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Company PresentationLaser beam welding – the alternative solution

13 May, 2014

Energy-Efficient Transportation Systems ConferenceGerman American Chambers of Commerce

Chicago, IL, USA

Mr. Thomas Fittkau – Photon Laser Manufacturing, Germany

Dr. Mariana Forrest – LASAP Inc, Troy, MI, USA(North American Representative)

Photon Laser ManufacturingPhoton AG references

Photon AG

• Founded in: 1998

• Headquarters: Berlin

• Supervisory board: Peter Schüring, Axel Kahsnitz, Paul Seiler

• Board of directors: Dr. Hermann Andreas, Holger Alder, Steffen Neumann

• Subsidiaries: Photon Laser Engineering GmbH, BerlinManaging directors: Holger Alder, Steffen Neumann

Photon Laser Manufacturing GmbH, Schönwalde-GlienManaging director: Steffen Neumann

Photon Meissener Technologies GmbH, MeißenManaging director: Steffen Neumann

Photon Laser ManufacturingPhoton AG references

Subsidiary companies:

• Location: Berlin• Core skills:

• Process development• Product development• Prototyping• Production of low-volume

products • Training

• Location: Schönwalde-Glien• Core skills:

• Laser beam welding• Conventional welding• Laser cutting• Metal forming• Production of low and

medium volume products

• Location: Meissen• Core skills:

• Assembling of metal components and chassis

• Telecommunication products

• Emergency and information terminals

• Laser cutting / metal forming

Photon Laser ManufacturingPhoton AG references

Value Added by Photon Group

Photon Laser ManufacturingPhoton AG references

Target market – railway industry

Possibilities

Especially for welded components with thin walled sheet bodies which also conform to strict planarity requirements

Product and service offers

Support during design and engineering to achieve compatible laser beam welding designs

Prototype manufacturing

Volume production manufacturing of low warpage components according to DIN EN 15085-2 CL1 (former DIN 6700-2 C1)

Conventional welding

Product examples

• locomotive roofs• tram roofs• side wall panels• beams• intermediate floors• end walls

References

• Alstom• Bombardier• Siemens• Talgo • ....

Photon Laser ManufacturingPhoton AG references

Target market – automotive industry

Possibilities

The application of new material types for light weight automotive designs

Product and service offers

Process development(new types of material and material combinations)

Technical consultation for laser beam welding equipment and processes at your production facilities

Prototypes and pilot series

Product examples

•Tailored Blanks•Liftgates•Gear Selector Forks•Side Panels

References

• OEMs - Audi, BMW, Daimler, Ford, GM, Nissan, Renault, VW, Volvo, ...

•Suppliers – Benteler, Gedia, ThyssenKrupp, ...

Photon Laser ManufacturingPhoton AG references

Target market – aeronautic industry

Possibilities

Substitution of conventional processes (e.g. riveting or milling)

Product and service offers

- Process development

- Prototypes and pilot series

Product examples

• Fan Blades• Outlet Guide Vanes• Composite Blades• Pressure Air Connections• Jet Pipes• Fairings

References

• Rolls Royce• Airbus Group• MTU Aero Engines• …

Photon Laser ManufacturingPhoton AG references

Milestones of development of Photon Laser Manufacturing GmbH

• 1998 - Commissioning of the first laser beam welding facility- One of the first companies with an approval of the “Deutsche Bundesbahn” to manufacture

laser beam welded components for rail vehicles (DIN EN 15085-2)• 1999 - Foundation of Photon Laser Engineering GmbH as part of Photon AG (equipped with 4 laser

cells)• 2002 - Laser welding project Golf V with Volkswagen Group, leading role for Photon, responsible for

facility and process specification, commissioning and training (420 laser sources, biggest laser beam welding project ever)

• 2003 - Commissioning of the 6th robot system for laser welding of high volumes (Tailored Blanks)• 2006 - First laser beam welding projects for aircraft industries• 2008 - Installation of a first gantry robot for XXL-parts with length of up to 20m• 2011 - Putting into operation of 2 articulating-arm robots, movable on a linear axis, for parts up to 16 m

in length• 2012 - Installation of the second gantry robot for parts of up to 7m length

• DIN EN ISO 9001:2008 certified• Approval according to DIN EN 15085-2 CL1 (former DIN 6700-2) for welding assemblies for rail vehicles• Approval according to DIN EN 2303 for welding of assemblies for defense technology

Photon Laser ManufacturingPhoton AG references

Motivation and Main Benefits of 3-D Laser Welding

Reduction  of Filling and Grinding

Higher Welding Speed

Higher Automation

Reduction of Production Costs

Weight ReductionReduction of Operation Costs

Higher Accuracy

Stiffness Increase

Improved Exterior Surface

Improving of Part Features

Photon Laser ManufacturingPhoton AG references

Photon Laser Manufacturing GmbH (PLM) = Laser beam welding for volume production

Tailor Blanks -Thicker material onlywhere necessary

Extra large blanksTotaly new design options

Complete roofs

Principle:Parallel application of laser beam

welding technology and conventional welding processes

Laser beam welding provides a significant alternative option

End walls

Photon Laser ManufacturingPhoton AG references

In-House Product range – Laser beam welding for railway industry:

