Among the many processes of laser welding, laser welding with filler wire is being adopted by more and more automobile manufacturers due to its unique advantages. This article will discuss in detail the role of laser wire welding in automobile manufacturing.
What is laser welding with filler wire?
Laser wire welding is a process method in which a specific welding wire is pre-filled in the weld or the welding wire is fed synchronously during the laser welding process to form a welded joint. It is equivalent to inputting approximately homogeneous wire materials into the weld pool at the same time as laser deep melting welding.
Application of laser wire welding in automobile manufacturing
In the process of automobile body manufacturing, laser wire welding is mainly used in the welding of aluminum alloy and steel parts of the body.
1. Aluminum alloy welding of the body
In the welding process of aluminum alloy parts of the automobile body, the surface tension of the molten pool is small, which is easy to cause the molten pool to collapse. The laser wire welding process can solve the pool collapse problem to a large extent by melting the welding wire during the laser welding process.
2. Welding of body structure parts
Key structural parts such as body frame, door sills, and longitudinal beams have extremely high requirements for welding quality. Laser filler wire welding can effectively cope with assembly gap changes, ensure weld strength and density, and improve the overall rigidity and safety of the car body.
3. Dissimilar material connection
For example, the connection of dissimilar metals such as aluminum and steel, magnesium and aluminum, by selecting suitable welding wire materials, laser filler wire welding can achieve high-strength, low-defect welding of dissimilar materials, and promote the lightweight process of automobiles.
Why is welding wire filled in laser welding?
- The chemical composition of the welded joint depends entirely on the parent material, and its performance cannot be adjusted as needed. When aluminum alloys are laser welded, low-boiling point elements are easy to evaporate, resulting in a decrease in bonding performance.
- Laser welding requires strict joint gaps, and the maximum gap for self-welding does not exceed 10% of the plate thickness. In actual production, especially in the aerospace industry, indirect laser welding of thin plates is inevitable. When the plate thickness is 1.2mm or more, the gap requirements of butt joints are difficult to meet. If the surface butt welds on thin plates, it is even more difficult to meet the gap requirements. Although the required assembly gap can meet the processing requirements, it will inevitably increase the cost, which is not conducive to the promotion and application of laser welding in industrial production.
- The aluminum alloy laser welding process is unstable, the weld formation is not ideal, the smoke pool has high reflectivity, and the surface tension is low, which will cause weld collapse, pores, softening, etc. These problems limit the application of laser welding technology in the aerospace and defense industries.
What are the advantages of laser welding with filler wire
Compared with laser deep fusion welding, laser wire welding has two advantages in the application of automobile number welding. First, it can greatly improve the tolerance of the assembly time between the waiting automobile body parts, and solve the problem of excessive requirements for the groove gap of laser deep fusion welding;
Second, the organization distribution of the weld area can be improved by using welding wires with different composition contents, thereby regulating the weld performance.
Summary
Laser wire welding with its advantages of high quality, high efficiency and high adaptability is becoming an indispensable advanced welding technology in the field of automobile manufacturing. If you have more questions about the product, please contact us!