Laser Welding that Forgives Imperfections

Getting started with laser welding is now easier than ever for fabricators thanks to tolerant laser welding with FusionLine technology in the new TruLaser Weld 5000 laser welding cell from TRUMPF Inc. (Farmington, CT). New design and software components have made operation even simpler for laser welding, which offers numerous advantages over conventional techniques: better weld quality, a robust bond and faster processing times. FusionLine makes tolerant laser welding possible and greatly simplifies the laser welding process by using a welding wire supply that allows for the welding of components with gaps.

Laser welding is known for perfect results and high quality visible seams, but preparing parts traditionally requires specific expertise that allows as little tolerance as possible in the design. FusionLine now makes it possible to overcome component imperfections in the welding process by closing gaps up to 0.04 in wide, with welding seam results and processing times that significantly outperform those of parts 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. Users can manufacture parts according to the drawing and laser weld a larger array of parts than ever before.

Users also retain full flexibility, easily switching between FusionLine and conventional laser welding techniques of heat conduction and deep welding with no need to reset the machine. This way they can manufacture one part run that isn’t worth modifying for laser welding using FusionLine, then manufacture a subsequent run using heat conduction or deep welding. They can also switch between techniques on the same component, allowing them to laser weld many more parts than before and make full use of their laser welding unit.

Shield gas is used in laser welding to ensure as oxide-free a weld as possible. In the past, shield gas was introduced by a four-finger nozzle fixed to the processing optics. This meant the entire laser head had to turn whenever there was a change in direction. Thanks to its rotary module, the TruLaser Weld 5000 features a movable nozzle that rotates around the optics for faster welding times since the robot does not have to reorient itself as much. This also simplifies programming and fixture design. In addition to offering a camera view of the work area, a new status monitor also supplies further information about the production status of the job, including the remaining time, the current production program and the quantity of parts manufactured. This gives sheet metal operators the most important indicators at a glance.

The production screen provides operators with an additional control option: they can perform simple tasks, such as selecting an existing processing program from the control, even if they have no programming knowledge. In other words, they require far less knowledge of KUKA control technology in order to launch an existing program. The production screen displays the active program, the remaining time and quantity of components being manufactured similarly to the status monitor.

The new TruLaser Weld 5000 features a striking cube design and comes with a swiveling support arm for the control panel that improves ergonomics and handling. On the exterior, the TruLaserWeld 5000 is fitted with a status light that provides an immediate assessment of the machine’s status. Bigger windows provide a better view into the safety cabin, and the interior provides new approaches to lighting and suction. 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, 860-255-6000, www.us.trumpf.com.