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University of Virginia - November 2010Lasers in the Automotive Industry 1
Laser Based Manufacturing in the Automotive Industry
TRUMPF, Inc.
David HavrillaManager – Product & Applications
University of Virginia - November 2010Lasers in the Automotive Industry 2
Agenda
Introduction
Trends in Laser Welding> Remote welding> Conventional laser welding> Brazing
Trends in Laser Cutting> Remote cutting> High speed cutting
Conclusion
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Powertrain
Motor
Torque ConvertersClutches
Gearbox
Driveshafts
Differentials
Roof
Brazing
Trunk lidB-Pillar
Tunnel
Hotforming
A-Pillar
Side memberDoor enforcementsBumper
Roof rail
Cross member
Side Panel
Doors
Rear CenterComponent
Seat Rests, Tracks, Recliners
Remote
Side member
IP Beam
Bumper
Battery
Laser applications - Automotive Industry
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Exhaust systems
Chassis/BIW
Suspension
ElectronicInteriorPassenger-safety
Engine
Powertrain
Components
Laser applications - Automotive Industry
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Manufacturing technology> application incubators> decreased investment cost> green synergy> throughput requirements
End product requirements> miniaturization> performance> weight reduction> cost reduction
Trend drivers
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Solid stateDiode pumpedExcellent beam qualityCompactHigh WPEFiber deliveredModular design> 1,000 sold
Disk Laser technology
TLS Disk - Cavity
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Principles of Programmable Focusing Optics
2D Scanner PFO 20PFO 33
3D ScannerPFO 3D
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appr
oach
Wel
ding
1
Posi
tioni
ng 1
Wel
ding
2
Posi
tiotn
ing
2
Wel
ding
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Posi
tioni
ng 3
Wel
ding
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Posi
tioni
ng 4
Wel
ding
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Posi
tioni
ng 5
Wel
ding
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Posi
tioni
ng 6
Wel
ding
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Posi
tioni
ng 7
Wel
ding
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Hom
e
Conventional Laser Welding
Process Start Process End
Appr
oach
Wel
ding
1
Wel
ding
2
Wel
ding
3
Wel
ding
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Wel
ding
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Wel
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Hom
eElimination of non-productive travelling timesMaximization of beam-on share
Laser Scanner Welding
Process Start Process End
unproductivetravelling times
Remote welding – increased productivity
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Customized weld patterns allow for optimum strength of the joints and increased design flexibility due to:
virtually any weld seam shapesvirtually any orientation of weld seamsuser defined distribution of weld seamsoptimum flow of forces
➩ reduced flange width
➩ material, weight andcost savings
Remote welding – increased flexibility
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Picture: Daimler
Picture: Daimler
Trunk Lid / Rear Panels Doors / Hang-on Parts Side Walls
B pillar
Remote welding in body-in-white
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Recliners Seat Frames
Seat PanelsSeat Tracks
Scanner welding: Seating
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Instrument Panel Carrier for automotive dashboards
Scanner welding: IP beams
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Laser remote weld - production
34 + shift code 1 robot, 1 scanner optic Welding time 13 s, ~9.5 s w/ 6 kW
Spot weld - production
34 + mech. shift code4 robots, 5 welding guns Welding time: 34.7s
Source: Volkswagen AG
Scanner welding: VW Passat hat rack
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Problem: Vaporization of Zn in between the panels causesweld spatter on the surface:
Poor weld seam quality
technical „0-gap“
Possible solutions to manage the problem:
Spacers integrated in:fixturepart design
Adapted melt pool dynamics(twin-spot focus)Adapted coating (Zn-Mg)Gap created by dimples
0.2 mm gap
Lap welding of Zn coated panels
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Constant dimple height (depending on zinc layer 0.1 - 0.2 mm (approximately)
Dimple height adjustable via laser parameter
Laser dimpling
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Step 1: Laser Dimpling
Step 2:Placement ofupper sheet
Step 3:Laser Scanner Welding
BEO or
PFO
PFOFeed Feed
Laser dimpling process
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5 laser dimples are covering the area of the later C-shaped weld seam
Spot pattern for laser dimpling
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welded parts:
Automotive Doors: Mercedes-Benz C and E class
welding station:
Source: Daimler AG
Production at Mercedes-Benz
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530 million remote welded seams by 2009 year end
Sedans and wagons welded on the same RobScan line
35% floor space reduction
40% cost reduction
Excellent part dimensional accuracy
Higher vehicle structural stiffness at lower weight
Remote welding success Mercedes-Benz
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Maximum viewing angle, window & door opening as customer benefit.
