Less energy, less material: Laser beam hybrid welding
Welding thick-walled steel components has traditionally required large amounts of energy and filler material. In the project "Laser beam hybrid welding with double wire for process- and energy-efficient joining of thick-walled components" (LaHDo), the consortium partners are developing a new hybrid process aimed at reducing material consumption. In this approach, an arc with two consumable wire electrodes fills the weld seam at a high deposition rate. An additionally oscillating laser beam selectively activates the groove flanks, ensuring better material bonding. Unlike conventional processes, in which the groove is filled layer by layer, the new process is designed to achieve this in a single pass – significantly reducing both energy consumption and material usage.
In the project, the partners work with thick-walled components made from unalloyed steels with material thicknesses of up to 30 millimeters. Components of this type are used in a range of applications, including mechanical engineering, pipelines, turbine blades, and shipbuilding.
LZH develops processing head and welding process
Within the project, the partners are building the entire process chain. The LZH's "Machines and Controls" group is developing a high-performance hybrid processing head, while the "Joining and Cutting of Metals" group is responsible for the associated welding processes. MERKLE Schweißanlagen-Technik GmbH is contributing an adapted welding power source, 4D Photonics GmbH a process-integrated inline monitoring system, and HAANE welding systems GmbH & Co. KG the demonstrator system. In addition, DURUM Verschleißschutz GmbH is developing novel filler wires with diameters of up to 2.4 millimeters and tailored material properties.
The development work is further supported by associated industry partners, including: B.I.G. Technology Services GmbH, CIVAN Lasers Europe GmbH, Laser on demand GmbH, Precitec GmbH & Co. KG, and Westfälische Drahtindustrie GmbH.
About LaHDo
The collaborative project "Laser beam hybrid welding with double wire for process- and energy-efficient joining of thick-walled components (LaHDo)" is funded under the applied energy research funding program within the framework of the 8th Energy Research Program by the German Federal Ministry for Economic Affairs and Energy (funding reference: 03EN4132A).
Laser Zentrum Hannover e.V. (LZH)
As an independent, non-profit research institute, the Laser Zentrum Hannover e.V. (LZH) stands for innovative research, development, and consulting. Supported by the Lower Saxony Ministry of Economics, Transport and Building, the LZH is dedicated to selflessly promoting applied research in the field of photonics and laser technology. Founded in 1986, almost 200 employees are now working at the LZH.
The LZH offers solutions to current and future challenges with its smart photonics. Along the process chain, natural scientists and engineers work interdisciplinary together: from component development for specific laser systems or for quantum technologies to process developments for a wide variety of laser applications, for example for medical and agricultural technology or lightweight construction in the automotive sector. 18 successful spin-offs have emerged from the LZH to date. Thus, the LZH creates a strong transfer between fundamental science, application-oriented research, and industry - and uses light for innovation.