Foreword:
The successful demonstration of the world's first laser more than 40 years ago, today, laser science and technology flourished, and its role far exceeds the original expectations of the early days of its invention. The application of laser technology is now in technology, economy, military and Many areas of society. The automotive industry is an important application field for laser processing, accounting for 15% of laser processing. Laser welding, laser cutting, laser marking, and laser drilling have a wide range of applications.
Technical feasibility of laser welding
The most basic characteristics of laser (stimulated radiation) are: monochromaticity, directionality, correlation, and these unique properties combined with the resulting ultra-high brightness, ultra-short pulse and other properties make it already tight and modern. Combining industry, these qualities are ideal for welding.
Lasers are generally classified according to the working substance that produces the laser, mainly semiconductor (GaAs, InP, etc.) lasers, solid (Nd: YAG, etc.) lasers, gas (CO2, He-Ne, etc.) lasers, liquids (tunable dyes, etc.) Lasers, chemical lasers, free electron lasers, etc. Among them, gas lasers use gas or metal vapor as luminescent particles. It is the most widely used type of laser with the most diverse types, the most diversified excitation modes, the widest laser wavelength distribution area, and easy to achieve high-power continuous output. The solid-state laser is a kind of laser-doped particles mixed with a solid matrix, and its concentration is larger than that of a gas, so that a relatively large laser energy output can be obtained, which has the characteristics of large energy, high peak power, compact structure, and durability. Lasers of these two excited species are mainly used in laser welding. The application of laser welding technology in the manufacturing field has grown steadily, from pulse to continuous, from small power to high power, from thin plates to thick parts, from simple single slits to complex shapes. Laser welding has gradually become a kind of continuous evolution process. Mature modern processing technology.
Laser welding is divided into pulsed laser welding and continuous laser welding. In continuous welding, it can be divided into heat conduction welding and deep penetration welding. With the increase of laser output power, especially the emergence of high-power CO2 lasers, laser deep penetration technology has been rapidly developed at home and abroad, the largest welding aspect ratio has reached 12:1, laser welding materials are also general Low carbon steel has developed into today's welded galvanized sheet, aluminum sheet, titanium sheet, copper sheet and ceramic material. The laser welding speed has reached tens of meters per minute. The laser welding technology is increasingly mature and applied to the production line in large quantities in the automobile production line. Such as gear welding, high-speed tailor welding of car floor and structural parts (including the door body) and has achieved great economic and social benefits. According to relevant statistics, in the developed industrial countries of Europe and America, 50%-70% of auto parts are processed by laser processing. Among them, laser welding is the main method and cutting, and laser welding has become a standard process in the automotive industry. The laser is used for the welding of the body panel. The metal plates of different thicknesses and different surface coatings can be welded together and then stamped, so that the panel structure can achieve the most reasonable metal combination. The speed of laser welding is about 4.5 m/min and it is rarely deformed, eliminating the need for secondary processing. Laser welding accelerates the process of replacing forged parts with stamped parts.
With laser welding, the overlap width and some reinforcing parts can be reduced, and the volume of the body structure itself can be compressed. The weight of this body alone can be reduced by 56kg. Laser welding is used to weld the roof casing to the frame. The welding converter cover is welded by the CNC. The cycle time is about 16 seconds. The actual welding time is only 3 seconds. It can run continuously for 24 hours a day. Used to weld the gearbox assembly and chassis of a car, the laser beam is fast, easy to automate and easy to merge into a flexible manufacturing system. The laser beam improves the manufacturer's product design and production cycle, reducing finished product waste. rate.
Laser welding in the automotive industry
Laser welding can bring huge economic benefits to the automotive industry. For example, a large number of spot welding in the body assembly, the two welding heads are clamped on the edge of the workpiece for welding, the flange width needs 16mm, and the laser welding is single-sided welding. It only needs 5mm, and the spot welding is laser welding, which can save 40kg of steel per car. Two pieces of 0.8mm steel stamping parts are welded by conventional spot welding, the average is 20 points/min, the welding distance is 25mm, that is, the speed is 0.5m/min, and the laser welding speed can reach more than 5m/min. The use of laser welding technology not only reduces costs, but also greatly increases production efficiency. At present, a set of kilowatt-level laser processing robot system is only a few hundred thousand dollars, the safety and reliability of the new laser are also guaranteed, its failure downtime is only 2%, and the protective measures are extremely reliable. Laser welding requires close matching of the workpiece contact surface, which is not easy to achieve in the process, but the current advanced clamping method and flange design suitable for laser welding have solved this problem, and the laser welding technology has gradually matured. All major automakers have applied laser welding to automotive production lines without exception.
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