In modern automotive transmission manufacturing, the welding technology with a laser beam is gaining in importance. There are almost no limits for creative engineers, developing automatic transmission with up to ten speeds. Ever higher torque at a more compact design should be transmitted. Very often sheet metal stampings and shaft type components need to be assembled. For a minimum of distortion the only option very often is the use of the laser welding process for the assembly. The advantage of the energy source laser is the extremely high energy density and the resulting small heat zone at the work pieces. With the laser optics the source can used very flexibly for spot-seam-and depth welding. Multiple single work pieces can be welded together in one setup. Based on the very simple laser beam guidance through a fiber optics cable, Felsomat FLW laser welding centers are exclusively equipped with solid disc lasers. The advantage of this source is its high performance in regards to beam quality, power and life time. To get a perfect weld seam with a high weld speed requires an extremely rigid and high damping machine design. Felsomat is using the same ultra high performance concrete as for the hard turning and hobbing machines for the machine base.
The welding itself is only one step of the complete process chain. Prior to welding there are usually requirements for assembly and part matching tasks. To achieve a long lasting and crack free weld seam, pre-heating is required for many materials. This can be done either through induction coils or with the UMH technology. During laser welding the parts remain in their proper location by being accurately clamped into a weld fixture.
A vacuum such as for the electro-beam welding is not required for the laser welding which saves time, cost, and energy. However Felsomat is building partial vacuum chambers for laser welding as an option to achieve highest quality for critical and sensitive applications.
If a weld wire is required for the welding process, the Felsomat FLW modular building platform can be equipped with such systems. Every process like welding, assembly and pre-heating, are monitored and controlled with in-process sensors.
Typical applications for laser welding are synchronizer gears, planet carriers, clutch bodies, dual clutch units and many more.