The Advantages of Laser Welding in Automotive Manufacturing
In May, our blog, “The Power Of Laser Welding: Precision, Versatility, And More,” gave an overview of why laser technology has become critical in everyday applications, from surgery to optical communications. In our June blog, “The Advantages Of Laser Welding In The Medical Industry,” we wrote about how laser welding is used in the medical field. This month, we are discussing what is behind the vast increase in the use of laser welding in automotive manufacturing.
Looking to enhance production capabilities while still maintaining the necessary quality standards, automotive manufacturers have found that laser welding offers unusual flexibility when it comes to joining a wide range of materials, such as different types of metals and alloys. It helps achieve higher quality, efficiency, and flexibility in production processes. Hence, laser welding is now in demand when handling complex assemblies made from various materials, including body frames, door frames, trunks, auto hoods, front and back lights, and electronic housings.
Additionally, where welds are required to be very small in size, laser welding is also being used for metal welding of many sub-components, including airbag initiators, motor coil windings, battery tab-to-bus bar connections for vehicle electronics, and electrical interconnections within an automobile build. Because laser welding imparts localized heat, operators can more easily address these smaller parts. With greater accessibility and fewer restrictions, design flexibility is enhanced, enabling approaches that may not have been possible with other techniques.
Another interesting application is with vehicles that require the welding of electric motor components, including powertrain connections and stator hairpins. Welding makes it possible to create the battery cell, join cells to develop a module or pack, and sometimes connect the modules to create a complete battery assembly.
Laser welding certainly helps manufacturers in the automotive industry achieve higher quality, efficiency, and flexibility in their production processes. However, there are added benefits for both safety and the environment. Laser welding systems can be enclosed and automated, reducing exposure to hazardous fumes and improving worker safety. The process produces less smoke and spatter than traditional welding, creating a cleaner working environment. The high efficiency of the process also leads to a better material utilization process, requiring fewer consumables (e.g., welding rods, flux), reducing waste and associated costs.
Laser technology offers numerous advantages across various fields due to its unique properties. The choice of leading OEMs, APT's laser flashlamps are widely used throughout the automotive and aerospace industries where round the clock operations demand only the highest quality light sources for applications that include welding, cutting, laser marking, and inspection. With a focus on high reliability, optimum performance, and long lifetime, APT has developed a range of products for the industrial laser and non-laser markets where success is measured by efficiency, precision, accuracy, and total cost of ownership.
We are excited about the role laser welding is playing in automotive manufacturing and APT is here to support that innovation with an eye toward current practices and trends for the future.