FINLAND. Lappeenranta. Helsinki. St.Petersburg. Oslo. Tallinn. Stockholm. Moscow. London Berlin

Transcription

1 FINLAND Oslo Stockholm Helsinki Lappeenranta St.Petersburg Tallinn Moscow London Berlin

2 Lappeenranta Laser Processing Centre Partners Lappeenranta University of Technology, Laser Processing Laboratory, VTT, Laser Processing Team Total about 30 persons in education, research and development of Laser processing 14 laser processing systems (from 1986)

3 Activities Metal processing - welding, cutting and surface treatments International networks Fine and micro processing -welding, cutting, drilling, ablation, engraving Paper processing -cutting of paper, cardboard, etc. Plastic processing -welding, cutting, tool and mold technology

4 Short overview of laser applications in automotive manufacturing Prof. Veli Kujanpää VTT Manufacturing Technology and Lappeenranta University of Technology, Lappeenranta, Finland Pro-Factory Brokerage meeting Gothenburg,

5 Introduction Laser processing is applied in automotive industry in many ways car body manufacturing power transmission and engines accessorial components polymer components electronics etc.

6 Laser Materials Processing Systems World Market by User Industry, 2004 Automotive industry Elektromechanical industry Electronics, Semicondr., Displays Other metal processing Other non-metal processing Job shops OPTECH CONSULTING - MAY Millionen Euro OPTECH CONSULTING

7 Car body manufacturing

8 Current Laser Technologies in the Automotive Industry Laser Hybrid Welding Laser and Remote Laser Welding Laser Brazing

9 The Evolution of Audi AG Aluminium Spaceframes AluminiumZentrum, Neckarsulm Audi A8 (D2); SOP 1994 Audi A2 (W10); SOP 1999 Audi A8 (D3); SOP 2002 Self-piercing rivets 1,100 Self-piercing rivets 1,800 Self-piercing rivets 2,400 MIG welding 70 m MIG welding 20 m MIG welding 64 m Resistance spot welds 500 Laser welding 30 m Laser welding 20 m Clinch joining spots 180 Hybrid welding 5 m Johnny Larsson, NOLAMP2003

10 Laser Hybrid Welding of the Audi A8 Roof Rail Welding Parameters: Laser power 3.8 kw Welding speed 3.6 m/min Wire feed rate 4.5 m/min Johnny Larsson, NOLAMP2003

11 Laser Hybrid Welding of Aluminium Side Doors VW Phaeton, Werk Wolfsburg MIG welding 7 seams 380mm Laser welding 11 seams 1030mm Laser hybrid welding 48 seams 3570mm Total weld length / door 4980mm Johnny Larsson, NOLAMP2003

12 Remote Laser Welding of a Swingdoor Chrysler Jeep Liberty, Sterling Heights Stamping Plant Johnny Larsson, NOLAMP2003

13 Laser Brazing of Split Trunklid Skin Panel VW Bora, VW Passat, Audi A4, Skoda Octavia etc.

14 20+ Meters of Laser Brazing and Laser Welding VW Toureg Laser Brazing Roof/Bodyside: 4m Laser Brazing Tailgate: 1.5m

15 Engine Compartment Panel BMW 3-series Compact Version, Munich Engine compartment panel ZStE 220BH E75/75, t = 0.7 mm Engine compartment panel, reinforcement ZStE 260BH E/75/75, t = 1.0 mm Cycle time RSW Cycle time LBW Cycle time RLW 40 seconds 30 seconds 8 seconds

16 Edge Roof Laser Welding of the Volvo XC90 Gothenburg Torslanda Plant + Improved weld quality + Easier quality check + Improved sealer quality + Increased styling possibilities + Increased weld speed - Equipment cost - Equipment complexity Johnny Larsson, NOLAMP 2003

17 Automotive Laser Development Trends and Future Outlook CO 2 with gantry CO 2 with robot Nd:YAG with robot Johnny Larsson, NOLAMP 2003

18 Hydroformed structures Source: Fraunhofer ILT

19 Cutting with cw Nd:YAG lasers Cutting of holes and edges with cw Nd:YAGlaser and robot Source: Trumpf

20 3D cutting with robot Source: Rofin-Sinar

21 Power transmission and engines

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23 Laser cladding

24 Laser Induction Welding of Torque Convertor Gear Plates DaimlerChrysler, Hedelfingen No cold cracks in WZ, HAZ or at the welding end position Reduced distorsion (compared to GTAW) Limited hardness drop

25 Drive shaft Central gear shaft

26 Welding of valve lifter Source: Rofin-Sinar

27 Laser drilling Tip of an injection nozzle and a metallographic section of hole at 60 degrees to the surface

28 Accessorial parts

29 In laser hardening, the laser beam heats the surface above the austenitizing temperature for a short time, but does not cause melting The heat conductivity ensures fast cooling, so that the material transfers to the harder martensitic structure Hardening

30 Seam welding of a pressure gauge Material: Stainless Steel

31 Welding of an ABS-sensor Material: Magnet core on CrNi Welding depth: 0.4 mm

32 Polymer welding

33 Welding of an electronic key

34 Welding of an oil tank Oil Tank Tank Lid Welding of an oil tank (GFK) Diode power Welding speed Focal diameter ca. 60 W 1-2 m/min 2 mm