The challenges of welding thick materials have long dictated the pace and approach of industrial manufacturing processes. Traditional methods, reliant on multi-pass welds and beveling, can be exhausting and inefficient. The depth achievable in one pass typically ranges up to 15-20mm, necessitating multiple passes—up to 30 times for a 50mm section—making the process notably time-consuming and material-intensive.
In the past year, significant progress have been made by Civan Lasers, who have dedicated their efforts to develop and refine welding processes for thick materials using Dynamic Beam Lasers (DBL). This technology now meets industry standards through the qualification of the welding processes.
The Shortcomings of Traditional Welding
Traditional multi-pass and beveling methods for welding thick sections are plagued with inefficiencies. These processes often result in increased welding volume, which in turn consumes more time and materials. Common welding defects in such thick sections include spatter, porosity, underfill, concavity, and cracks induced by cooling. These defects primarily arise from issues like keyhole collapse and uncontrolled melt pool dynamics, exacerbated by rapid and uncontrolled cooling rates.
The DBL Advantage
Dynamic Beam Lasers introduce a new era in welding technology. DBLs offer unique features that significantly mitigate common welding defects by enhancing fluid dynamics, keyhole stability, weld geometry, and controlling solidification and cooling rates. The technology boasts a large depth of focus and focus steering capabilities as well as beam steering, which enable it to maintain stability over varied gap sizes up to 2mm, crucial for welding thick sections. Furthermore, DBL’s remote operation feature allows welding from meters away, providing protection of the laser optics.
Impressive Welding Results
Civan Lasers has demonstrated remarkable success in welding applications across various materials and industries. For instance, DBL has shown excellent results in welding mild steel, particularly in constructing ship panels and wind tower structures. In stainless steel, DBL has proven effective for applications in power generation and pressure vessels, showcasing superior strength and durability. Aluminum, particularly in the 5xxx series, has been successfully used in ship panel construction, highlighting DBL’s versatility and capability in handling different materials and applications.
Looking Ahead: The Future of DBL Welding
The potential for Dynamic Beam Lasers in industrial applications of thick sections is vast and still unfolding. Future plans include qualifying more weld types in thicker thicknesses and wider range of materials. There are plans to harness higher power settings of up to 120kW, pushing the boundaries of what can be achieved in welding technology.