Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O’Brien R&D Manager ThyssenKrupp Tallent Ltd, UK Richard Hewitt Project Manager PVLT, WMG, UK LTS 2011 – WMG, 20th July, 2011 Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 1 ThyssenKrupp Tallent Ltd Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products 1. ThyssenKrupp Tallent and WMG Introductions 2. Why Remote Laser Welding? 3. Remote Fibre Laser Welding (RFLW) Project 4. Future Project Work & Plans 5. Questions and Answers Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 2 ThyssenKrupp Tallent Ltd ThyssenKrupp Tallent Ltd ThyssenKrupp Metal Forming Overview ThyssenKrupp Metal Forming Turnover: € 991m • EBT: 3.128 Mio € • Employees: 5,389* Metal Forming UK Metal Forming Germany Metal Forming France Metal Forming RoW TK Tallent, Ltd. TK Umformtechnik GmbH TK Sofedit, S.A.S. Francis (CEO) Heyhurst (CFO) Dr. Egelkamp (CEO) Osburg (CSO) Dr. Plümpe (HR) Willenberg (CFO) Espeel (CEO) Koll (CFO) Dr. Overrath (COO) China (Wuhan) Turkey (Gebze) Turnover 269,2 Mio € Employees *: 1,774 Turnover: 321,2 Mio € Employees *: 1,631 Turnover: 361,0 Mio € Employees *: 1,570 Aycliffe (UK) Cannock (UK) Fareham (UK) Washington (UK) Bourn (UK) Llanelli (UK) Brackwede (D) Ludwigsfelde (D) Pure (F) Le Theil (F) Gouzeaucourt (F) Sermaises (F) Wroclaw (PL) St. Romain (F) Valladolid (E) Turnover: 48,3 Mio € Employees *: 414 Wuhan (CN) Gebze (TR) * Figures as of 30.09.2009 Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 3 ThyssenKrupp Tallent Ltd ThyssenKrupp Tallent Ltd ThyssenKrupp Metal Forming European Overview Capability Locations Chassis Products Design & Analysis Tallent Brackwede Test & Development TK Steel Sofedit Program Management Tata 3.1% Other OEM 0.1% Other Tier 1 13.9% Non-automotive 4.0% Ford 10.7% General Motors 1.1% Paccar Truck 0.1% Volvo Truck 0.6% Daimler 14.1% Honda 1.2% Manufacturing Toyota 4.6% Fiat 0.6% Volkswagen 4.3% Peugeot Citroën 17.1% Porsche 0.1% BMW 6.7% Renault Nissan 17.7% Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 4 ThyssenKrupp Tallent Ltd ThyssenKrupp Tallent Ltd Typical Products and Customers from UK plants Chassis Body 2 4 1 1 2 6 5 3 4 3 7 6 5 Typical Chassis products Selected examples Typical Body products Mercedes Sprinter 1. 1 Front subframe/assembly Mini, Ford EUCD, new PSA/Fiat G9 1 Side wall 2. 2 Front transversal link Ford Galaxy 2 Cross car beam 3. 3 Control arms VW Touareg, Porsche Cayenne, Land Rover Discovery 3 4. 4 Cross member Mini, Ford Fiesta 5. 5 Rear lateral link Volvo S80 4 Pillars/pillar reinforcements 5 Outer door panels 6. 6 Axle cases Land Rover Defender OEMs Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 5 Selected examples Toyota Yaris Side intrusion beams Mercedes C-Class, various BMW models (1, 3, 5, 7 series) Renault Laguna, Audi A3, Q7 Renault Clio, Bentley Flying Spur 6 Door reinforcement 7 Longitudinal Mercedes Sprinter Renault Trafic/GM Vivaro OEMs ThyssenKrupp Tallent Ltd WMG Overview Mission Statement “to improve competitiveness through the application of value adding innovation, new technologies and skills deployment” Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 6 ThyssenKrupp Tallent Ltd Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products 1. ThyssenKrupp Tallent and WMG Introductions 2. Why Remote Laser Welding? 3. Remote Fibre Laser Welding (RFLW) Project 4. Future Project Work & Plans 5. Questions and Answers Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 7 ThyssenKrupp Tallent Ltd Why Remote Laser Welding? Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 8 ThyssenKrupp Tallent Ltd Why Remote Laser Welding? OPPORTUNITIES • Faster Processing Speeds ? • • • • • • • • • • • • • Compared to MIG/MAG ? Compared to Spot ? Compared to others ? Single Sided Weld Access ? Access issues ? Flexible Manufacturing ? Reduced Floor Space ? Investment Costs ? Operating Costs ? Product Design ? Weight reduction ? Reduced distortion ? Customer perception ? Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 9 CHALLENGES • • • • • • • • • • • Panel Fit Up Important ? Batch & material variation issues ? Thicker Materials ? Degassing of Weld Vapour ? Structural performance ? Tooling Specification ? Process Monitoring ? Laser Safety Requirements ? Few System Integrators ? Education & Training ? Customer lack of experience ? ThyssenKrupp Tallent Ltd Why Remote Laser Welding? Range of opportunities and interest particularly for ThyssenKrupp Tallent: • • • • • • • • • Relatively New and Emerging Technology Flexibility and reduced floor space requirements Operating and investment costs Speed of welding? Ability of process to overcome access issues? Improved consistency of welding? No consumables (No filler wire or shield gas) Weight Reduction Reduced Distortion • • • • especially compared to MIG/MAG applications Durability and strength performance effects? Quality aspects? Physical plant considerations, including Health and Safety? Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 10 ThyssenKrupp Tallent Ltd Why Remote Laser Welding? How ThyssenKrupp Tallent may use RFLW? • • • • • • Technology Demonstration projects (like this project) Replacement or alternative to spot welding Replacement or alternative to MIG welding Solution to particular issues with access restrictions for conventional welding processes Flexible manufacturing cells for multiple product lines • Increased product lines • Increased flexibility • Lower volume or higher value niche products where traditionally we have not focused Improved capability for High Volume Products following multiple process routes • Use RFLW as fast setting/tacking cells to feed lines • Reduces process variability • More consistent product going into multiple parallel manufacturing lines Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 11 ThyssenKrupp Tallent Ltd Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products 1. ThyssenKrupp Tallent and WMG Introductions 2. Why Remote Laser Welding? 3. Remote Fibre Laser Welding (RFLW) Project 4. Future Project Work & Plans 5. Summary, Questions and Answers Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 12 ThyssenKrupp Tallent Ltd RFLW Project Supporting the Business Case for RFLW versus welds RSW v RLW v MIG Matrix RSW Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 13 RLW ThyssenKrupp Tallent Ltd MIG RFLW Project Supporting the Business Case – Cost Model INVESTMENT COSTS OPERATING COSTS Engineering Production Area Incoming Services Services Consumables Process Consumables Hardware Spare Parts Process Quality Control Maintenance Implementation Quality Process Parameters Operating Parameters COST PER HOUR COST PER JOINT Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 14 ThyssenKrupp Tallent Ltd RFLW Project Supporting the Business Case: 4kW RFLW versus MIG Cost Per Metre € 1.400 € 1.200 Quality € 1.000 Spare Parts Maintenance Process Consumables Services Consumables € 0.800 Production Area € 0.600 Implementation Costs Process Quality Control € 0.400 Hardware Incoming Services € 0.200 Engineering € 0.000 MIG RFLW At present an equivalent 4kW remote fibre laser weld (RFLW) stitch seems to costs 35% more than a comparable MIG weld Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 15 ThyssenKrupp Tallent Ltd RFLW Project Supporting the Business Case: 8kW RFLW versus MIG Cost Per Metre € 1.000 € 0.900 Quality € 0.800 Maintenance Spare Parts € 0.700 Process Consumables € 0.600 Services Consumables € 0.500 Production Area € 0.400 Implementation Costs Process Quality Control € 0.300 Hardware € 0.200 Incoming Services € 0.100 Engineering € 0.000 MIG RFLW At present an equivalent 8kW remote fibre laser weld (RFLW) stitch seems to costs 10% more than a comparable MIG weld Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 16 ThyssenKrupp Tallent Ltd RFLW Project Supporting the Business Case: 8kW RFLW versus MIG Power Consumption Cost Per Metre € 0.06000 € 0.05000 Extraction € 0.04000 Cooling Water Compressed Air € 0.03000 Electrical Power Weldgun/Laser € 0.02000 Electrical Power - Robot € 0.01000 € 0.00000 MIG RFLW Note: MIG power Usage shown as a combined total usage Full evaluation on-going Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 17 ThyssenKrupp Tallent Ltd RFLW Project Supporting the Business Case: 4kW RFLW versus Spot Cost Per Joint € 0.014 € 0.012 Quality € 0.010 Spare Parts Maintenance Process Consumables Services Consumables € 0.008 Production Area € 0.006 Implementation Costs Process Quality Control € 0.004 Hardware Incoming Services € 0.002 Engineering € 0.000 RSW RFLW SPR