Laser Welding Cell Forgives Imperfections

Laser welding offers numerous advantages over conventional techniques, including better weld quality, a robust bond and faster processing times. In Booth N-236217, TRUMPF Inc. (Farmington, CT) will be showcasing their TruLaser Weld 5000, a laser welding cell that greatly simplifies the laser welding process for experts and beginners through a new cube design, software components and hardware innovations that have made operation even simpler, and the FusionLine process option that makes tolerant laser welding possible. FusionLine is a laser welding process that uses a welding wire supply to allow for the welding of components with gaps.

Laser welding is known for its perfect results and high quality visible seams, but preparing components for laser welding calls for specific expertise. There should be as little tolerance as possible in the design, or at least that is how things used to be. Today, FusionLine offers an ideal technology that helps users get started by making it possible to overcome component imperfections in the welding process and even to close gaps of up to 0.04 in wide. At the same time, the welding seam results and processing times significantly outperform those of components processed using conventional welding techniques. This means users can take advantage of the perfect combination of laser beam guidance, optics and a weld feed system to perform cost-effective laser welding operations, even if their component portfolio is not optimized for laser welding. It is now possible to laser weld an array of parts developed for conventional welding without having to modify them. This enables users to manufacture parts according to the drawing, and laser weld a larger array of parts than ever before.

Additionally, customers retain full flexibility. Manufacturers can easily switch between FusionLine and the conventional laser welding techniques of heat conduction and deep welding with no need to reset the machine. That way they can manufacture one part run that isn’t worth modifying for laser welding by using FusionLine, then manufacture a subsequent run using heat conduction or deep welding. Users can also switch between techniques on the same component. Shield gas is used in laser welding to ensure as oxide-free a weld as possible. In the past, the shield gas was introduced by a four-finger nozzle fixed to the processing optics, which meant that the entire laser head had to turn whenever there was a change in direction. Thanks to the rotary module, the TruLaser Weld 5000 features a movable nozzle that rotates around the optics which results in faster welding times.

This laser welding cell features the striking cube design and also comes with a swiveling support arm for the control panel to improve the ergonomics and handling. On the exterior, the TruLaser Weld 5000 is fitted with a status light that provides an immediate assessment of the machine’s status. The laser welding unit operates using a TruDisk laser that can also power other TRUMPF machines, such as a 2D laser machine. In a laser network, several machines share a single laser – which can significantly reduce the initial investment cost of a new machine.

TRUMPF Inc., Farmington Industrial Park, 111 Hyde Road, Farmington, CT 06032, 860-255-6104, www.us.trumpf.com.