FLW-D50 SF and wobble

D50 Wobble and Seam Tracking Head

Wobble and seam tracking module in one package

IPG’s Wobble and Seam Tracking welding head adaptor integrates two technologies into one compact module. The module allows for simultaneous laser beam wobbling and welding seam tracking. Wobbling the laser beam improves weld quality as well as finish, and the seam tracker enables automatic adjustment of welding head lateral position when the seam location varies.  IPG’s welding heads with wobble functionality deliver unmatched weld quality, even on highly reflective materials.  Ideal for bridging gaps without filler material, IPG’s wobble Heads provides stunning visual finish and weld consistency throughout the seam. The module is plug-and-play compatible with the D50 high power welding head.

3D

Features

Unmatched laser power handling Fully integrated seam tracking
Programmable scanning parameters Sealed for long term stability
Variable wobbling radius and frequency Plug-and-play architecture for all IPG lasers

 
 

Specifications

Wobble Frequency 500 Hz
Laser Power 12 kW

Example Configuration

Focal Length 500 mm*
Wobble Diameter 5 mm

Seam Tracking Range
with Wobble (Single Axis)

± 5 mm

Full Scanning Range
(Single Axis)

± 7.5 mm

* Other focal lengths are available.

 

Ideal for poorly fitting parts, providing a visually impressive weld finish.
 

Carbon Steel
Corner Joint

 

Aluminum
 Butt Joint

 

Austenitic Stainless Steel
 Butt Joint

 

Austenitic Stainless Steel
Tube  & Shell Heat Exchanger

 

Austenitic Stainless Steel
Tube & Shell Heat Exchanger

Wobble Process Heads Brochure 2018

The Benefits of Wobble Welding Compared to Conventional Welding Methods


 Wobble modes

  • The welding heads equipped with the Wobble / Seam Tracking module have the following wobble modes available:

 

  • The wobble frequency and amplitude can be modified based on the application

 


 Weld Quality / Consistency

  • Compared to conventional (laser) welding methods, welding with the wobble option results in superior weld quality.
  • Wobbling also helps to overcome consistency issues related to back reflections when welding materials like aluminum, copper, etc.
 

Corner weld on 6061-T6 aluminum (thickness 1.5 mm). The picture on the left showing the overall quality and the microscopic image on the right showing the close up of the weld.

 


 Materials Prone to Cracking / Porosity

  • When welded with conventional methods, some materials are sensitive to welding defects, for example:

–Some grades of aluminum that are prone to the pore formation during the welding process
–Spring steel which is sensitive to thermal cracking

  • When using the wobbler welding head, the welding process can be further optimized (various wobble modes, amplitudes and frequencies), so that the welding defects can be minimized or eliminated.
   
6061 aluminum sample welded with conventional laser welding process: obvious pores in the cross section   6061 aluminum sample welded with the wobbler head: the cross section is free of porosity

 


Welding Dissimilar Metals

  • When welding dissimilar metals, the wobbler has incomparable benefits, for example:

–If one material has a higher melting point or higher reflectivity than the other, the melting behavior of the materials can be “balanced” by choosing the wobble parameters appropriately.
–Some combinations of metals tend to form brittle intermetallic compounds as a result of welding. When using the wobbler, the melting / solidification of the intermetallic layer can be controlled better, which improves the weld quality.

 
304 stainless steel and oxygen free copper tubes welded together using circular wobble   EDS-image showing the blending of the metals in the cross section of the weld

 


Tolerance for Process Variables

  • As it comes to process variables, such as the gap between the workpieces, wobble welding allows a considerably wider process parameter window that results in good quality welds.

  • Example: Butt welding stainless steel sheets (thickness 1.5 mm):

 

A) Variation in the gap between workpieces   B) Offset from the center line between the workpieces
 

 

Gap, μm 0 50 100  150 200 250 300 350 400 450 500   
Conventional Laser Welding o o Δ  Δ  × × × × × × ×  
Laser Welding with Wobble o o  o  o o o Δ Δ Δ Δ ×  
Offset, μm 0 50 100 200 300 400 500 600 700 800 900 1000
Conventional Laser Welding o o o o Δ × × × ×  ×  × ×
Laser Welding with Wobble o o o o o Δ Δ Δ Δ ×

 

o  = Good Weld

Δ = Acceptable

× = Unacceptable /Not Welded

Seam Tracking

  • Complete seam tracking system
  • Increases productivity through automated adjustment of weld location to match varying seam positions
  • Utilizes high speed CCD camera and LED strobe illumination to image fast moving parts
  • Locates seams with <10 um accuracy
  • Provides increased process consistency

Drilling

  • Drilling holes with adjustable diameter
  • Utilizes a drilling nozzle to provide optimized gas flow
  • Provides process consistency over percussion drilling applications
  • The hole shape can be customized using a scan controller

Scanning

  • Ideal for small-field scanning applications
  • Utilizes IPG Scan Controller and IPG Weld Software for job setup and execution
  • Increases flexibility of the wobbler to include a multitude of shapes and features
  • Allows utilization of welding accessories such as air-knifes, gas-assist ports, coax nozzles in high-power scanning
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