At present an equivalent 4kW remote fibre laser weld (RFLW) ‘spot’ seems to costs 5% less than a comparable Resistant Spot Weld (RSW) Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 18 ThyssenKrupp Tallent Ltd Business Case – verses RSW Power Consumption Cost Per Joint € 0.00140 € 0.00120 Extraction € 0.00100 Cooling Water € 0.00080 Compressed Air € 0.00060 Electrical Power Weldgun/Laser € 0.00040 Electrical Power Robot € 0.00020 € 0.00000 RSW RFLW SPR Full evaluation on-going Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 19 ThyssenKrupp Tallent Ltd RFLW Project Trial Facility Robot Technology Laser Technology Application Demands Trial Facility available within WMG Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 20 ThyssenKrupp Tallent Ltd RFLW Project Process Evaluation Parameter Power Speed Focus Incident angle Joint condition WELD OK/NOK Interface width Penetration Gap - tooling Gap - degassing Stitch profiles Flange condition Distortion Porosity Weld strength System Performance Surface Concavity Material Envelope Repeatability Focus drift On/off test Top Bead Width Stack-up Coating Material type Contamination Top Surface Cut Through Spatter Burn Through Cracking Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 21 ThyssenKrupp Tallent Ltd RFLW Project Component Weld Trials Rear Subframe – Current Production Part Material: Galv-annealed Coated HSLA Steel Pre-process 57 Spot Welds 4 Projection Weld collars No pressing modifications: Standard Production Parts Used RFLW Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 22 ThyssenKrupp Tallent Ltd RFLW Project Component Weld Trials Rear Subframe – Current Production Part Material: Galv-annealed Coated HSLA Steel 57 Spot Welds 4 Projection Weld collars No pressing modifications: Standard Production Parts Used Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 23 ThyssenKrupp Tallent Ltd RFLW Project Component Weld Trials Front Subframe – Current Production Part Material: HSLA Steel 2.5 & 3.0mm Thick Standard Production Parts Used Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 24 ThyssenKrupp Tallent Ltd RFLW Project Weld Quality Evaluation – Front Subframe Model 1 The welds examined below were not fully optimised and fit ups were not adjusted from the MAG weld condition. 5 4 1 2 3 upper to lower section locations Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 25 Laser seam appearance ThyssenKrupp Tallent Ltd RFLW Project: Weld Quality Evaluation 1 2 3 Upper Upper Lower Lower ERR reinforcer 4 5 Front Subframe 1: Weld Macro Sections Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 26 ERR reinforcer Seam Bend Test ThyssenKrupp Tallent Ltd RFLW Project: Weld Quality Evaluation Front Subframe Section 2: weld crack In this weld, the fit up gap has caused the weld metal in the upper panel to sag leaving a characteristic groove in the seam. Weld metal in the widest part of the gap has cracked on solidification. Weld metal Heat Affected Zone Parent metal Vickers micro hardness Vickers micro hardness Vickers micro hardness 170 - 219 167 - 174 167 - 177 Peak hardness occurred in the weld metal. HAZ hardness was virtually identical to the parent metal value. Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 27 ThyssenKrupp Tallent Ltd RFLW Project: Weld Quality Evaluation Observations from Trials and Sectioning The trials to date have succeeded in making functional welds on all chassis parts used Sensitivity to fit up condition is evident Small fit up gaps did not prevent a joint being made Characteristic of weld to sag creating a signature groove in the upper panel at gaps In some cases this resulted in small weld cracks Effect of such grooves on the strength & durability of the weld is being investigated The effect of the narrower laser weld on fatigue durability is subject to further testing. No evidence of porosity in the laser welds on the galv-annealed parts Very little weld distortion Potential benefit with regards to corrosion No silicon deposits (seen with MIG) which prevent and reduce local paint adhesion. Also less damage to the zinc coating compared to MAG on coated steels Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 28 ThyssenKrupp Tallent Ltd RFLW Project: Weld Quality Evaluation Recommendations from Trials and Sectioning