Universal tool LASER - application examples for welding of HT fuel cells as well as heat exchangers and tank systems for H2 processing

The laser tool is predestined for automated manufacturing processes and has already proven its suit-ability in many areas. In particular, joining technologies in the field of hydrogen production, its storage and for bi-polar plates have to meet the highest requirements in terms of seam quality, reproducibility and manufacturing efficiency. By the examples 700 bar car H2 pressure tank with laser welded connection (welding depth 25 mm) Laser Remote Welding of HT Fuel Cell Stacks Laser-welded aluminum tube-ground heat exchanger for gas liquefaction the article presents the possibilities of modern laser beam welding technologies. Furthermore, it gives an outlook on future challenges, especially with regard to the requirements of welding bi-polar plates for upcoming applications in the field of mobilit

Universal tool LASER - application examples for welding of HT fuel cells as well as heat exchangers and tank systems for H2 processing

The laser tool is predestined for automated manufacturing processes and has already proven its suit-ability in many areas. In particular, joining technologies in the field of hydrogen production, its storage and for bi-polar plates have to meet the highest requirements in terms of seam quality, reproducibility and manufacturing efficiency. By the examples 700 bar car H2 pressure tank with laser welded connection (welding depth 25 mm) Laser Remote Welding of HT Fuel Cell Stacks Laser-welded aluminum tube-ground heat exchanger for gas liquefaction the article presents the possibilities of modern laser beam welding technologies. Furthermore, it gives an outlook on future challenges, especially with regard to the requirements of welding bi-polar plates for upcoming applications in the field of mobilit

In situ observation with x ray for tentative exploration of laser beam welding processes for aluminum based alloys

In recent years, laser processes have taken an everincreasing market share in the manufacture of components. The development of new, improved beam sources with corresponding systems technology and the decreasing investment costs of the beam sources are important keys for this success. Especially high frequency beam oscillation has a great potential in laser beam welding and cutting. The main obstacle for the widespread breakthrough of high frequency beam oscillation is the still insufficient understanding of the underlying physical mechanisms. Gaining a deeper insight is essential for process optimization. The in situ observation with X ray enables the visualization and analysis of these highly dynamic processes inside the workpiece. The goal of the performed experiment described in this paper was to insitu analyze the structural evolution of and defect generation in laser welding beads of different aluminum alloys. A fiber laser max. 600 W, cw output power including a beam scanner control system for rapid beam guidance was used. Of general interest was the comparison between static and oscillated beam guidance and the effects on the joining procedure. The paper shows first results of the analysis of the melt pool behavior and seam formation as well as the formation of seam irregularities during the laser process. In the simplest case, radiographs were taken, i.e. 2D projections of the X ray absorption coefficient distribution within a material. Thereby recordings from 10000 up to 40000 fps could be generated. Furthermore, tomoscopies the continuous acquisition of tomographic 3D images up to 100 tomograms per second could be generated with proven equipment, whose main components are a high speed rotation stage and camera system. The findings will help to get a better understanding of keyhole phenomena as well as effects of turbulent melt flow such as pore formation and guide to solutions for preventing them. Hence first results for high frequency beam oscillation processes including melt pool degassing and porosity reduction will be shown and discussed. Introductio