AD&P; > June 2013 > NOTABLE
Lasers for Improved Design & Engineering
One part of laser technology that probably can't be
emphasized enough is the fact that it can allow not only
changes in the manufacturing plant, but in the design
and engineering ofces. That is, deploying lasers can
allow (1) design modifcations and (2) improved physical
properties in assembled components.
This became clear during a discussion with Tracey Ryba,
product manager, Lasers—North America, TRUMPF Inc.
(us.trumpf.com), which provides both CO2 and solidstate (disk, diode, fber) lasers.
A clear example of the frst is found on the roofs and
rear license plate surrounds on an increasing number
of vehicles. Take the roof. Ordinarily when the roof and
body side stamping are welded together, the result is a
cosmetically unsightly seam running along both sides
of the roof. The ditch welds are not pretty. So there is a
trim piece that's ftted into the ditch to cover it up.
Designers can take advantage of that. Another area where
lasers can make a diference is in the design of window
apertures. As Ryba explains, the size of fanges necessary
to weld door inners and outers is greatly reduced—by as
much as 60%—if laser welding is used instead of spot
welding. Which simply means that there can be more
open space and less metal.
This metal reduction can be carried out throughout the
vehicle design, which means that the overall weight of
the car can be brought down through the elimination of
large fanges.
Realize also that unlike spot welding, only one-sided
access is needed for laser welding, and unlike arc welding,
the actual laser equipment can be a considerable distance
away from the work area, so otherwise inaccessible areas
can be readily reached because the work is being done by
a beam of light, not a physical tool.
→
But by using a laser—say a diode laser—the side and the
roof are brought together, the laser heats the
joint and a fller material is laid down.
The result is a smooth seam. No
extraneous additions are
necessary.
p What don't you see in this picture of the Volkswagen
Golf VII? Pieces of trim running along the roof of the vehicle
where the body side is welded to the roof. Laser brazing is why.
VW extensively uses lasers for joining in this vehicle.
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