Fig. 4 — Small adjustments lead to big fitup improvements, and ultimately a better weld. in. was used on the contoured tube while a 0.16-in. inside radius was used on the noncontoured tube, and the result was very little space between the two. It is worthwhile to try a few different combinations of radii to find what works best for the application. The results from this design are satisfying and appropriate for the task at hand. In Fig. 4, you can see how well the tubes now fit together. No matter what type of welding will be used, this allows the assembly to be welded more cleanly. No longer is a filler metal needed. With laser welding, the end result will be a smooth and beautiful weld reminiscent of gas tungsten arc welding, but with greater consistency throughout the weld and produced in a fraction of the time. It is also less costly to produce since any refinishing work has been greatly reduced or completely eliminated. Finding the Right Fit for Laser Welding A fabricator should always strive for the most cost-effective manufacturing process that meets the application demands, such as strength and weight requirements. Although the application discussed in this article might not apply to everyone, laser welding is an enabling technology. Designers who gain a deeper understanding of the properties and applicability of this process will understand its benefits as a profitable manufacturing solution. When it is necessary to apply creativity in part design, laser welding provides unique answers as a noncontact joining process that generates a very small heat-affected zone and only requires limited access to one side of the material that is being welded. It offers advantages in speed, quality, and weld strength compared to traditional means such as gas metal arc or gas tungsten arc welding, and it enables manufacturers to increase profits by eliminating secondary processes such as grinding, straightening, and polishing. Cost Considerations For many fabrication shops, these benefits are easily understood, but the cost of entering into laser welding is seen as a prohibiting factor. Advances here have also made laser welding more attractive and less intimidating. The possibility of “laser networking,” for example, allows one laser source to be used for cutting and welding. This configuration is illustrated in Fig. 5. Fabricators simply share a single laser source between multiple technologies (e.g., one cutting unit and one welding unit). In the early days, it was thought that sharing a laser source would never work for manufacturers who run their lasers for multiple shifts, but it has become increasingly evident that this is not the case. By dynamically sharing the laser beam back and forth from cutting to welding, the beam utilization is much greater than just using the laser source for a single purpose. With the addition of a laser welding system used in tandem with existing modern sheet metal manufacturing equipment, the sky is the limit on making a better, more profitable product. The obvious benefit here is cost: If you only have to buy one laser source for two separate systems, then there is a significant cost savings in the form of at least one laser resonator. Ending Thoughts No matter the application or style of your fabrication shop, it is always important to keep an eye out for new technologies and how they might impact the manufacturing process. Taking the time to research new developments and assess how they might be applied, any shop can increase its productivity and competitiveness. WJ BRETT THOMPSON is a laser product engineer with TRUMPF, Inc. (us.trumpf.com), Farmington, Conn. MARCH 2016 / WELDING JOURNAL 47 Fig. 5 — With laser networking, one laser can be shared between a 2D laser cutting machine and laser welding system.
Welding Journal | March 2016
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