Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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On Welding of High-Strength Steels Using Laser Beam Welding and Resistance Spot Weld Bonding with Emphasis on Seam Leak Tightness

2023 , Schmolke, Tobias , Brunner-Schwer, Christian , Biegler, Max , Rethmeier, Michael , Meschut, Gerson

The design of most electric vehicles provides for the positioning of the heavy energy storage units in the underbody of the cars. In addition to crash safety, the battery housing has to meet high requirements for gas tightness. In order to test the use of high-strength steels for this sub-assembly, this paper examines welded joints utilizing resistance spot weld bonding and laser remote welding, with special regard to the gas tightness of the welds. For this purpose, the pressure difference test and helium sniffer leak detection are presented and applied. The combination of both leak test methods has proven ideal in experimental investigations. For laser remote welding, gas-tight seams can be achieved with an inter-sheet gap of 0.1 mm, even if occasionally leaking samples cannot be prevented. Resistance spot welding suits gas-tight joining with both one- and two-component adhesives. Against the background of leak tightness, process fluctuations that lead to weld spatter and defects in the adhesive layer must be prevented with high priority.

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Laser Welding of L-PBF AM components out of inconel 718

2022 , Brunner-Schwer, Christian , Simón-Muzás, Juan , Biegler, Max , Hilgenberg, Kai , Rethmeier, Michael

With regard to efficient production, it is desirable to combine the respective advantages of additively and conventionally manufactured components. Particularly in the case of large-volume components that also include filigree or complex structures, it makes sense to divide the overall part into individual elements, which afterwards have to be joined by welding. The following research represents a first step in fundamentally investigating and characterizing the joint welding of Laser Powder Bed Fusion (L-PBF) components made of Inconel 718. For this purpose, bead-on-plate welds were performed on plates manufactured using the L-PBF process and compared with the conventionally manufactured material. Conventional laser beam welding was used as welding process. The weld geometry was investigated as a function of the L-PBF build-up orientation. It was found that the welding depth and weld geometry differ depending on this orientation and in comparison to the conventional material.

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