laser welding for automotive powertrain applications
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( © EMAG Automation GmbH, 2013 )Page 1
EMAG LASER SYSTEMS
for Powertrain Welding Applications
TEAM TLAS
( © EMAG Automation GmbH, 2013 )Page 2
TEAM TLAS
LASER WELDING – WHY?
■ enables size & weight reduction
■ replaces mechanical joints ( caulking, bolting )
■ enables new component designs using
material combinations (e.g. case hardening
steel / cast iron, steel / sheet metal )
■ suitable for high volume production ( takttime,
repeatability )
■ allows filler wire, e.g. suitable for cast iron /
steel welds
■ suitable for pre-assembled components
■ can integrate additional operations like laser
cleaning, assembling, pre- and postheating,
brushing. gaging/testing...
( © EMAG Automation GmbH, 2013 )Page 3
TEAM TLAS
ADVANTAGES OF LASER WELDING
■ Suitable for Powertrain Components
■ Depth & weld shape can be adapted to part
requirements
■ Very good weld quality
■ Allows filler wire, e.g. suitable for cast iron /
steel welds
■ Suitable for pre-assembled components like
diff cases
■ Additional operations like laser cleaning,
assembling, pre- and postheating, brushing
can be integrated.
■ Offers lower Cost per Piece compared to
Electron Beam Welding ( EBW )
( © EMAG Automation GmbH, 2013 )Page 4
TEAM TLAS
POWERTRAIN WELDING
Challenges:
■ Welding of finished components
■ More challenging materials
■ Process Monitoring
■ Process Integration
e.g. Assembling / Welding / Testing
General Aspects
Circular Welds
Penetration 2..8 mm
Typical Materials:
■ Case Hardening Steel
(e.g. 16MnCr5,20MnCr5, 25CrMo4)
■ Carbon Steel (e.g. C35)
■ Contruction St. (e.g. St52)
■ Cast Iron (GJS600 , GTS)
■ Low Carbon Sheets
( © EMAG Automation GmbH, 2013 )Page 5
TEAM TLAS
APPLICATIONS: DRIVEN GEARS ( Manual & Double-Clutch Transmissions)
( © EMAG Automation GmbH, 2013 )Page 6
TEAM TLAS
LASER WELDER FOR DRIVEN GEARS EMAG ELC160
Electrical Cabinet Chiller
Shield Gas
Delivery
Shield Gas
Delivery
Assembling / PressingAssembling / Pressing
Pre-HeatingPre-Heating
WeldingWelding Laser
Pneumatics
Purge Air
Pneumatics
Purge Air
( © EMAG Automation GmbH, 2013 )Page 7
TEAM TLAS
LASER WELDER FOR DRIVEN GEARS EMAG ELC160
( © EMAG Automation GmbH, 2013 )Page 8
TEAM TLAS
APPLICATION EXAMPLE: DRIVEN GEAR ( PASSENGER CAR )
Weld Dia. 53,5 mm
Material 16 MnCr5 ( both )
Pre-Heating not required
Penetration 2,5 mm (min)
Power ca. 2,0 kW
Cycle Time ( F2F ) < 8 sec
( © EMAG Automation GmbH, 2013 )Page 9
TEAM TLAS
APPLICATION EXAMPLE: DCT ( Double Clutch Transmission ) COMPONENTS
( © EMAG Automation GmbH, 2013 )Page 10
TEAM TLAS
ELC 160 POWERTRAIN WELDER
( © EMAG Automation GmbH, 2013 )Page 11
TEAM TLAS
PRINCIPLE ELC 160
3-Axis-Unit
( Spindle )
X/W/C
Welding Head
Upper Tooling
(Welding)Assembly Press
Options, e.g. Wire Brush,
Induction Coil ( Pre-Heating), Gaging, ...
( © EMAG Automation GmbH, 2013 )Page 12
TEAM TLAS
APPLICATION EXAMPLE: INPUT SHAFT FOR AUTOMATIC TRANSMISSION.
