Fraunhofer Institute for Material and Beam Technology IWSSystem technology
Focus: Laser multi-pass narrow-gap welding (Laser-MPNGW)
remoweld® special laser welding head for laser multi-pass narrow-gap welding.
Technical data
- Highly dynamic 2D beam oscillation with frequency of max. 4 kHz
- Laser power: max. 8 kW
- Integrated components:
- Control unit for process control and regulation
- Combined feed of welding filler material and shielding gas
- Sensor technology for weld seam detection
- High-speed camera and sensors for process monitoring and quality assurance
Applications
- Thick sheet range: 10 to 250 mm, e.g. turbine construction (rotor shafts), housing segments
- Structural steelwork, presses, crane and tank installations, shipbuilding
Focus: Highly dynamic beam oscillation
remoweld® FLEX special laser welding head for high-frequency beam oscillation.
Technical data
- Highly dynamic 2D or 3D beam oscillation with frequencies in the kilohertz range
- Lissajous figures, high dynamic range: 1.5 x 1.5 mm2
- Laser power: max. 5 kW
- Option to implement:
- Sensor technology for weld seam detection
- Sensor technology for process monitoring, e.g. acoustics, image recognition, triangulation
Applications
- Thin sheet range: 0.5 to 5 mm, e.g. aluminum-copper mixed joints, aluminum die casting
- Foil welding, e.g. batteries, electrical contacts
- Aggregates, cooling, air conditioning, heat exchangers, pillow plates, turbocharger shafts
Focus: Acoustic process monitoring
Acoustic weld signature with characteristic process frequencies for real-time process analysis.
Technical data
- Membrane-free optical microphone
- Low inherent noise
- Frequency range: 10 Hz to 1 MHz (acoustic and ultrasonic)
- Dynamic range: 50-150 dB (A) SPL
Applications
- Wide range of applications from automotive to welded joints in household appliances, aerospace and a variety of measurement tasks to ensure component quality
- Real-time process monitoring of highly dynamic welding processes
- Correlation between weld seam quality and airborne noise possible
- Can be linked to AI evaluation methods
Focus: Geometric topology monitoring
High-resolution triangulation measurement for quality assessment of weld topographies.
Technical data
- Measuring principle: optical triangulation
- Low reflection sensitivity
- Resolution range: 2.5 to 50 µm
- Repeatability: 0.3 to 0.5 µm
Applications
- Position and distortion measurement of weld contours and welded components
- Inline / offline process monitoring of welding processes
- Correlation between weld quality and external weld appearance (flaking, geometric weld parameters)
- Stand-alone unit can be integrated into new and existing processes
- Combination with other sensors and AI evaluation methods
- Wide range of applications from automotive manufacturing to welded joints of household appliances, aerospace technology and a variety of measurement tasks to ensure component quality
Focus: Evaluation of the CO2 footprint of products and processes
Life Cycle Assessment for the description of material flows using the example of CO2 equivalent – utilization for laser-based manufacturing processes at Fraunhofer IWS.
Technical data
- Conformity of CO2 balancing based on DIN ISO 14064 and DIN ISO 14040
- Generation, calculation and visualization of CO2 and life cycle assessments
- Linking with technical databases, e.g. Gabi
- Generation of Sankey diagrams
Applications
- Assessment of CO2 emissions caused by human production and mobility to achieve European or global climate targets - keyword: max. 1.5°C global warming
- ”Computer Aided Eco-Balancing” (CAEB) for laser-based process chains and products
- Process comparisons for welding processes and production chains