Gas laser welding in the automotive industry: steering support welding automation solutions

2023-07-14

As the automotive industry continues to electrify and consumer demand for safety and comfort features increases, laser welding is emerging as a fast and clean technology for automotive applications. It is widely used in cameras, control units and even components of electric vehicle transmissions. However, appropriate materials need to be selected in the laser welding process, because the use of some materials may bring an increase in the failure rate of parts, and then affect the brand reputation. Therefore, it is important to ensure that appropriate material solutions are selected in order to reduce the risk of failure.

The global laser welding demand is projected to reach $5.387 million by 2032 as electronic functions such as cameras, adaptive cruise control, and control units are integrated into automotive components.

Oems can use laser welding technology to achieve fast and clean processing as well as higher design flexibility. This makes laser welding well suited for integrating sensing components such as advanced driver assistance systems, global navigation satellite systems, and cameras. Laser welding can also provide moisture and dust protection for electric vehicle electronics and battery systems. Because of its high accuracy, laser welding is also an efficient and relatively more cost-effective technique for high-volume applications that require automation.

As laser welding becomes more widely used, it is increasingly important to ensure that the right material solution is used. Using the wrong materials can damage the reputation of your brand and business. Some laser welding materials are widely used in the market, but may have limitations in specific situations, which may lead to failure. Defective parts can lead to product recalls, damaged brand reputation, additional repair costs, and even liability for damages. To avoid these problems, working with a partner with deep design and material expertise is essential.

The application of advanced material solutions can help reduce costs and improve efficiency.

A variety of laser welding materials, including the high performance Arnite® poly-butylene terylene ester (PBT), which process cycles A variety of laser welding materials, including the high performance Arnite® poly-butylene terylene ester (PBT), can achieve faster cycle times than conventional solutions. Arnite® PBT is available in a variety of welding material thicknesses and colors, including custom laser transparent black, to meet a variety of application requirements and designs.

In a study where Arnite® PBT material and conventional PBT were used for laser welding on radar housing, Arnite® PBT welded twice as fast as the comparison material and showed no signs of surface defects or burns. Therefore, choosing Arnite® PBT (LT TV4 261) instead of conventional PBT can increase productivity and reduce costs.

Conventional PBTArnite®PBT

• Double the welding speed

The Enhuali material is a suitable material for demanding laser welding applications with significantly lower moisture absorption than competing materials. This corresponds to Enwali material with better stability and lower degassing opportunities, which means customers can design parts with higher tolerance requirements and support a range of laser welding options to achieve fast welding and good performance.

 high grade of transparency

High transparency is essential for thicker, stronger designs and higher dimensional stability because it supports wider machining Windows. In the case of laser penetration welding, the laser beam passes through a transparent or quasi-transparent upper cover to reach the lower laser absorbing component. The combination of good transparency and absorptivity will allow the molten pool to form precisely where the layers meet. When the lower layer absorbs laser energy and melts, it transfers heat to the upper layer, causing it to melt as well. When the molten polymer cools under the clamping force, they bond together to form a weld.

The wider the machining window, the less likely the part will be defective throughout the manufacturing process. Arnite® (LT TV4 261) is three times more transparent than conventional PBT, improving manufacturing efficiency while reducing part defects.

In conventional PBT, glass fiber (GF) reinforcement is usually used to prevent loss of hardness and stiffness during welding. But the presence of additives tends to reduce the transparency of plastics. When the transparency of the polymer drops too low, the welding process becomes challenging or even impossible. However, in laser welding, the laser beam not only passes through the upper layer, but is absorbed into the plastic, forming an ablation on its surface even before the welding begins. Arnite® PBT is an inherently high transparency material that provides a good basis for laser transmission welding of various thicknesses and GF percentages.