTH Aachen University
Concept Laser-GMA Hybrid
GMAfront
GMAback
Laser Beam
x-, y-, z-Adjustment
MSG Torch
Laser Optics withScanning Mirror Workpiece ILV Scanning Mirror
Schematic Drawing
200 mm
PAGE 25www.wir-fuegen-alles.de© RWTH Aachen University
Effect – Integration of the laser welding process
1mm
1mm
Base Material: Grade A (5 mm)
Consumable: G4Si1 (Ø 1,2 mm)
No joint gap
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No Joint Gap; Plasma Cut Edges
vS
[m/min]SG M21[l/min]
vWire
[m/min]fP
[Hz]IG
[A]IP
[A]tP
[ms]PL
[kW]AS
[%]fS
[Hz]xP
[mm]
front
1,5
15 3,5 96 39 390 1,9 6 15 100 20
back 15 5,0 138 39 390 1,9 - - - 0
1mm
Base Material: Grade A (5 mm)
Consumable: G4Si1 (Ø 1,2 mm)
PAGE 27www.wir-fuegen-alles.de© RWTH Aachen University
2 mm Joint Gap; Plasma Cut Edges
vS
[m/min]SG M21[l/min]
vWire
[m/min]fP
[Hz]IG
[A]IP
[A]tP
[ms]PL
[kW]AS
[%]fS
[Hz]xP
[mm]
front
1,5
15 6,0 181 39 390 1,9 6 25 100 20
back 15 6,0 181 39 390 1,9 - - - 0
1mm
Base Material: Grade A (5 mm)
Consumable: G4Si1 (Ø 1,2 mm)
PAGE 28www.wir-fuegen-alles.de© RWTH Aachen University
No Joint Gap; Plasma Cut Edges
vS
[m/min]SG M21[l/min]
vWire
[m/min]fP
[Hz]IG
[A]IP
[A]tP
[ms]PL
[kW]AS
[%]fS
[Hz]xP
[mm]
front
0,9
15 2,0 42 39 390 1,9 6 10 100 20
back 15 4,0 84 39 390 1,9 - - - 0
1mm
Base Material: Grade A (7 mm)
Consumable: G4Si1 (Ø 1,2 mm)
PAGE 29www.wir-fuegen-alles.de© RWTH Aachen University
2 mm Joint Gap; Plasma Cut Edges
vS
[m/min]SG M21[l/min]
vWire
[m/min]fP
[Hz]IG
[A]IP
[A]tP
[ms]PL
[kW]AS
[%]fS
[Hz]xP
[mm]
front
1,2
15 5,5 116 39 390 1,9 6 20 100 20
back 15 5,5 116 39 390 1,9 - - - 0
1mm
Base Material: Grade A (7 mm)
Consumable: G4Si1 (Ø 1,2 mm)
PAGE 30www.wir-fuegen-alles.de© RWTH Aachen University
Minimal Distortion
Wall Thickness 7 mm
No Joint Gap
PAGE 31www.wir-fuegen-alles.de© RWTH Aachen University
Fillet Weld; No Joint Gap; Plasma Cut Edges
vS
[m/min]SG M21[l/min]
vD
[m/min]fP
[Hz]IG
[A]IP
[A]tP
[ms]PL
[kW]AS
[%]fS
[Hz]xP
[mm]
vorne
1,0
15 3,5 106 39 390 1,9 6 5 100 20
hinten 15 4,5 136 39 390 1,9 - - - 0
Base Material: Grade A (5 mm)
Consumable: G4Si1 (Ø 1,2 mm)
PAGE 32www.wir-fuegen-alles.de© RWTH Aachen University
Outlook – Sensor Integration
Fully mechanized, sensor based vertical down welding for the section fabrication
1 LPF-camera detects the vertical andlateral postion of the joint
2 Axis to adjust the focal position
3 Axis to adjust the lateral position
4 Laser-Hybrid Welding Head YH50
Quelle: Precitec Group
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Outlook
Implementation of a high power solid state laser and different weldingpower sources
Usage of metal cored wire
Further welding trials to determine parameters and to increase therobustness of the processes using DoE
Field Trial Shipyard -> Comparison of „FaSek“ with the conventionallyused processes
Preparation of concepts for the workplace safety based on currentregulations, state of scientific research and firing test in the laboratory
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Das IGF-Vorhaben 16865 N der Forschungsvereinigung Center ofMaritime Technologies e.V. (CMT), Bramfelder Straße 164, 22305 Hamburg wurde über die AiF e.V. im Rahmen des Programms zur Förderung der industriellen Gemeinschaftsforschung und -entwicklung (IGF) vom Bundesministerium für Wirtschaft und Technologie aufgrund eines Beschlusses des deutschen Bundestages gefördert.
Vielen Dank für ihr Aufmerksamkeit!