OF POWERTRAIN COMPONENTS
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1 TRUMPF Inc. LATEST TRENDS IN LASER WELDING OF POWERTRAIN COMPONENTS Stephan Ziermann, Group Leader Laser Applications Plymouth, MI 48170, 9/19/2013 LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/2013 1
2 Latest Trends in Laser Welding of Powertrain Components Agenda Motivation Laser Welding of Dual Clutches With CO 2 and Solid State Lasers Laser Welding of Differential Gears With CO 2 Laser With Solid State Laser Marking and Cleaning of Powertrain Parts with Marking Lasers LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/2013 2
3 TRUMPF Laser Applications in Powertrain Powertrain Laser Applications Differentials Motor Gearbox Torque Converters Clutches Driveshafts LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/2013 3
4 Advantages of Laser Welding high welding speed low heat input / low distortion high weld seam quality welding under atmospheric condition different materials and thickness weldable can be highly automated high process and geometry flexibility Cost savings and higher flexibility with laser welding process! LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/2013 4
5 Laser Welding of Dual Clutches Advantages No interruption of power transmission Very fast gear change Reduction of gas consumption Driving pleasure Proven technology (since 2005) TruDisk and TruFlow Laser series References: Audi, Volkswagen, BMW, Daimler, SAIC, LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/2013 5
6 Laser Welding of Dual Clutches Laser welds in Dual Clutch DQ250 source of DC pictures: BorgWarner source: Volkswagen AG LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/2013 6
7 TRUMPF - Laser welded Dual Clutch DQ250 source of DC pictures: BorgWarner source: Volkswagen AG LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/2013 7
8 TRUMPF - Laser welded Dual Clutches DL501 (Audi) DQ250 (Volkswagen) MPS6 with damper (Getrag BMW) Getrag 436 (BMW) source of pictures: BorgWarner LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/2013 8
9 Laser welding of Differential Gears Weight savings, reduced production cost T t D Bolted d Advantages of Laser welding Cost reduction as screw fasteners are eliminated Material savings the diameter and thickness of the housing flange is reduced (t<t; d<d): Weight reduction (approx. 1kg/diff) Smaller part dimensions Larger torques can be transmitted Reduced noise emission Material Housing: GGG 60 Ring gear: 16MnCr5 Laser welded LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/2013 9
10 Laser welding of Differential Gears CO 2 Laser Production Sequence US installation (part handling) German installation (welding) TLC1000/TruLaser Cell 7006 Laser: TruFlow 6000 Weld speed: 1.5 m/min Penetration: ca. 5 mm Cast material / case hardened steel With filler wire LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/
11 Welding with Solid State Laser Solutions for Powertrain Welding Welding at atmosphere: More spatters compared to CO 2 laser welding Better and adjusted extraction system solution required Part needs to be covered Easy fixture cleaning procedure necessary Metal vapor plume control LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/
12 Welding with Solid State Laser Solution: Air knife to minimize power absorption in metal vapor plume without air knife with air knife Metal vapor has quite some influence on the welding quality LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/
13 Welding with Solid State Laser Coaxial MDE nozzle (metal vapor effect) Parameter: f = 200 mm; t = 6 mm; 3 m/min; FL-2 mm; 4.5 kw top bottom without t MDE nozzle with MDE nozzle > penetration > stability < contamination LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/
14 Welding with Solid State Laser Strategy: welding below atmospheric pressure Weld direction 1013 mbar 500 mbar 100 mbar 10 mbar Reducing the ambient pressure causes severe reduction the metal vapor plume in size and brightness the spatters source: V. Rominger S mm P = 6000 W v s = 2.0 m/min fp = -2 mm LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/
15 Welding with Solid State Laser Strategy: welding below atmospheric pressure Test setup welding optic LLC mbar mbar mbar mbar protection glass chamber cover axis system welding extraction system LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/
16 Laser Welding of Differential Gears TruDisk Process Parameters Laser: TruDisk Material: GJS 600 / 16 MnCr 5 Filler Wire: , Ø 1.0 mm Weld Depth: 4 mm Power: 2800 W Feed Rate: 1.5 m/min Wire Feed Rate: 4.5 m/min LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/
17 Welding of Differential Gears TruDisk Process Results Setup (wire nozzle and air knife) Cross section Hardness Profile LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/
18 Laser welding of Flange Tulips (source: GKN) TRUMPF - Innovative Laser Solutions for Powertrain LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/ Darmstadt, September 26th and
19 Laser welding of Flange Tulips (source: GKN)
20 Laser welding of Drive Shafts (source: Neapco) TRUMPF - Innovative Laser Solutions for Powertrain LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/ Darmstadt, September 26th and
21 New Automatic Transmission 8- and 9-speed automatic transmission source: ZF TRUMPF TruDisk / TruMark Lasers source: Felsomat LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/
22 Laser Marking of Powertrain Components Crown wheel Con-rod Bevel gear LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/
23 Marking Lasers for Powertrain Components Laser cleaning with short pulse technology TruMark 6130 =>removing of phosphate layer ring gear improved welding results less spatters cleaner process LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/
24 Distortion free Laser Welding Process 50% 50% shaft of turbo charger LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/
25 TRUMPF in Powertrain - References LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/
26 TRUMPF Inc. YOUR CONTACT Stephan Ziermann +1 (734) LATEST TRENDS IN LASER WELDING, Stephan Ziermann 9/19/
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