With the constant advancement in laser power, high-power laser welding automation solutions are increasingly being used in high-end manufacturing, leading to its growth as a new application of laser welding.
The transformation and modernization of the manufacturing industry is driving its implementation, as the benefits of high-power laser welding equipment in processing become more evident. The application rate is growing especially in the processing and manufacturing of metal materials and parts.
Application of laser welding in automobiles
Currently, the main applications of laser welding in the automotive industry include welding of plates of unequal thickness, laser assembly welding for bodies and subassemblies, and welding of automotive components.
Laser welding is suitable for mass production, which aligns with the high output of automobiles. Furthermore, the high degree of automation in automotive manufacturing also aligns with the automated nature of laser welding.
There are several advantages of using laser welding in the automotive industry:
(1) Reduces body weight:
The adoption of laser welding in the automotive industry can reduce the total weight of the vehicle by 50-100 kg compared to other welding methods as the welding rod does not need to be melted.
(2) Firm and reliable:
Laser welding is known to be firm and reliable as the strength of laser welded parts is higher. Tensile test results show that approximately 3,500N of force is required to break a welding spot, while the strength of the weld of the same length formed by laser welding is 1.5 times that of spot welding.
(3) More efficient:
Laser welding is much more efficient than other welding methods, with a welding speed of 5-6m/min. This contrasts with spot welding, which has an average speed of 1/3s. For example, if spot welding is used to weld the top cover of a car, it takes 5 minutes, while switching to laser welding reduces the time to just 0.8 minutes.
(4) Beautifully welded:
Laser welding results in short, smooth, and bright welds, making it an attractive option for the automotive industry.
Application of laser welding on electric battery
There are numerous manufacturing processes for ion batteries or battery packs, including explosion-proof valve seal welding, pole terminal welding, soft connection welding, hard hat spot welding, housing seal welding. battery, module and package welding, among others. Of these, laser welding is considered the best process.
Battery laser technology
Battery explosion-proof valve welding
The battery explosion-proof valve is a thin-walled body on the battery sealing plate. If the internal pressure of the battery exceeds the designated value, the valve body will break to prevent the battery from exploding.
Welding battery terminals
One of the steps in the power battery manufacturing process is to weld the battery terminal and pole to the starting point. In the production of secondary batteries, it is necessary to weld an additional aluminum safety valve. Welding must not only ensure a reliable connection between the terminal and the post, but it must also have a smooth and attractive appearance.
Spot welding with battery electrode strip
A pulse welding machine is commonly used to weld battery pole strips. It has exceptional advantages in welding high reflectivity aluminum or copper bands, or narrow band battery pole bands (widths less than 15mm) due to its high quality beam and small welding spot.
Seal welding of battery casing and cover plate
The battery shell is made of aluminum alloy or stainless steel, with 3003 aluminum alloy being the most common aluminum material used. 304 stainless steel is the most weldable material and is ideal for pulsed or continuous laser welding to produce a beautiful and efficient weld.
Pack power and welding battery module
Series and parallel connection between power batteries is typically achieved by soldering the connecting parts and individual batteries. The materials used for the positive and negative electrodes vary and are copper or aluminum. However, laser welding between copper and aluminum produces a brittle compound that does not meet the requirements, so ultrasonic wave welding is generally used. To weld copper to copper or aluminum, laser welding is generally used.
Application of laser welding technology in the aerospace industry
In the aerospace industry, common welding techniques include laser welding, electron beam welding, friction stir welding, diffusion welding, and linear friction welding. Among these, laser welding is the most commonly used and occupies a significant position in the field.
Laser welding is widely used in the manufacture of aerospace equipment, mainly in the production of weapons and aircraft. It is also used for aircraft skin splicing, welding of skin and long derivatives, manufacturing of thin-walled parts and assembly of fuselage accessories.
The use of laser welding improves the structural performance of aircraft and improves die quality.
Application of laser welding technology in shipbuilding
In the shipbuilding and repair industry, the most advanced laser welding technology is found in Europe's shipbuilding sector.
To meet the weight reduction demands of ships, laser welding technology was introduced and quickly replaced traditional welding methods, improving efficiency and quality.
In shipbuilding, laser welding is mainly used on ship decks and bulkheads.
With continued advancements in laser welding technology by researchers, its application in the shipbuilding industry is becoming increasingly sophisticated. For example, in submarine manufacturing, high-strength steel is manufactured using laser cutting and welding. In the case of defects in large pistons of low-speed machines during operation, laser welding can be used for direct repairs, extending the life of the pistons.
The incorporation of laser welding technology into the national naval industry has driven reforms in the industry as a whole.
As laser technology continues to be more widely understood and recognized, its applications are becoming increasingly prevalent, including in industries such as aerospace, shipbuilding and automobiles.
Laser welding technology, a key focus of laser technology, has a promising future and is expected to expand from military and high-precision manufacturing to the civilian sector, driving growth and development across the industry.
