When welding aluminum parts, the filler wire introduces additional material into the weld, which prevents the material from becoming brittle. Together with the diode laser, specific laser processing heads are used, which, by means of tactile or optical sensors, guarantee a very precise brazing process.
UNMATCHED IN APPLICATION
Because of the low heat input, the corrosion protection of galvanized sheet metal remains intact even in the joint area, and the components show extremely low distortion. This, together with excellent surface quality, is the reason why the sheets may be painted directly after brazing without any further treatment.
- Excellent surface quality and high speed
- Superb process stability
- High process reliability and best power consistency
- Superior economic efficiency compared to other laser types I Systems of high reliability for serial production
- Low space requirements and mobility facilitate new equipment concepts
Nowadays, brazing heads from most manufacturers are designed for diode lasers, which means that replacing old laser systems by diode lasers is possible without difficulty. And this is also possible at a later stage, since the process parameters are easily transferable.
The typical process requirements of the beam source for laser brazing are: output power of up to 6,000 W, spot of between 1.5 and 3.5 mm together with a homogeneous intensity distribution. Laserline diode lasers provide this in an ideal form.
With the greatest efficiency of all laser types, the very long lifetime of the laser diodes and the low space requirements, the diode laser is the most economically efficient beam source for brazing and welding with filler wire.
Brazing - and the related process of welding with filler wire - are modern techniques for the joining of metal components. In addition to the requirements of high strength and a small heat affected zone, particularly high demands are made on the appearance of the weld seam in the case of visible seams. Therefore, in automotive industry, laser brazing is used for joining the visible, external parts of vehicles, for example, tailgates, roof seams, doors or C pillars.
Greatest process stability and high availability of equipment in three-shift production are requirements in automotive industry which are ideally met by the diode laser that is considered proven technology in many applications.
The diode laser is clearly superior to other laser beam sources because it is almost maintenance-free with a lifetime of more than 30,000 operating hours at the greatest level of efficiency. As a comparison: with lamp pumped Nd:YAG lasers it is necessary to change lamps approximately every 1,000 operating hours, which causes stoppages and gives rise to service costs at each lamp change.
ALWAYS A STEP AHEAD: DIODE LASERS
Space requirements in production have become an important criterion for future production lines. One advantage of diode lasers is therefore the low space requirement, which is only about a fifth of that required for other lasers of the same performance class.
The compactness and robustness of the diode laser even allows for a mobile use, whenever necessary, which opens up entirely new backup strategies. For maintenance work or in the case of malfunction, the laser can simply be exchanged and replaced, so that maintenance or repair can take place not in the production line, but separately and without any production stoppages. Servicing by customer or by Laserline technicians is thereby made significantly more flexible.