Bifocal hybrid laser welding - Fillet welds of aluminium

Kronthaler, M.R.; Spengler, S.; Zaeh, Michael F.

doi:10.2351/1.5062299

International Congress on Applications of Lasers &Amp; Electro-Optics 2011

DOI: 10.2351/1.5062299

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Bifocal hybrid laser welding - Fillet welds of aluminium

M.R. Kronthaler¹,

S. Spengler²,

Michael F. Zaeh³

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Cited by 2 publications

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“…Another commonly used aluminum alloy in the automotive industry is EN AW 6060, especially for extrusion profiles. Studies conducted by Kronthaler et al [25] have shown that although it is challenging, it is possible to weld parts made of this alloy without leading to bead defects, such as pores, using laser technologies. With the idea of producing hybrid structures, Nahmany et al [26] and Shribman et al [27] studied the properties of a joint between additively manufactured AlSi10Mg parts and EN AW 6060.…”

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confidence: 99%

Studies on the Use of Laser Directed Energy Deposition for the Additive Manufacturing of Lightweight Parts

Zapata,

Bernauer,

Celba

et al. 2023

Lasers Manuf. Mater. Process.

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Despite the numerous benefits of battery electric vehicles, their relatively short maximal range compared to internal combustion engine vehicles limits their attractiveness to the consumer. Implementing lightweight structures is one solution to reduce the mass of the vehicle, which in turn lowers the energy consumption and thus extends the maximal range. Additive Manufacturing processes, such as the Laser Directed Energy Deposition (DED-LB), offer great potential for the resource-efficient manufacturing of lightweight components because they allow producing near-net-shaped parts of variable sizes and geometries. Therefore, in this study, DED-LB was assessed concerning its use for the rapid manufacturing or modification of lightweight parts. The additive process was performed on EN AW 6060 aluminum extrusion profiles commonly found in battery electric vehicles and an AlSi10Mg wire was used as feedstock. The investigations included temperature and microhardness measurements. Furthermore, the effect of the deposition rate on the geometric quality of the part was investigated. The results indicate that DED-LB can be performed on thin-walled structures to produce defect-free components. Furthermore, the findings reveal a trade-off between a fast build-up and the surface quality of the parts. Notably, it was observed that the different deposition rates had no impact on the hardness of the produced parts. Further studies on heat management are needed to optimize the process for producing lightweight parts with improved mechanical properties.

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mentioning

confidence: 99%

Studies on the Use of Laser Directed Energy Deposition for the Additive Manufacturing of Lightweight Parts

Zapata,

Bernauer,

Celba

et al. 2023

Lasers Manuf. Mater. Process.

View full text Add to dashboard Cite

show abstract

Numerical simulation of laser beam welding using an adapted intensity distribution

Liebl

Stadter

Ganser

et al. 2017

Journal of Laser Applications

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The automotive industry has a high demand for lightweight solutions for car body components to reduce the carbon dioxide emissions and to increase the range of electric cars. In this context, the joining methods play a significant role in enabling the lightweight construction. Specifically, the use of aluminum alloys for structural components or body panels poses a major challenge for joining technologies. These parts are often made from aluminum alloys AA6xxx, which are very susceptible to hot cracks during fusion welding. As laser beam welding is increasingly used for welding car body components, special techniques are required to avoid hot cracks in weld seams. Besides the use of filler wire, laser welding using an adapted intensity distribution is an innovative approach to get a defect-free weld seam coupled with a high surface quality. Due to the lack of flexible beam shaping optics for investigations on high power material processing using an adapted intensity distribution, a simulation method for this technique is presented. The impact of the adapted intensity on the process characteristics, e.g., the temperature field, the temperature gradients, or the molten pool geometry, can be determined by using this numerical model. The heat input by the adapted intensity distribution is composed of a stationary capillary geometry for the deep penetration welding process and an additional surface heat source. An experimental analysis was carried out to calibrate the simulation model. Using design of experiments, the weld seam geometry depending on the laser parameters can be predicted. Finally, the impact of an adapted intensity distribution on the geometry of the molten pool and the temperature field is shown.

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Bifocal hybrid laser welding - Fillet welds of aluminium

Cited by 2 publications

References 4 publications

Studies on the Use of Laser Directed Energy Deposition for the Additive Manufacturing of Lightweight Parts

Studies on the Use of Laser Directed Energy Deposition for the Additive Manufacturing of Lightweight Parts

Numerical simulation of laser beam welding using an adapted intensity distribution

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