Laser beam welded side wall panels for tramsS355J2CuC+N t=2mm and S355J2WC+N t=4mm

Photon Laser ManufacturingPhoton AG references

In-House Product range – Laser beam welding for railway industry:

Photon Laser ManufacturingPhoton AG references

In-House Product range – Laser beam welding for railway industry:

Side wall panels passengers coaches (double-decker)length: 15m, height: 3,5m

Laser beam welded

Photon Laser ManufacturingPhoton AG references

In-House Product range – Laser beam welding for railway industry:

Roof panels - passenger coacheslength: 16m

1.4301, t=1,25mmlaser beam welded

Photon Laser ManufacturingPhoton AG references

In-House Product range – Laser beam welding for railway industry:

Locomotives and Passenger Coaches

Various roofs and side wall panelslaser beam welded

Photon Laser ManufacturingPhoton AG references

In-House Product range – Laser beam welding for railway industry:

tram roofsLaser beam welded

1,5 mm, stainless steel

Photon Laser ManufacturingPhoton AG references

In-House Product range – Laser beam welding for railway industry:

Roof beams for trams

L=10.5 metersT=2 mm 1.4003

Laser welded joints and ribs

Photon Laser ManufacturingPhoton AG references

Photon Laser Manufacturing – Laser Welding Solutions for Highly - Challenging Applications!

3D-Laser beam welding:

•Side walls•Roofs•Longbeams

View of Photon’s Production Area

Photon Laser ManufacturingPhoton AG references

Major challenge:

2D - Laser beam welding in new, larger dimensions:20 m x 3 m x 1 m

Photon Laser Manufacturing – Laser Welding Solutions for Highly - Challenging Applications!

View of Photon’s Production Area

Photon Laser ManufacturingPhoton AG references

2D - Laser beam weldingof

medium sized parts(6 m x 3 m x 1 m)

Photon Laser Manufacturing – Laser Welding Solutions for Highly - Challenging Applications!

View of Photon’s Production Area

Photon Laser ManufacturingPhoton AG references

Examples R&D and low-volume production

Photon Laser Engineering

Photon Laser Manufacturing – Laser Welding Solutions for Highly - Challenging Applications!

Photon Laser ManufacturingPhoton AG references

Certificates

Photon Laser ManufacturingPhoton AG references

High Performance and Flexible Equipment

• cutting:• „Trumpf TruLaser 3060“ – 6 m x 2 m

• welding:• multiple laser sources 3 KW – 6 KW • 2 articulating-arm robots, fixed installation, for small and medium size assemblies• 2 articulating-arm robots, movable on a linear axis, for parts up to 16 m in length• 1 gantry system for parts up to 7 m in length• 1 gantry system for parts up to 20 m in length• 1 articulating-arm robot, movable on a linear axis, for parts up to 7 m in length• conventional welding machines (MAG, WIG, MIG)

• bending / rolling:• 2 bending machines, 300 t, for length up to 8 m • bending machine up to 4 m length• Various sheet metal forming machines

Photon Laser ManufacturingPhoton AG references

Conclusion

Photon Group

has proven experience in laser processing of various materials

Steel Stainless steelAluminum Titanium

is seeking to expand its presence in the US market by offering the advantages of laser technology for the new generation of energy–efficient transportation products

Photon Laser ManufacturingPhoton AG references

Photon AG – North American RepresentativeLasAp Inc. - Troy, MI, USA

Dr. Mariana G. Forrest - Founder and President

LasAp is an engineering and manufacturing consultancy firm dedicated to development and transfer into production of advancedmanufacturing technologies for component fabrication, joining & assembly .

Prior to founding LasAp in 2007, Dr. Forrest held various technical, R&D and executive management positions in engineering and manufacturing with Control Data, Chrysler and DaimlerChrysler, most recently, Senior Manager of Advanced Joining TechnologiesDevelopment group at DaimlerChrysler Corp. in Auburn Hills, MI. Currently she is a member of the International Editorial Advisory Board (Automotive Applications) for ILS (Industrial Laser Solutions).

Competencies / Consulting ServicesApplied Research – process, toolingTechnology state of art assessments studiesNew Process Technology feasibility studies (technical and economic)Process development and optimization Process demonstrations to potential customersLiaison with system integrators Technical marketing Competitive analyses Comparative process/equipment studies - material joinability characterization; technical and economicsDevelopment of Best Practice GuidelinesTechnology Demonstrator ProjectsProject Management

Gewerbegebiet Rosengarten 15D-14621 Schönwalde-GlienGermanyTelefon: +49 (33231) 705-0Telefax: +49 (33231) 705-20www.LM.PhotonAG.comLM@PhotonAG.com

NA Representative – LASAP Inc.

Dr. Mariana Forrest5160 Orchard Crest Dr.Troy, MI 48085Office: (248) 619.9077Cell: (248) 24-6709www.las-ap.commariana.forrest@las-ap.com

Photon Laser ManufacturingPhoton AG references