Mark Thompson of Photonics Express describes how a new UK first was achieved; in May 2024, a Civan Lasers Dynamic Beam fibre laser was installed at WMG, the University of Warwick.
The installation came at the end of a period of collaborative work between AILU members WMG, Civan Lasers and Photonics Express to ensure that the UK has access to the next generation of strategically important laser joining technology. The new technology will be used to advance UK automotive and e-mobility joining applications.
The technical capability of dynamic beam lasers is not only important for joining automotive components, it also has an important role to play in a range of other industrial applications including, heavy goods, transportation, power generation, nuclear, natural resources, oil and gas, and clean energy generation.
Dynamic beam lasers are an advancement on commodity fibre lasers, with the photon beam manipulation presenting in a similar way to an electron beam. The clear advantage of the photon beam over an electron beam is that a vacuum chamber is a choice but no longer a necessity. When compared to ring-core fibre lasers, the dynamic beam offers more advanced beam shaping possibilities.
Beam shaping is a core attribute of dynamic beam lasers. Within the area of a conventional focused laser spot, the dynamic beam can be easily programmed to form a preferred beam shape and optimal focus. Moreover, this beam shape can be rapidly modified to accommodate features and various points along the weld path. Clearly, there is a substantial benefit when aiming to join along compound weld paths such as those in a battery pack, a car door, electric motor hairpins, or a heat exchanger.
Moreover, these types of joint require the use of bright metals, such as copper, steel, and conventional automotive lightweighting materials, such as five, six and seven thousand series aluminium alloys.
Welding dissimilar materials has presented the e-mobility industry with a range of challenges that impact the profitability of the emobility supply chain. Dynamic beam offers the opportunity to improve welding applications and manufacturing effectiveness, to deliver more capable processes. For example, dynamic beam offers superior control of weld penetration depth, material mixing or dilution, and compensation of fit-up issues such as lateral or blind gaps.
Image: Pasquale Franciosa (WMG), left, and Mark Thompson (Photonics Express) with Civan’s Dynamic Beam Laser
Contact Mark Thompson
mthompson@photonicsexpress.com
Pasquale Franciosa
https://warwick.ac.uk/fac/sci/wmg/
Ami Spira
ami.spira@civanlasers.com