Low-distortion and low-energy Laser-Multilayer-Narrow-Gap-Welding for the production of large and thick-walled steel structures (VE-MES)
Working Areas

Welding

Low-distortion and low-energy Laser-Multilayer-Narrow-Gap-Welding for the production of large and thick-walled steel structures (VE-MES)

  • Funding agency: Sächsisches Staatsministerium für Wirtschaft, Arbeit und Verkehr
  • Reference: 100320711
  • Duration: 14.08.2017 – 29.02.2020

In cooperation with the Fraunhofer IWS Dresden, BANG Kransysteme GmbH & Co. KG and ANTARES GmbH, a new automated laser beam multi-layer welding technology for the production of thick-walled (15 to 100 mm) large assemblies for crane and heavy steel construction using a high-power diode laser is being developed.
The contents of the development are the low-distortion welded construction, the heat-minimized welding technology, an industrial welding head and a laser protection device adapted to the process and components.

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Michael Schnick, Sascha Rose, Achim Mahrle, Uwe Füssel, Eckhardt Beyer: Influence of the Plasma Arc by Low-Power Laser Radiation. Symposium on 60 years of production technology in Dresden, 20th -21st. 11 .2014

Michael Schnick, Ronald Jüngling, Todt Deißer: Energy Efficiency as a Customer Benefit – New Welding Technologies by Kjellberg Finsterwalde. Innovation Congress Cottbus 2014

Michael Schnick: TIG High-performance Welding InFocus – Fundamentals and Application in Vehicle Manufacturing – 4th VDI conference: Joining in vehicle Manufacturing, Eisenach 26. 27.01.2015

Dreher, M .; Schnick, M .; Krink, V .; Schuster, H .: InFocus – TIG High-Performance Welding in Steel Production. 26th Welding Symposium, Magdeburg 12.5.2016

M. Schnick; V. Krink; F. Laurisch; J. Friedel: Cutting and Joining Thick Steel Sheets for Wind Turbines. DVS Congress and Expo in Nuremberg from 15th – 17th September 2015

Dreher, M .; Schnick, M .; Krink, V .; Schuster, H .: InFocus – High-Performance Welding in Steel Construction. Symposium for Welding Supervisors. DVS®-Verbundbildungseinrichtung (VBE) of the Dresden Chamber of Trade, Welding Educational Institute of Dresden, Dresden, 16.10.2015

Michael Dreher and Gaston Fettke: InFocus – Fundamentals and Applications for TIG High Performance Welding. 28th Welding Technology Colloquium of the District Association of Hamburg 7.2.2017

Development of a new processing head for laser-assisted plasma welding (LuPS)

  • Funding agency: Sächsisches Staatsministerium für Wirtschaft, Arbeit und Verkehr
  • Reference: 100189174
  • Duration: 01.01.2016 – 02.02.2018

The content of the cooperative research project supported by SAB with the Fraunhofer IWS and the TU Dresden is the investigation of a novel laser-assisted plasma welding process in coaxial arrangement.

Within the framework of the project, the scientific basis for the development of a coaxial plasma laser torch is to be developed and the process advantages of the laser plasma process are to be analyzed, in particular the possibilities of substituting cost-intensive laser power by plasma power.

Welding Torch as a Technology Carrier

We are a research company specialized in automated welding processes using laser and plasma arc technologies. The main focus of our business is on high-performance TIG welding technologies for iron and non-ferrous metals, and aluminum. Our torch-developments support the InFocus and ARCLINE® PP high-performance technologies. The se torches stand for highest quality, productivity and robustness.

Component-specific Gas-Shield-Systems in 3D-metal-printing

A high-quality gas cover is very important for welding processes, not only in the process area but also in the hot temperature fields on the workpiece.
Through the use of additive manufacturing processes, complex gas protection systems can be manufactured individually for each component and in individual production at low cost.

