LASER WELDING
Precision and efficiency for the highest requirements
Laser welding has established itself as an indispensable technology in demanding manufacturing processes and offers solutions for challenges such as narrow weld seams, minimal heat-affected zones and high process speeds. This technology enables the reliable joining of a wide range of materials - from thin-walled metals to complex structures in hard-to-reach areas. The ability to ensure maximum precision and repeatability in processes makes laser welding the ideal choice for applications where efficiency and flawless results are crucial.
Challenges in laser welding
Laser welding has numerous advantages, but the technology also brings with it certain specific hurdles that must be carefully mastered to ensure high quality and process stability.
Precision and dynamics of the welding processes
For sensitive processes such as the welding of battery housings or bipolar plates, precise z-layer control is therefore crucial for quality. High dynamics and flexibility are also important: different welding points need to be reached quickly and precisely or wider, more stable seams need to be produced by “wobbling”. For these requirements, highly dynamic deflection units are needed that allow fast, precise movements in all dimensions and thus ensure optimum welding quality.
RAYLASE supplies pre-focusing beam deflection systems that achieve the best possible combination of a large processing field and small spot diameter. Yet the necessary high dynamics are achieved thanks to lightweight mirrors. Thus we offer the optimum systems for demanding welding applications.
Durability and robustness of the components
Laser welding requires small laser spots on the workpiece in order to achieve the necessary energy density in the material. But the intense laser radiation combined with harsh process conditions place high demands on the optics and machine components. As a result, the components must be robust enough to cope with continuous operation without significant wear.
For this reason, RAYLASE relies for its beam deflection units for laser welding on mirrors and lenses with high power tolerance, a dust-tight housing and production under clean room conditions. This ensures that the sensitive optics are well protected and the risk of failure is minimized.
Cost and resource efficiency of the laser welding solution
As competition in the manufacturing industry is fierce, cost and resource efficiency are decisive factors. Machine builders are faced with the challenge of developing highly functional machines and at the same time operating economically.
With the AXIALSCAN FIBER series, RAYLASE offers highly integrated scanning solutions that can be seamlessly combined with sensor systems such as the OCT-based RAYDIME METER or the RAYSPECTOR for in-focus vision. Suitable software solutions are also available and significantly reduce the development effort and complexity of integration.
From the laser laboratory to serial production
The fields of application for laser welding are diverse. While the focus in the laboratory is on the feasibility and precision of welding processes, in production it is all about high quantities, process reliability and consistency. This poses special challenges: laser systems need to be optimized so that they reliably meet the high standards of industrial production.
Therefore, RAYLASE has developed optimized products and tools that are designed for laser welding in serial production:
- Thanks to its integrated collimator and interfaces for process sensors, the AXIALSCAN FIBER series can be easily and seamlessly integrated and comprises perfectly matched components.
- In addition to calibration in the xy direction, the SCAN-FIELD-CALIBRATOR also allows a precise focus calibration in the z-direction.
- Software solutions such as RAYGUIDE MATCH or an autofocus enable fully automated production in combination with camera solutions or our OCT-based distance sensor RAYDIME METER.
Interesting applications and use cases
Laser welding offers a wide range of applications in numerous industries. Here are some interesting examples that illustrate the potential of this technology.
