Laser welding of three–dimensional automotive parts

Abstract

Laser welding of automotive body components is now being focused in Japan, where in the past laser applications were restricted to cutting and drilling. There are a few success reports in laser welding of three-dimensional parts.Recently, a center pillar with an innovative flangeless design was introduced by one Japanese automotive manufacturer for its stylish hardtop model. It was impossible to fabricate the pillar with conventional spot welding methods because the weld access is only available on one side. A high power CO2 laser was finally selected because of its single-sided welding capabilities, fast welding speed, deep penetration and small thermal distortion attributes.Through complete evaluation, a rectilinear cantilever robot system with indexing fixtures was developed by Sanyo Machine Works, Ltd. Machine design concept and details are described here with the evaluation process for determining what type of machine was desirable for this laser welding application.Laser welding of automotive body components is now being focused in Japan, where in the past laser applications were restricted to cutting and drilling. There are a few success reports in laser welding of three-dimensional parts.Recently, a center pillar with an innovative flangeless design was introduced by one Japanese automotive manufacturer for its stylish hardtop model. It was impossible to fabricate the pillar with conventional spot welding methods because the weld access is only available on one side. A high power CO2 laser was finally selected because of its single-sided welding capabilities, fast welding speed, deep penetration and small thermal distortion attributes.Through complete evaluation, a rectilinear cantilever robot system with indexing fixtures was developed by Sanyo Machine Works, Ltd. Machine design concept and details are described here with the evaluation process for determining what type of machine was desirable for this laser welding application.