1. Pressing Shaft / Cup
2. Laser Welding Shaft/Cup
3. Laser Welding Cup / Ring
4. Turning of Face
5. Laser Welding Gear
6. Brushing
Cycle Time ~ 40 sec
Shaft
Ring
Gear
Cup
( © EMAG Automation GmbH, 2013 )Page 13
TEAM TLAS
EMAG HVSC 250 DUO
( © EMAG Automation GmbH, 2013 )Page 14
TEAM TLAS
PICKUP-MASCHINES
■ The Chuck „picks“ the parts off the conveyor
■ Handling & Automation is „integrated“
■ The part is moving, the „tool“ is fixed
■ Fixed Optics are much easier than „Flying“
Optics (Robustness, Ease of use, Tightness,
Optical...)
■ Less Tooling
■ Proven Concept for Mass Production
■ More expensive tooling, higher moving
masses
( © EMAG Automation GmbH, 2013 )Page 15
TEAM TLAS
APPLICATION EXAMPLE: LASER WELDING DIFFERENTIAL CASE / RING GEAR
The bolts between diff case and ring gear are
replaced by a laser welded joint.
Advantages:
■ Less Weight
■ Less Cost
■ Better Quality
( © EMAG Automation GmbH, 2013 )Page 16
TEAM TLAS
APPLICATION EXAMPLE: LASER WELDING DIFFERENTIAL CASE / RING GEAR
The Process:
■ Laser Cleaning of both components
■ Assembling / Pressing
■ Laser Welding
(Cast Iron / Case Hardening Steel,
with Filler Wire)
( © EMAG Automation GmbH, 2013 )Page 17
TEAM TLAS
APPLICATION EXAMPLE: LASER WELDING DIFFERENTIAL CASE / RING GEAR
Challenges:
■ Welding of Nodular Cast Iron and
Case Hardening Steel
An adapted welding process is required
■ Diff Case is pre-assembled and lubricated
( Risk of pollution in the weld zone )
Local cleaning prior to welding is required
■ Ring Gear is „finished“
Heat distortion must be improved
■ Ring may be phosphate coated
Local removal of phospate coating is required
( © EMAG Automation GmbH, 2013 )Page 18
TEAM TLAS
APPLICATION EXAMPLE: LASER WELDING DIFFERENTIAL CASE / RING GEAR
The Process:
■ Laser Cleaning
to remove pollution on the diff case
to remove phosphate coating on the
ring gear
■ Assembling / Pressing
■ Laser Welding
Cast Iron / Case Hardening Steel,
with Filler Wire)
■ (Brushing)
( © EMAG Automation GmbH, 2013 )Page 19
TEAM TLAS
LASER CLEANING
Before After
Laser Cleaning allows local, impact-free removal of
surface coatings and / or organic contamination
( © EMAG Automation GmbH, 2013 )Page 20
TEAM TLAS
LASER CLEANING
Surface
( © EMAG Automation GmbH, 2013 )Page 21
TEAM TLAS
LASER CLEANING OF DIFF.CASE
■ Rotational Cleaning ( EMAG )
■ Removal of any grease, oil etc. from the surface
■ Utilisation of the welding laser, no additional
laser is needed ( Time Sharing )
LASER BEAM
( © EMAG Automation GmbH, 2013 )Page 22
TEAM TLAS
WELD JOINT EXAMPLE
( © EMAG Automation GmbH, 2013 )Page 23
TEAM TLAS
TOOLING
■ Robust Welding Process
■ No tack weld required
■ Transmission is completely covered and protected
against weld spatter etc.
