Fraunhofer Institute for Production Systems and Design Technology
Fraunhofer Institute for Production Systems and Design Technology

Efficient, High-performance Processes for Joining Large, Thick-walled Structures

High working pressures and extreme static and dynamic loads in the operation of pipelines or components in the gas, petrochemical, shipbuilding and offshore industries require the use of high-strength steels. As these are used at their strength limits, the wall thicknesses of the components must be designed accordingly to ensure safe operation. Components with sheet thicknesses of three to 450 millimeters are not uncommon. We develop high-performance joining processes that offer both economic benefits - such as high filling speeds and smaller weld volumes - and technological advantages - such as lower heat input into the component - when joining thick-walled large structures.

 

© Fraunhofer IPK / Larissa Klassen

Hybrid Laser-arc and Narrow-gap Submerged-Arc Welding

We are developing a process that combines the efficient high-power laser beam hybrid process with narrow-gap submerged arc welding to join thick-walled structures. This reduces production time and increases the cost-effectiveness of the welding process while improving quality. 

Laser Hybrid and Narrow Gap Submerged Arc Welding for Thick-walled Steel Structures

© Fraunhofer IPK

Multi-wire Submerged Arc Welding

In submerged arc welding, the liquid weld pool is protected from atmospheric interference by a powder. The process is characterized by good thermal efficiency and high deposition rate. Our submerged arc welding system allows five individually controlled welding wires to be fed to the weld zone simultaneously.

© Fraunhofer IPK

Electron Beam Welding

Using electron beams, metallic materials can be welded, coated, hardened and engraved with the highest precision. Thin seams with weld depths of up to 100 mm in aluminum and 50 mm in steel are no problem, as are challenging production tasks such as mixed joints and welding of copper or nickel-based superalloys that are prone to hot cracking. Put this highly flexible and fully automated process to work for you.

© Fraunhofer IPK

Laser Welding of Thick Sheets

High speed, large seam depth, low heat load and extreme precision make laser beam welding the technology of the future. The thick sheet metal industry is a particular beneficiary of this technology, as a small seam cross section provides massive economic advantages. Steel sheets up to 20 mm thick can be welded in a single layer using the laser beam. The process is fully automated and has excellent reproducibility.

© BAM

Hybrid Welding Processes

Laser hybrid welding has been established by exploiting the synergistic effects of the laser beam and arc welding processes. This makes it possible to achieve high welding depths with low sensitivity to gap and edge misalignment. As a result, entire pipes with material thicknesses of up to 16 mm can be welded in a single layer. With electromagnetic weld pool support, sheets up to 30 mm thick can be welded in a single layer.

 

© Fraunhofer IPK

Joint Welding of Additive Components

Welding additive parts brings efficiency to your production. You can overcome system limitations on component dimensions, integrate new components into assemblies, realize a more flexible design, or combine different AM processes. We provide process design and feasibility studies for specific applications.

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