TRUMPF Business Field Laser Technology and Electronics WELCOME AND KEYNOTE Laser in the automotive industry Klaus Löffler Managing Director Sales & Service Ditzingen, 27.01.2015 1
Global Megatrends Megatrends influence automotive innovations Globalization Digital Connection Health Environment Miniaturization Energy & Resources 3D-Printing Urbanization Individualization Mobility 2
Global Megatrends Megatrends influence automotive innovations Artificial intelligence and social network connection Digital Connection Globalization Health Region and age specific cars Miniaturization Environment Reduction of consumption and emissions 3D-Printing Energy & Resources Individual and highly configurable cars Individualization Mobility Urbanization New urban car concepts / car sharing 3
Why Laser? Some of its unique properties make the Laser an enabling tool in modern production No mechanical forces No inertia Highest precision Low thermal influence Fast control Easy automation Production without specific tools Adaptable to different processes Adaptable to different materials Where does the laser drive automotive innovations today? 4
Agenda Where does the laser drive automotive innovations today? 1. New mechanical designs: lightweight sheet metal construction 2. New materials: lightweight material combinations 3. New process chains: laser applications in hot forming 4. New processes: ultrashort laser pulses and additive manufacturing 5. New concepts: laser processes in E mobility 5
Intelligent joining with K-Joints* K-Joints enable flangeless and weight reduced joining of metal sheets flange 7 mm flange 15 mm K-joint Spot welding *Patent pending 6
The Street Scooter The first car to implement flangeless design is the Street Sccoter We welcome the newest OEM car manufacturer in Germany: Deutsche Post 7
Agenda Where does the laser drive automotive innovations today? 1. New mechanical designs: lightweight sheet metal construction 2. New materials: lightweight material combinations 3. New process chains: laser applications in hot forming 4. New processes: ultrashort laser pulses and additive manufacturing 5. New concepts: laser processes in E mobility 8
CFRP and E-mobility New car concepts like the BMW i3 utilize innovative lightweight design (CFRP) and electrical engines Source: BMW 9
Energy efficiency in the automotive industry: CFRP Laser cutting of CFRP Biaxial fabrics s = x * 0,1 mm CF-Preform s = 2 bis 5 mm CFK infiltratet s = 1 bis 5 mm TruFiber (SPP 0.4 mm*mrad) TruDisk (SPP 4.0 mm*mrad) TruFlow (SPP 4.0 mm*mrad) TruDisk (SPP 4.0 mm*mrad) TruFlow (SPP 4.0 mm*mrad) TruDisk (only suited to a certain extent) TruFlow(SPP 4-6 mm*mrad) 10
Laser based metal and plastics joining: principle By structuring and heating a metal surface, a durable connection can be formed with thermoplastic materials 11
Weight reduction by use of aluminium Mercedes SL- Class: Aluminium body architecture Holger Schubert, Daimler AG, Conference Fügen, Bad Nauheim, 2012
Aluminium Remote Welding The clad alloy Novelis Fusion TM 8840 enables remote welding of 6xxx aluminium No hot-cracking in the weld Improved weldability and stabilization of molten pool oxide film Laser welding without filler metal possible, even at high speed or near edge welding Maintains all advantages of 6xxx monolithic alloys (Remote) Laser welding - without filler - without gas protection 14
Agenda Where does the laser drive automotive innovations today? 1. New mechanical designs: lightweight sheet metal construction 2. New materials: lightweight material combinations 3. New process chains: laser applications in hot forming 4. New processes: ultrashort laser pulses and additive manufacturing 5. New concepts: laser processes in E mobility 15
Energy efficiency in the automotive industry: hot stamping Hot stamping allows significant weight reduction of car body parts Hot stamping part 1 ZSte260 (1.5 mm) -4.6 kg part 2 22 MnB5 hot stamped (2.00 mm) part 2 CPW800 (2.25 mm) part 3 TRIP700 (1.75 mm) part 1 ZSte260 (1.5 mm)
Energy efficiency in the automotive industry: hot stamping Laser processes along the hot stamping process chain: partial softening Partial softening of flanges Create ductile areas to reduce possibility of embrittlement for welding processes Material properties can be adjusted close to the properties of base material before hardening Laser or Induction heating Induction heating (example) Partial softening of A or B pillars TruHeat HF 5010 with multi-turn tunnel inductor 760 C in 4 seconds with temperature control 18