Design of part & fixtures optimised for laser welding should greatly improve the fit up Will help reduce / eliminate the weld sag / crack issue Control and repeatability of pressed parts is essential Especially for panels above 2.0mm where it becomes harder to clamp out gaps The welds usually penetrated through both panels, therefore: means that visual inspection could provide a reliable confirmation the weld is fully formed. presence of grooves in the upper weld bead could be used to: indicate potential fit up associated weld quality problems. Possibility laser welds can be more reliably visually assessed than MAG or Spot welds Further investigation is required to gain confidence in this Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 29 ThyssenKrupp Tallent Ltd Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products 1. ThyssenKrupp Tallent and WMG Introductions 2. Why Remote Laser Welding? 3. Remote Fibre Laser Welding (RFLW) Project 4. Future Project Work & Plans 5. Questions and Answers Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 30 ThyssenKrupp Tallent Ltd Future Project Work & Plans Current On-going and Future Planned Investigations: Continue to develop and refine cost models based on increased experience Carry out facility level comparison of RFLW versus MIG (not just single cell based) Refine the area comparison and cost comparisons out of the above studies Manufacture of further front sub-frame parts to fully finished level for rig test at TKT Part RFLW and part MIG due to current part design To assess strength & durability performance against existing parts & processes Manufacture of further rear sub-frame parts to fully finished level for rig test at TKT Fully RFLW to replace all existing spot welds, some projection welds and most MIG To assess strength & durability performance against existing parts & processes Preliminary discussion underway with OEM about trying to put part on vehicle test Investigations into clamping fixtures and panel control to minimise gap issues Demonstrator Design project to re-engineering existing part to be suitable for RFLW and conduct full test, feasibility and cost comparison (longer term) Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 31 ThyssenKrupp Tallent Ltd Future Project Work & Plans OPPORTUNITIES CHALLENGES • Faster Processing Speeds • • • • • • • • Single Sided Weld Access Access issues Flexible Manufacturing ? Reduced Floor Space ? Investment Costs ? • • • • • • Compared to MIG/MAG ? Compared to Spot Compared to others ? Depends on speeds Operating Costs ? Product Design Weight reduction ? Reduced distortion Customer perception Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 32 • • • • • • • • • • • Panel Fit Up Important Batch & material variation issues ? Thicker Materials Degassing of Weld Vapour Structural performance ? Tooling Specification Process Monitoring Laser Safety Requirements Few System Integrators Education & Training Customer lack of experience Successful implementation requires a new way of thinking! ThyssenKrupp Tallent Ltd Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products 1. ThyssenKrupp Tallent and WMG Introductions 2. Why Remote Laser Welding? 3. Remote Fibre Laser Welding (RFLW) Project 4. Future Project Work & Plans 5. Questions and Answers Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 33 ThyssenKrupp Tallent Ltd Thank you for your attention. Any questions ? Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 34 ThyssenKrupp Tallent Ltd Contact Details For further information, please contact: Roger O’Brien - R&D Manager ThyssenKrupp Tallent Ltd. Richard Hewitt - Project Manager PVLT Centres of Excellence - WMG, Skerne Road Aycliffe Business Park Newton Aycliffe County Durham DL5 6EP UK University Of Warwick Coventry Warwickshire CV4 7AL UK Tel: +44 1325 313 232 extn 7481 Direct: +44 1325 329 226 Mobile: +44 7946 892 568 Tel: +44 24 765 75358 Fax: +4424 765 75365 Mobile: +44 7968 227 008 E-mail: E-mail: roger.obrien@thyssenkrupp.com Remote Fibre Laser Welding benefits when applied to leading edge chassis structural and suspension products Roger O‘Brien – ThyssenKrupp Tallent Richard Hewitt - WMG Lightweight Technologies Showcase Date: 20th July 2011 35 Richard.Hewitt@warwick.ac.uk ThyssenKrupp Tallent Ltd