Page 1 - Laserline-Case-Study-Aluminum-welding-of-visible-surfaces

Aluminum welding of visible surfaces

Task Result

Previous positive experience utilizing diode lasers for The aluminum weld produced meets the highest
brazing of zinc coated car bodies prompted Audi to also specifications for the optical quality of a visible joint without
try using the same proven lasers for aluminum welding. further post-processing. Excellent process stability,
The task set for Laserline was to generate a class A weld reliability and cost advantages have resulted in diode
that was smooth and visually appealing. lasers subsequently being utilized in many new additional
aluminum welding applications at Audi.
Process

Welding of aluminum requires an AlSi filler material to
prevent hot cracking of the weld. The welding equipment
used for this process is largely the same industrially proven
components as those used in the brazing process. The
filler wire is added using tactile seam tracking optics. Three
years of process optimization on different generations of
lasers and cars has allowed Audi to clearly define the best
characteristics required for the laser source. The LDF
4000-40, developed in 2007, offers a beam quality and an Material: 1.2 mm aluminum sheets
output power that completely fulfills all the requirements Task: Visually appealing show surface
necessary for this high quality, class A aluminum welding. Laser: LDF 4000-40
Optics: Seam tracking welding optics with AlSi filler wire
Weld speed: 3 m/min
Result: Running in mass production since 2008

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