Energy efficiency in the automotive industry: hot stamping TRUMPF TruMicro Series 7000: AlSi ablation Removal of 10-25 µm AlSi along the edge Adjustable remaining Al content (down to 0%) Preserve properties of base material Removal width of 1 mm 2 mm Simultaneous removal of two sides of blank Linear removal speed of >30m/min Square (1:1) Line (1:10) 25% 45 % 25 % of heat conduction in direction of ablation + 80 % 45 % of heat conduction in direction of ablation 19
Agenda Where does the laser drive automotive innovations today? 1. New mechanical designs: lightweight sheet metal construction 2. New materials: lightweight material combinations 3. New process chains: laser applications in hot forming 4. New processes: ultrashort laser pulses and additive manufacturing 5. New concepts: laser processes in E mobility 21
TruMicro Series 5000 Success story Industrial production of direct fuel injection nozzles at BOSCH TruMicro Series 5000 Common fuel injection: Partial wetting of cylinder and piston leads to inefficiencies images: Different diameters of drilled holes enable optimized fuel distribution in the combustion chamber and lead to a decrease in fuel consumption and emissions. 22
Additive Manufacturing Laser Metal Fusion (LMF) and Laser Metal Deposition (LMD) LBM LMD Bild: Fraunhofer IPK LBM Criterion LMD Part complexity Material range (10-20 cm³ / h)* Deposition rate (40-150 cm³ / h) (< 0.1 mm) Precision (< 1 mm) (Ra 5-10 µm) Surface quality (Ra 10-20 µm) Costs Technological maturity *) Standard machine with laser power P = 400 W 24
Additive Manufacturing Additive Manufacturing can be employed for metals and plastics Do you remember the street scooter? 3D printed doorframe 25
Agenda Where does the laser drive automotive innovations today? 1. New mechanical designs: lightweight sheet metal construction 2. New materials: lightweight material combinations 3. New process chains: laser applications in hot forming 4. New processes: ultrashort laser pulses and additive manufacturing 5. New concepts: laser processes in E mobility 26
Application and Solution Production Step Laser processes in E-mobility Production of battery cells Source: Breyer GmbH Source: newlong.com Source: BMW Coating and compressing Slitting or Sheet Cutting Tap welding Packaging Filling Assembling Cutting Cutting Welding Welding Welding Welding Marking TruMicro + TruMicro + TruDisk + TruDisk + TruPulse + TruDisk TruMark + 28
Agenda Where does the laser drive automotive innovations today? 1. New mechanical designs: lightweight sheet metal construction 2. New materials: lightweight material combinations 3. New process chains: laser applications in hot forming 4. New processes: ultrashort laser pulses and additive manufacturing 5. New concepts: laser processes in E mobility 29
Thinking outside the box Laser welding at reduced ambient pressures: motivation Conventional laser welding with SSL Bright and large metal vapor torch Torch is tilted with very high dynamics Strong spattering against feed direction at atmosphere Loss of material No homogenous in coupling Solution: Integrate the disadvantages of two different processes: laser welding + electron beam welding = laser welding at reduced ambient pressure 30
Laser welding at different ambient pressures Influence on penetration depth by reducing ambient pressure 1013 mbar 500 mbar 100 mbar 10 mbar Increased penetration depth up to an ambient pressure of 100 mbar: ca. 35% (!) 1000mbar 100mbar 10mbar 1mbar 0,1mbar Pen. depth: 3,4mm Pen. depth: 4,9mm Pen. depth: 5,0mm Pen. depth: 5,1mm Pen. depth: 5,0mm S355, P=3kW, v=5m/min 31
Re-evaluating old ideas Laser welding of threaded sleeves Welded nut Press nut Formed bushing Laser welded bushing 32
Re-evaluating old ideas (Prof. Griebsch HTW Saarland) Laser welding of threaded sleeves Welded nut Press nut Formed bushing Laser welded bushing Year 2000 2015 High-strength Diode Lamp Grade steel steel pumped SSL Fatigue - - + + Gap corrosion - - + + Relaxation + + + - + Producibility + + + - + Costs p.p. 0 + 0-0 - 33
Next speaker: Peter Busuttil, KuKa North America Expert for automotive laser applications with a long successful track record Radiator Support Assembly at GM Willow Run (SOP 1991) 105 Miles of Welds produced. 98,7 % uptime 66 Jobs per hour 34
TRUMPF Business Field Laser Technology and Electronics Thank you very much for your attention! Have a fruitful conference! Klaus Löffler, Managing Director Sales & Service Ditzingen, 27.01.2015 WELCOME AND KEYNOTE, Klaus Löffler 27.01.2015