Adoption of laser welding starts with prototyping

 Conventional welding methods, like spot and arc welding, reached their mature state a long time ago. Over the last decade, laser welding has been well on its way to becoming the new star on the horizon. As laser welding starts where traditional techniques end, its use can really set you apart from the rest.

Laser welding is a fast and clean process and it has a broad scope of applications. High welding speeds and short weld-to-weld times are key to the enormously high output laser welding can generate. Furthermore, the weld made by a laser can be a cosmetic one; in that case no post-process treatments are necessary.

Adoption of laser welding
The adoption of laser welding within your own company is not easy. Different opinions and ideas about the benefits of the new and existing methods, the parameters of the process and, of course, compatibility with the current production process are the main reasons for discussion when thinking of adopting laser welding as the new standard. To get a better understanding of the tremendous advantages laser welding can offer, a lot of companies start by testing this new technology in the AWL laser-test facility. 

The advantages of laser welding
The market is changing and so are your customers’ demands. AWL sees three major drivers for moving into laser welding: cost savings, uniform quality and product design.

Cost savings
When using laser welding on products with high production numbers, long welding lengths and/or many subparts, the cost savings are, in comparison with traditional welding methods, impressive. These savings are primarily created by the high welding speeds, the quick weld-to-weld times, the fast change-over times and the excellent possibility for automated loading of the parts. This last reason can also result in the use of fewer machines and operators. Some indirect cost savings are realized by the small footprint of the machine, the decrease in maintenance and the absence of post-process treatments.

Uniform quality
The unique product design needed for successful laser welding, combined with accurate fixture clamping, makes uniform quality possible. The parameters for laser welding are also easier to determine than with arc welding, for example, resulting in a reduction of the scrap rate.

Product design
The high welding speed and the low heat input enable long continuous welding lengths, due to the fact that the reach ability and the weld accessibility are much easier than with other welding methods. It’s now possible to develop new product designs, gaining maximum results in weight reduction of the (end) product and the reduction of waste materials. 

Start with prototyping
All roads lead to Rome, but at some point they all have to cross the prototyping junction. With welding, sometimes the reason for prototyping is just for gaining information about the possible cycle times and the quality. However, in most cases it is for the validation of the welding process. At the AWL test facility we define the weld parameters based on the following characteristics:

1. The right heat-affected spot
2. Necessary weld depth
3. Welding length and width
4. Optimal welding speed
5. Ideal welding patterns

The most common reasons for doing a weld-process validation are:
1. New product development
2. Change from conventional to laser welding
3. Optimizing your ROI
4. Improving your weld process

As laser welding can be used for both creating cosmetic welds and creating high output by key hole welding, this technique is interesting for a large variety of markets in the general sheet metal industry and the automotive industry. Some common products which qualify for laser welding are: design radiators, office furniture, household appliances like ovens and sinks, car components like: car seats, sill beams and car body parts.

AWL prototyping service
AWL offers a unique service that enables you to consider the welding properties of a product from the early stages of product development right up to the manufacture of the product.

By engaging in a weld-process validation you are ensured of an optimal welding process and a high weld quality during the production in your plants. Our experts can assist you in obtaining vital information regarding the weld tests and provide their expertise concerning the validation test and all other relevant information.

Interested?
Would you like to know more about AWL’s laser welding-process validation? If so, please contact Ralf Daggers, Marketing Manager AWL. Phone 31 (0)341 411 811 or send an e-mail to: r.daggers@awl.nl