Innovative welding conception for thin-walled sheet metal components

Welding of thin-walled sheet metal structures is a challenging task in various applications. For bipolar plate manufacturing, complex requirements regarding effective welding speed, reliable welding process, high surface quality and minimal distortion have to be fulfilled.
A new welding conception for 100 µm stainless steel strip material was fundamentally developed, using a continuous processing in roll-to-roll principle with laser welding in the roll gap. Weld seams can be produced along and transverse to the strip running direction by using a fast scanner system, achieving very high welding speed of 30 m/min and more. High seam quality, virtually no damage of coated outer skin and minimal welding distortion demonstrate the technological potential.
The set-up including roller system, strip guiding and laser optics will be presented as well as results of process development. Potential application in fusion cell bipolar plate manufacturing will be shown referring complex process chain of strip coating, forming and welding.