Proof-of-Concept – Laser welding and welding automation

„CREȘTEREA INOVĂRII ÎN COMPANIA ANOTECH PRIN RIDICAREA UNUI CONCEPT DE ELEMENTE STRUCTURALE COMPUSE, DIN OȚEL, CU PEREȚI SUBȚIRI, FORMATE LA RECE ȘI ASAMBLATE CU TEHNOLOGII DE SUDARE CU PRODUCTIVITATE RIDICATĂ DE LA NIVELUL DE MATURITATE TEHNOLOGICĂ TRL 3 LA NIVELUL DE MATURITATE TEHNOLOGICĂ TRL 4” – Cod SMIS+ 156509

General objective of the project/Project scope

The main objective of the research project is to increase innovation in the company in the areas of smart specialization by acquiring the rights to use built-up cold-formed steel beams with corrugated webs and developing the innovative concept to the TRL 4 technological maturity level by studying composite structural elements, made ocold-formed steel sheets and assembled with high-productivity welding technologies (robotic welding).
Specific objectives of the project
1. Development, manufacturing and experimental testing (Proof-of-concept) of the concept of structural systems with cold-formed steel beams, with a core of corrugated sheet and assembled with high-productivity welding technologies, by raising it to the TRL 4 level, currently at the TRL 3 level;
2. Studying smart assembly technologies with robotic and automated equipment and components;
3. The project interconnects the existing expertise in Politehnica University Timişoara with the experience and technologies available at the economic agent for the development, improvement and optimization of new structural systems through numerical simulations, in order to validate the concept and increase the degree of innovation of the enterprise;
4. Making comparisons between structural systems with cold-formed steel beams, with a corrugated sheet core and assembled with high-productivity welding technologies and conventional structural systems, in order to study the competitiveness of these systems;
5. Dissemination and promotion of the results of the research and development project.

Laser welding

Laser welding is a sophisticated technique that utilizes focused laser beams to join materials, primarily metals. Its precision has gained popularity across various industries, including automotive, aerospace, and manufacturing, due to the ability to produce strong and clean welds.
One of the key advantages of laser welding is its high precision, allowing for intricate and complex welds with exceptional control. The process generates a minimal heat-affected zone (HAZ), which significantly reduces the risk of material distortion. Additionally, laser welding tends to be faster than traditional methods, thereby increasing production efficiency. Its versatility enables the joining of various materials, including thin and dissimilar ones, making it suitable for a wide range of applications. Moreover, the potential for automation means that laser welding can be easily integrated into automated systems, boosting both productivity and consistency.
  • WhatsApp Image 2024-02-05 at 6.39.03 PM
  • WhatsApp Image 2024-02-05 at 6.39.04 PM (4)
  • WhatsApp Image 2024-02-14 at 11.38.39 PM (1)
  • WhatsApp Image 2024-03-11 at 3.55.03 PM (4)
  • WhatsApp Image 2024-01-19 at 4.10.51 PM (4)

Spot welding

Spot welding is a widely used welding process that involves joining overlaps of metal sheets by applying heat and pressure through concentrated electrical current. This method is particularly prevalent in various manufacturing sectors, including the automotive industry, where it plays a crucial role in the assembly of components.
One of the main advantages of spot welding is its speed and efficiency. The process allows for rapid joining of materials, making it ideal for high-volume production environments. Additionally, spot welding produces a minimal heat-affected zone (HAZ), which reduces the likelihood of warping or distortion in the materials. This technique also requires less material preparation compared to other methods, resulting in lower operational costs. Moreover, spot welding can be easily automated, making it well-suited for robotic applications where precision and consistency are essential.
Despite its advantages, spot welding does come with some disadvantages. The quality of the weld can be highly dependent on the alignment of the components being joined; misalignment can lead to weak joints. Spot welding is generally limited to thinner materials, as the method may not provide adequate strength for thicker sections. Furthermore, this technique is typically not suitable for joints requiring access from only one side, limiting its applicability in certain situations. Lastly, specialized equipment and training are required to ensure that the process is performed correctly, which can add to the initial investment.
In the context of robotic welding, spot welding has become increasingly popular due to its efficiency and consistency. Robotic systems can quickly and accurately perform spot welding operations, making them ideal for high-demand production lines. Typical applications for spot welding in robotic systems include the assembly of automobile frames, battery packs, and household appliances, where numerous welds are required in a short amount of time. As industries continue to adopt automation, spot welding remains a vital process that contributes to streamlined manufacturing and enhanced product quality.

Explore the findings of the Proof-of-Concept research project detailed in the following papers:

  • Modelling of plastic mechanisms in TWCFS members under combined load using 3D laser scanning, V. Ungureanu et. al., 2023;
  • Design of buildings in the circular economy context, V. Ungureanu, 2023;
  • Resistance of thin sheets lap joints connected by spot welding and brazing, V. Ungureanu et. al, 2023;
  • Laser welding connections for cold-formed steel elements. Experimental investigations. V. Ungureanu et. al., 2023;