Advantages of Laser Welding in Auto Manufacturing

(Image courtesy of EMAG.)

In the automotive industry, one trend has been consistent for years: passenger vehicle transmissions are becoming smaller and lighter while the number of speeds—and of toothed gear components—continue to increase.

How does the entire assembly not become heavier?

The answer becomes obvious by taking a closer look at the individual components. A gearwheel, for example, consists of two components that are joined by laser welding. This allows automotive design engineers to work without screws, which makes for overall lighter components.

These benefits explain why laser welding has become a core process in transmission manufacturing. However, integrating laser welding into a complete production line can be difficult because the actual laser welding process is preceded and followed by many other processes.

Depending on the component, these may include checking, washing and/or joining of components before laser welding, as well as a brushing process and a final ultrasonic inspection of the welding seam.

"Implementing comprehensive production lines that integrate laser welding into the overall sequence—is the special expertise of EMAG Automation", said Andreas Mootz, managing director of EMAG Automation. "We are very familiar with the production sequence for central transmission components. Therefore, we do not just design another laser welding machine. With our multi-stage production solutions, we focus on creating a perfect process chain that operates quickly, and very safely."

For example, EMAG Automation has developed its own ultrasonic inspection method. "The trend goes toward zero-defect production that ensures the quality of every single welding seam. We can guarantee it with this technology", said Mootz.

(Image courtesy of EMAG.)

In EMAG’s case, the laser welding machines themselves are customized solutions based on EMAG’s ELC series machines—each model being best suited to different types of components. For example, the ELC 160 HP machine is a special solution for gearwheels, while the ELC 160 model provides an all-round solution for automatic transmission and dual clutch components.

EMAG Automation also collaborates with EMAG Maschinenfabrik in Salach, Germany. By combining their resources, they can implement a more complete production sequence for transmission components—from welding to turning and grinding.

"In this way, production planning has become so much easier. This is a huge benefit that is continually increasing its market recognition," Mootz concluded.

For more information on laser welding, visit the EMAG website.