Abstract
In recent decades, beam welding processes have been set up as a key technology for joining applications in automotive engineering and particularly in gearbox manufacturing. Due to their high beam quality, energy efficiency, reliability as well as flexible beam guidance, modern solid-state lasers offer numerous advantages, but also pose increased requirements on the production and positional accuracy of the components for the joining process. In particular, small-focus diameters present a challenge for components with process-induced tolerances, i.e., disc carriers in automatic transitions. Furthermore, welding processes utilizing solid-state lasers show an increased spatter formation during welding at high welding speeds. Accordingly, the primary objective of the presented work consists in extending the current areas of application for solid-state laser beam welding in gearbox manufacturing through an improved process reliability regarding tolerance compensation and spatter formation. Therefore, this experimental study aimed to describe the effects of a dynamic beam oscillation in combination with a reduced ambient pressure in the process environment on both gap bridging ability and spatter formation during the laser beam welding of case hardening steel. For basic process evaluations, laser beam welding at reduced ambient pressure and laser beam welding with dynamic beam oscillation were initially studied separately. Following a basic process evaluation, samples for 2 mm full-penetration-welds with varying gap sizes were analyzed in terms of weld seam geometry and weld spatter formation.
Highlights
The current trends in the automotive industry show an increased demand for the power beam technologies, in the sheet metal processing as well as in powertrain manufacturing, induced by the continuous development in laser beam sources, optics and electronics [1]
This experimental study aimed to describe the effects of a dynamic beam oscillation in combination with a reduced ambient pressure in the process environment on both gap bridging ability and spatter formation during the laser beam welding of case hardening steel
It can be assumed that with reduced ambient pressure and applying dynamic beam oscillation, an effective welding process with a low amount of spatter and good gap bridging ability can be achieved
Summary
The current trends in the automotive industry show an increased demand for the power beam technologies, in the sheet metal processing as well as in powertrain manufacturing, induced by the continuous development in laser beam sources, optics and electronics [1]. It has been reported that the model gives a good approximation about the process behavior and makes possible the selection of feasible parameters Another problematic issue of the solid-state laser is the fact that the keyhole mode welding often entails a high amount of spatter, which is in several applications, such as gearbox manufacturing, not acceptable [11]. Using the benefits of the vacuum combined with the high focusing ability of the laser beam, the process efficiency can be increased due to the possibility of using higher welding speeds or lower powers [21]. It can be assumed that with reduced ambient pressure and applying dynamic beam oscillation, an effective welding process with a low amount of spatter and good gap bridging ability can be achieved
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