Our patented gas protection systems extend the application possibilities and the potential of our modern welding torches as well as conventional processes in your production environment.

Cutting

Research and Development for Plasma and Laser Technology

Overview Plasma and laser cutting technologies enable high quality and productive cutting of plates. Kjellberg Finsterwalde is an international brand which stands for the state-of-the-art plant technology and producing cutting edges that are free from post-processing. Our research company works for Kjellberg Finsterwalde in the field of preliminary research and technology development. Based on our state-of-the-art cutting equipment, at the same time we offer developing niche applications for plasma and laser cutting. For example, the plasma cutting of woven fabric structures in fiber composite components.

Research and Development for Plasma and Laser Technology

Plasma and laser cutting technologies enable high quality and productive cutting of plates. Kjellberg Finsterwalde is an international brand which stands for the state-of-the-art plant technology and producing cutting edges that are free from post-processing. Our research company works for Kjellberg Finsterwalde in the field of preliminary research and technology development. Based on our state-of-the-art cutting equipment, at the same time we offer developing niche applications for plasma and laser cutting. For example, the plasma cutting of woven fabric structures in fiber composite components.

Thermal Separation from 0.1 to 150 mm

In plasma cutting, the material is locally melted by means of an extremely focused plasma jet that is up to 30,000 K hot and moves at several 1000 m/s. This process results in casting out the material to form a kerf. Kjellberg Finsterwalde has already realized process optimally: The plant technology achieves the highest productivity and accomplishes cutting edges of 1 to 150 mm thick plates. The
outcome is very similar to laser cutting and nearly needs no post processing. The Laser beam cutting is a thermal separation process by means of a laser beam. It can be used for electrically conductive and non-conductive, as well as flammable and non-flammable materials. This method is specifically used when complex contours need to be cut precisely and quickly, preferably in the lower plate thickness range of up to 10 mm, and with particularly high-quality requirements (shape deviations in the contour area).

Thermisches Trennen von 0,1 bis 150 mm

Beim Plasmaschneiden wird mittels eines extrem fokussierten, bis zu 30.000 K heißen und mehrere 1000 m/s schnellen Plasmastrahl, das Material lokal aufgeschmolzen und zu einer Schnittfuge ausgetrieben. Kjellberg Finsterwalde hat dies bereits bestmöglich realisert: Die Anlagentechnik erreicht höchste Produktivität und laserschnittähnliche, nahezu nachbearbeitungsfreie Schnittkanten von Blechendicken zwischen 1 und 150 mm.

Das Laserstrahlschneiden ist ein thermisches Trennverfahren für elektrisch leitende und nicht leitende sowie brennbare und nicht brennbare Materialien mittels eines Laserstrahls. Das Verfahren wird besonders dort eingesetzt, wo komplexe Konturen präzise und schnell geschnitten werden sollen, vorzugsweise im unteren Blechdickenbereich bis 10 mm und bei besonders hohen Qualitätsanforderungen (Formabweichungen im Konturbereich).

Coating

H.Freisse, M.Stroht, N.Brocke: Novel Diode Laser with Coaxial Beam Guidance for Deposition Welding and Additive Manufacturing. Laser Magazine, Issue 4/2015 (BIAS)

Nils Brocke, Michael Schnick, Ronald Jüngling, Volker Krink: 3D Deposition Welding with a Coaxial Construction of Diode Laser and Central Filler Material Feed. 11th Symposium about Wear Protection of Components by Deposition Welding. Halle (Saale), 15 and 16 June 2016

H.Freisse, H. Köhler, C. Thomy, F. Vollertsen, N. Brocke, M. Schnchn: Process Monitoring System for a Novel Direct-Radiating Diode Laser with Coaxial Beam Guidance. Welding and Cutting Reports 68 (2016) Issue 6 S61 + S62

Optimising Wear Protection Layers

For our wear protection customers, we develop plasma and laser technologies for the purpose of deposition welding of wear protection layers or for repairing components and tools. The focus here is on the process characterisation and optimisation. It is specifically about the adaptation of the energy input, the material supply and the gas shielding, as well as the analysis and avoidance of process instabilities. Owing to our high-performance materials laboratory, we are capable of analysing and documenting the achieved coating properties during the experiment, e.g. microstructures, and mixture or coating irregularities.

