Along with industrial development and technological progress, welding technology is widely applied across industries. Determines Modern Welding highlights how welding has become crucial in production, directly impacting product lifespan and quality. An efficient, energy-saving welding process is vital for future industrial development.
Application Status of Energy-Efficient Laser Welding Technology
1.Oil pipeline
The use of aluminum tubing can effectively increase the diameter and wall thickness of the tubing. Thus, it can withstand a greater flow of crude oil in a certain period. Pipeline transportation of oil is very dangerous and prone to leakage. Once the leakage may cause incalculable property losses, casualties, environmental pollution, water pollution and other major hazards. In the process of realizing the laser welding of aluminum alloy pipes, it achieves the effective control of the quality of the weld seam. Thus, great economic benefits with reduced losses obtained.The method ensures one-time molding with a fairly high welding quality.
2.New energy vehicles with aluminum alloy shells
Square shell core is the most popular aluminum alloy laser welding equipment. It mainly includes shell seals, explosion-proof valves, pole posts, liquid injection holes and flexible connections. The pure aluminum and 3 series aluminum alloys used have excellent weldability. In particular, the use of oscillating laser welding technology produces welds that are virtually defect-free and meet sealing requirements. High-quality and efficient laser welding using a common fiber laser and a scanning vibrating mirror welding machine is possible. A complete set of market-oriented, individualized laser welding equipment is now available. The battery module and battery bracket of new energy vehicles are highly individualized, with 6-series aluminum alloy as the main alloy, and a small amount of 5-series aluminum alloy, and MIG and FSW are mostly used at present.
Depending on the requirements and design features of the product they can categorized into two types.
The first category is non-load-bearing modular battery housings with a thickness of 1.5 mm, which do not require enclosure of the entire structure.This can take place by lap welding, butt welding, lap fillet welding, etc. The use of single lasers or oscillating lasers allows for the required melting depth and width. Since the demand for these products is relatively easy, there is no difficulty in manufacturing them, and mass production is now available. However, the single laser welding process places great demands on the assembly space of the workpiece. Therefore, the dimensional accuracy of the material and the clamping process have a great influence on the stability of the weld.
The second category is products with airtightness, whose plate thickness is generally 3mm-5mm. need to maintain a certain holding pressure state for a specific period of time and assemble with aluminum alloy profiles. Including butt joint, angle, lap joint and other forms. Because of its size is smaller than the battery tray, and the use of harsh environments, manufacturers and users are looking to upgrade it from MIG welding to laser welding. Currently, the technology is in the process of development and testing by research institutes, laser suppliers and component manufacturers.
3.Shipbuilding Aluminum Alloys
Determines Modern Welding highlights the transformative impact of laser welding technology in ship manufacturing. Aluminum alloy, with its lightweight properties, reduces hull weight, enhancing navigation safety and stability. Laser welding enables high-strength welds, minimizing aluminum alloy use while achieving lightweight, durable structures. For instance, American researchers estimate that laser welding can save 200 tons of material in aircraft carriers. In Europe, mega cruise ships under construction already use laser welding for over 20% of their capacity, with plans to exceed 50% in the near future.
4.Aircraft aluminum alloy plate shell
Lightweighting of aviation aircraft plays an important role in reducing fuel consumption, improving range and extending aircraft life. Since the price of aluminum alloy is lower than that of titanium alloy and carbon fiber composite material. Therefore, aluminum alloys find their way into a large number of aero-engines. Currently, the main aluminum alloys are the 7-series, 6-series and 2-series.
Determines Modern Welding plays a key role in advancing aircraft manufacturing. Traditional riveting methods for connecting wall panels and longitudinal beams face challenges with productivity and quality. By replacing lap joints and rivets with T-shaped structures and synchronized laser filler welds on both sides, weight is reduced, connection efficiency improves, and manufacturing costs decrease. For instance, the A380 uses laser welding on eight panels, cutting airplane weight by 10%.