Consequence:Welding flange (< 6 mm).No conventional spot welding technology possible.
AUDI Q5 requirements to the door concept
Scanner welding: Audi Q5 door
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Solution:Remote laser welding with PFO33
45 laser stitches (25 – 40mm each)
Cycle time < 30 sec
2220
1917
151311 2118
1614
12
10
9
87
6
5
43 2 1
31
30
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26
24
32
29
27
25
23
40
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45
3938 37 36 35
3433
Scanner welding: Audi Q5 door
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Remote Welding of doors in high-volume productionAudi A4 / Q5
Scanner welding: Audi Q5 door
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Conventional Laser weld with a Trumpf TruDisk 4002 and welding head with filler wire.
Conventional welding: BMW aluminum door
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7 Series Sedan
• 15,4 meters of laser seam
7 Series Sedan Long
• 16,2 meters of laser seam
Conventional welding: BMW aluminum door
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Laser welding of Aluminum doors BMW 7series sedan in production
Conventional welding: BMW aluminum door
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Thyssen
Weight reductionLess materialLess transportation weight
Higher stabilityHigher dynamic strengthHigher crash performance
Reduced quantity of partsLess tooling costLess forming costLess logistics cost
Tailor welded blanks
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Longitudinal Transverse
Mat
eria
lW
all t
hick
ness
Tubes & Tailor welded tubes
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MotorGearbox Driveshafts
Differentials
Brakes / Hubs
Wheel
Torque Converters
Clutches
Damper Parts
Powertrain
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Step 1Overlap JointResistance weldingSealer15mm molding
Step 2Overlap Joint Laser stitch weldingSealer8mm molding
Step 3Edge Fillet Laser weldingNo Sealer8mm molding
Step 4Fillet JointLaser brazingNo SealerNo roof ditchNo molding
Laser brazing – Roof Joint
y- / z-Compensation
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American License Plate
European License Plate
Global Products customized to local markets with the help of laser technology.
Laser brazing – deck lid
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Melt ejection by melt pressure downwards
Remote cutting on the fly with PFO (no cutting nozzle!)
Good (burr free) cut quality, but oxidation layer
Up to 4 mm sheet thickness
Cutting speed < welding speed (approx. 50%)
One tool for remote welding & cutting
t = 1mm;, v = 8m/min; P = 6 kW t = 3mm; v = 3.5 m/min; P = 6 kWt = 2x 1 mm; v = ca. 3 m/min;
P = 4 kW; kerf welded together
pv
melt
Top side
Bottom side
Melt pressure cutting
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Cutting with disk laser
Material: 1.4301Power: 1000 WFocus: 100 µm Thickness: 0.8 mm Speed: 15 m/minGas: N2Pressure: 12 bar
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TruF
low
(CO
2)Tr
uDis
k (F
KL)
TruLaser Cell 7000 series
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Maximum production speed for mild steel and stainless steel
0
5
10
15
20
25
30
35
1,0 mm 1,5 mm 1,8 mm 2,0 mm
TruDisk 2001
TruFlow 5000
TruDisk 3001
Production speed* *
*3D processing speed depends on part geometry
Faster cutting with SSL in thin sheets
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Cutting of hot stamped material
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Innovative technologies can be trend drivers
The beam quality & power of TRUMPF’s disk laser has enabled several recent applications employed by automotive:
Remote weldingRemote welding of zinc coated steels w/ dimplingHigh speed robotic cuttingRemote cuttingHigh speed 3D cutting
The automotive industry has a incorporated laser processing in virtually every sub-system of the automobile
Ongoing laser innovations will continue to enable new trends in materials processing and will continue to make laser implementation more and more affordable
Conclusion