Developing an Innovative Temperature Field Measuring System

Process monitoring system for an innovative direct-radiating diode laser with coaxial beam guidance (ZIM funding number ZF4124701DF5, funding period 01.03.2016 – 30.09.2017)

The aim of the project is to develop and to test an innovative non-axial and affordable temperature field measurement system for the purpose of process monitoring and documentation for laser powder welding and for the coaxial laser processing head of Oscar PLT. In the course of the project, lenses are integrated into the machining head, plus various temperature field measurement possibilities are compared and evaluation algorithms are developed. This project is conducted in collaboration with the Bremen Institute for Applied Beam Technology (BIAS).

Coating Technologies in the High Performance Area and 3D Area

Plasma-powder deposition welding or Plasma-Transferred Arc (PTA) welding is a decades-long established coating technology. With OSCAR PLT, we further develop this technology, specifically in the high-performance range of up to 400 A. By implementing two separate powder feeders, considerably higher powder distribution rates can be achieved, and graded powder compositions in the process possible will be feasible. Laser deposition welding enables deposition welding with high-precision energy supply for minor dilution, distortion and residual stress. The developed technology in our facility is based on a coaxial (fully 3D capable) machining head with centric material feed and circular direct diode modules. The head is highly flexibly applicable with wire and powder materials. It has a phenomenal shielding gas flow and powder efficiency.

3D Manufacturing

H.Freisse, M.Stroht, N.Brocke: Novel Diode Laser with Coaxial Beam Guidance for Deposition Welding and Additive Manufacturing. Laser Magazine, Issue 4/2015 (BIAS)

H.Freisse, H. Köhler, C. Thomy, F. Vollertsen, N. Brocke, M. Schnchn: Process Monitoring System for a Novel Direct-Radiating Diode Laser with Coaxial Beam Guidance. Welding and Cutting Reports 68 (2016) Issue 6 S61 + S62

Michael Schnick, Frank Silze, Nils Brocke, Johannes Volpp, Victor Hohenäcker, Dieter Tyralla und Claus Thomy: Coaxial Direct Diode Laser with Temperature Field Monitoring for 3D Printing. User Forum Additive Manufacturing, Bremen 23.11.2017

V.Hohenaecker, H.Freiße, C.Thomy, N.Brocke, M.Schnick: Camera-based Process Monitoring for Quality Assurance in Laser Powder Deposition Welding. LASER (Publisher b-Quadrat). Filed on 16.03.2018

Hot Wire Laser Deposition Welding on Your Component

At OSCAR PLT, we have developed a coaxial direct-diode laser processing head for the shaping laser deposition welding. The coaxial construction with its central material feed enables high-quality shape generation in all positions independently of direction. By that means, the process can be easily and quickly converted from the frequently used powder materials (high volume deposition rate and stable process) to wire-shaped filler materials (high surface quality and material efficiency).

Highest volume deposition rates and resource efficiency are achieved through hot wire laser deposition welding. The robust system has brilliant shielding gas coverage and powder efficiency.

3D Shaping with Various Materials

3D Manufacturing or additive manufacturing has the potential to revolutionise current construction rules and manufacturing processes. The rules and processes enable components with a completely new design, functionality, materials, material combinations and individualisation. We deal with generative manufacturing using deposition welding technology. Unlike the powder-bed based generative technologies, by using the laser deposition welding, a “real 3D shaping” in different spatial directions of the component coordinate system can be carried out by pivoting and turning the process head or the workpiece. Simultaneously, considerably higher buildup rates can be achieved, partly also with different materials on one component.

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