■ Automatic Changeover is available
Tooling Lower
Axial Force
(100kN max)
Pressing
Ring
Mandrel
LASER BEAM
( © EMAG Automation GmbH, 2013 )Page 24
TEAM TLAS
EMAG LASER CELL ELC 250DUO
■ Pickup Principle
■ 2 Stations
■ St.1: Laser Cleaning
■ St. 2: Laser Welding
■ Fixed Optics (Double)
■ Beam Switch
■ Integrated Press for Assembly and Clamping
( © EMAG Automation GmbH, 2013 )Page 25
TEAM TLAS
EMAG ELC 250 DUO
Laser
Chiller
Automation
Electrical
Slide ( 2* )
( © EMAG Automation GmbH, 2013 )Page 26
TEAM TLAS
EMAG ELC 250 DUO
( © EMAG Automation GmbH, 2013 )Page 27
TEAM TLAS
APPLICATION EXAMPLE : TRANSMISSION SHAFT
The Process:
■ Assembling
■ Pre-Heating ( Inductive )
■ Welding
■ Post-Heating
( © EMAG Automation GmbH, 2013 )Page 28
TEAM TLAS
APPLICATION EXAMPLE:
Link Shafts, Steering Shafts
( © EMAG Automation GmbH, 2013 )Page 29
TEAM TLAS
ELC 200 H: LASER WELDER FOR SHAFTS
■ Pickup
■ Fixed Optics
■ Flexible Automation
( © EMAG Automation GmbH, 2013 )Page 30
TEAM TLAS
EMAG ELC 200 H
( © EMAG Automation GmbH, 2013 )Page 31
TEAM TLAS
MULTI-KW LASERS FOR MATERIAL PROCESSING
Manufacturer
Wave Length
Max. Power
Investment / kW
Suitable for
Cutting
Heat Conduct. Welding
Key Hole Welding
Cladding
Laser Hardening
Brazing
Beam Delivery
Efficiency
CO2
Fast Flow
CO2
Diffusion
Cooled
Solid State
(Rod)
Solid State
( Disc )
Solid State
(Fibre)
Diode
Laser
Multiple ROFIN Multiple TRUMPF IPG Multiple
10,6 µm 10,6 µm 1,06 µm ~ 1,0 µm ~ 1,0 µm
0,808 µm
0,940 µm
max. 12 kW max. 6 kW max. 4,5 kW max. 8 kW max. 20 kW max. 5 kW
100% 90% 150% 130% 130% 80%
++ ++ o o o --
-- -- ++ ++ ++ +
++ ++ -- ++ ++ --
++ ++ ++ ++ ++ ++
+ + ++ ++ ++ ++
+ + + + + ++
Mirror Mirror Fiber Fiber Fiber
direct,
Fiber
8% 10% 4% 30% 30% 15%
( © EMAG Automation GmbH, 2013 )Page 32
TEAM TLAS
WHY EMAG?
■ EMAG is considered to be a technology leader
in the field of production systems
■ Only EMAG can offer such a wide portfolio of
technologies for powertrain components
■ EMAG ELC laser welders are installed major
OEM‘s and Tier 1 / 2 suppliers
■ EMAG ELC laser welders are designed for
volume production in terms of reliability and
performance.
■ EMAG offers turnkey solutions including
workholding, automation, process
and support.
■ EMAG has a global sales&service network and
is capable to support customers anywhere on
the planet.
( © EMAG Automation GmbH, 2013 )Page 33
TEAM TLAS
SUMMARY
■ Laser welding is used for a huge variety of
powertrain components
■ Production systems include numerous
peripheral processes like
laser cleaning, assembling, pre- / post-heating,
brushing, testing
■ Range of welded materials is increasing
■ Welding of finished components is a key for
flexible production
■ Solid State Lasers will gain significant market
share but require a lot of learning...
( © EMAG Automation GmbH, 2013 )Page 34
CONTACT
EMAG Holding GmbH
Austrasse 24
73084 Salach
Germany
Phone: +49 / 7162 / 17-0
Fax: +49 / 7162 / 17-199
communications@emag.com
www.emag.com
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