Exploring the Potential of Dynamic Beam Lasers: Advancements in Welding Technology

Over the past few years, the introduction of Dynamic Beam Lasers has sparked a wave of excitement within the laser community. This innovative laser technology has shown immense promise, leading to extensive research and investigations into its potential applications. In this article, we will explore some of the recent developments in Dynamic Beam Laser technology, focusing specifically on advancements in welding techniques for various materials such as high-strength aluminum, aluminum die cast, and galvanized steel.

Mitigating Cracks in High-Strength Aluminum

One of the primary areas of research with Dynamic Beam Lasers has been the mitigation of cracks in high-strength aluminum. In this regard, IFSW presented a groundbreaking study that utilized a sequence of beam shapes to influence fluid velocity during the welding process. By carefully manipulating the laser beam, researchers were able to present methods to overcome cracking issues in high-strength aluminum, opening up new possibilities for industrial applications that demand the use of this material.

Figure 1. Utilizing shape sequence of beam shapes to influence fluid velocity

Reducing Cracks and Spatter in Al 6xxx Welding

BBW Lasertechnik, a prominent job shop in the automotive and aerospace industry, focused their efforts on welding Al 6xxx without cracks and excessive pores. Traditionally, a compromise had to be made between crack reduction and pore free. However, through experimentation and parameter optimization, BBW Lasertechnik successfully discovered a set of parameters that minimize both cracks and pores, revolutionizing the welding process for Al 6xxx and expanding its practical usage across industries.

Figure 2. Comparison of standard laser with Dynamic Beam Laser

Welding Aluminum Die Cast Components

The utilization of Dynamic Beam Lasers has revolutionized the welding process for aluminum die cast components, leading to significant advancements. These components serve a critical function in electric vehicles (EVs), such as heat exchangers and camera module closures. existing joining methods like riveting, friction stir welding, or electron beam welding not only consume time but also incur high costs. However, the implementation of Dynamic Beam Lasers has successfully addressed the challenges of pore formation and blow holes commonly associated with laser welding of aluminum die cast components. This has been accomplished by stirring the melt-pool, allowing the pores to rise to the surface and exit the fluid, while also employing beam shapes that elongate the melt-pool and provide trapped gas bubbles with ample time to rise and evaporate. This remarkable achievement has effectively eliminated pores, resulting in exceptional welding quality for aluminum die cast components.

Figure 3. Dynamic Beam Laser of Al Die Cast reducing porosity and avoiding blow holes

Advancements in Welding Galvanized Steel

Another intriguing application of Dynamic Beam Lasers lies in the welding of galvanized steel. The existing welding process for galvanized steel involves a dimple process to generate a gap, which helps prevent spatter and blowholes during welding. However, with the introduction of Dynamic Beam Lasers, this multi-step process can be avoided. The laser's dynamic capabilities enable it to weld galvanized steel in a single stage, eliminating the need for additional steps and ensuring a defect-free weld. This advancement not only saves time but also enhances the overall efficiency and reliability of the welding process for galvanized steel.

Figure 4. Comparison of welding galvanized steel with and without Dynamic Beam Laser

Welding Dissimilar materials

Dynamic Beam Lasers have also demonstrated their capabilities in welding Al-Cu alloys, particularly for bus bar applications. Bus bars are vital components used for electrical power distribution in various industries. When welding Al-Cu alloys, achieving a desirable weld geometry while minimizing intermetallic mixing has always been a challenge. However, with the implementation of Dynamic Beam Lasers, researchers have made significant strides in this area. Compared to traditional welding techniques, Dynamic Beam Lasers produce a shallower but wider weld geometry, resulting in reduced intermetallic mixing at the weld interface. This improved weld geometry, combined with the unique properties of the laser beam, has led to exceptional results in mechanical tests. In fact, studies have shown that welds created with Dynamic Beam Lasers exhibit up to 30% stronger mechanical properties compared to conventional welding methods. This breakthrough is poised to enhance the performance and reliability of bus bars, contributing to more efficient power distribution systems.

Figure 5. Welding Al-Cu. Left: using spiral beam shape. Right: using a single point.

Advancements in Welding Thick Sections

In addition to the remarkable developments in welding various materials, Dynamic Beam Lasers have shown promise in welding thick sections. Traditional welding techniques often require multiple passes or complex setups to achieve a strong weld in thick sections. However, with the utilization of Dynamic Beam Lasers, the process becomes significantly more efficient and streamlined. By harnessing the power of an 80 kW Single Mode laser combined with Dynamic Beam Laser features, researchers have successfully accomplished single-pass welds on sections as thick as 70 mm. This breakthrough not only saves time but also minimizes the risks associated with multi-pass welding, such as distortion and heat-affected zone issues. The ability to achieve high-quality welds in thick sections using Dynamic Beam Lasers opens up new possibilities for industries that rely on the fabrication of large-scale structures, such as shipbuilding and wind towers.

Figure 6. Single pass welds of 25mm - 70mm with Dynamic Beam Laser without the usage of filler wire

As research continues to unfold, we can anticipate even more remarkable breakthroughs in Dynamic Beam Laser technology. With each new advancement, the laser community is inching closer to realizing the full potential of this cutting-edge technology, revolutionizing welding processes, and contributing to advancements in various industries worldwide.