laser welding for automotive powertrain applications

( © 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