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BODY ASSEMBLY PROCESSLASER WELDING VS SPOT WELDING
AUTOMOTIVE LASER WELDINGLASER WELDING COMPARISON
Process Type Laser Type Application Area Advantages Disadvantages Remarks
Single Sided Process
• CO2 - High Power (6 kW)• Nd:YAG - Low Power (4 kW)
• Butt / Edge joint (brazing applications)
• Lap joint
• TWB – Door inner panels
• Roof to side structure• Sub assembly process• Closure hemming flange
• Good weld accessibility (Single Side Process)• Reduced width of - or elimination of - the flange, resulting in reduced vehicle weight.• Low operational cost
• Panel gap constraint (no clamping force)• Narrow penetration (nugget)• Tighter parts & assembly tolerance• Worse corrosion risk vs spot welding• High price
• Jig / fixtures needed for panels clamping / support to eliminate panel gap• Suitable as MIG welding (eg CO2) alternatives
Double Sided Process
• Laser Seam Stepper (LSS) - Low Power (2 kW)
• Lap joint • Respot process • Higher process speed (shorter cycle times)• Increased component strength by longer seams with higher torsional stiffness• ‘Build in’ clamping force function (eliminate panel gap)• Low operation cost
• Weld point accessibility same as spot welding gun
• Suitable as spot welding alternatives
AUTOMOTIVE LASER WELDINGCOST COMPARISON
Estimated Cost Resistance Spot Welding
GMAW (Mix Ag/CO2) Welding
Laser Welding
RemarksSingle Sided Process
Double Sided Process
Welding Equipment per set
RM 50k to 70k RM 60k to 70k RM 450k ???•Waiting estimation from vendor
Cost per Spot
Servo / Trans Gun – 70kW
Total : RM 0.0115 Total : RM
0.016 / 10mm length
Total : RM 0.008 / 25mm
length
Total : RM 0.012 / 30mm length
*Equivalent to 3 spot welding
Pneumatic Gun – 150kW
Total : RM 0.048
Resistance Spot Welding
GMAW (Mix Ag/CO2) Welding
Laser Welding
RemarksSingle Sided Process Double Sided Process
1 spot (general) =
4√tmin (Ø) 10mm (length)18 ~ 25mm
(length)*Straight pattern
30mm / LSS*Equivalent to 3 spot
welding* Zig-zag pattern
• Reference : i. Single Sided Process : Volvo practice ii. Double Sided Process : Photonics.com
WELDING EQUIVALENT APPROXIMATION
*Note : Please refer to calculation table on “Reference” section
REFERENCESLASER WELDING VS SPOT WELDING
AUTOMOTIVE LASER WELDINGLASER SEAM STEPPER (LSS)
FIGURE 1. Laser-Seam-Stepper (left without C-Gun; right with C-Gun)
FIGURE 2. Resistance spot welding vs. laser welding with COSY LSS1-C-Gun
1 laser weld seam = 2~3 spot points
Laser welding for the production of sheet metal components in body plants offers the following advantages:
• Higher process speed (shorter cycle times)• Increased component strength by longer seams with higher
torsional stiffness• Efforts and costs comparable to today’s modern resistance
welding systems• Realization of high job safety requirements with reduced costs
AUTOMOTIVE LASER WELDINGNd : YAG LASER WELDING
Figure 1:Standard Operation
Figure 2:Schematic Diagram
Laser welding advantages:
• Narrow weld profile• Consistent weld bead• No electrode wear (Non-contact process)• High spot accessibility (1 sided process)• No filler material
AUTOMOTIVE LASER WELDINGGENERAL GUIDANCE
CO2 LaserNd : YAG
Laser
AUTOMOTIVE LASER WELDINGREFERENCE FROM VOLVO
AUTOMOTIVE LASER WELDINGCOSTING CALCULATION
Day Night Average0.355 0.219 0.287
ElementsVin (V) Iin (A) Powerin (kVA) Weld Time (Cycle) Energyin (kWh)
415 170 70.55 15 0.005879167 0.001687321Powerin (kW) Moving time / Spot (sec) Energyin (kWh)
7.2 5 0.01RM / hour
78.88RM / Tip Spot / Tip
2.4 6000
0.011530654
Powerin (kVA) Weld Time (Cycle) Energyin (kWh) Cost / Spot (RM)150 15 0.0125 0.0035875
Daily Production Working Day Spot / Man Salary / Man100 20 20 1500
RM / hour78.88
RM / Tip Spot / Tip2.4 6000
Forceweld (kN) Velocityelectrode (m/sec) Powerin (kW) Squeeze Time (cycle) Hold Time (cycle) Energyin (kWh)2.45 0.2 2.23 20 5 0.000494949
0.048202884
Vin (V) Iin (A) Powerin (kVA) Weld Speed (m/sec) Weld Length (m) Weld Time (sec) Cost / length (RM)15 95 1.425 0.005 0.01 2 0.000227208
Powerin (kW) Moving time / Spot (sec) Energyin (kWh)6 5 0.011666667
Car / roll RM / Roll Length (mm/car) RM/mm RM/10mm1000 86 250 0.000344 0.00344
Car / roll RM / Cylinder RM / Car RM/10mm500 118 0.236 0.00944
0.016455542
Powerin (kW) Weld Speed (m/sec) Weld Length (m) Weld Time (sec) Cost / length (RM)4 0.083 0.025 0.301204819 0.00009605
Powerin (kW) Moving time / Spot (sec) Energyin (kWh)6 5 0.008835341
0.008931392Powerin (kW) Weld Time (sec) Cost / length (RM)
2 2 0.00031889Powerin (kW) Moving time / Spot (sec) Energyin (kWh)
6 5 0.011666667
0.011985556Total
Lase
r Wel
ding
- 0.0116666677.5
- - - - - -
Doub
le S
ided
Pro
cess Weld Setting - -
Robot Power Apparent Power (kVA)
- 0
Total
- -
Sing
le Si
ded
Proc
ess
- - - - -
Weld Setting
Robot Power Apparent Power (kVA) - 0.0088353417.5
GMAW
( M
ix Ag
/ CO
2)
- -
Total
0.003348333
0.00344
0.00944
0
CO2 Gas - -
- - - -
CO2 Wire -
Weld Setting
Robot Power Apparent Power (kVA) -7.5
-
Total
Resis
tanc
e Sp
ot W
eldi
ngElectrical Tariff, RM / kWh
Parameters
- - -
- - -
-
-
-
-
Total
- -
-
- -
-
-
-
-
0.0004
Pneumatic / Air0.000142051
- - - -
- - -
Serv
o /
Tran
s Gun
Pneu
mati
c Gu
n
Welding Transformer
Manpower 0.0375
Water Pump 0.006573333
Electrode Tip
Water Pump 0.006573333
Electrode Tip 0.0004
0- - - -
Welding Transformer
Robot Power Apparent Power (kVA)9
0.00287
Cost / Spot (RM)