Posters

Abstract

Arc-based welding processes especially multi-wire submerged arc welding, are currently used for the joining of thick plates in the onshore wind energy industry. Several layers are required to weld steels with a wall thickness of up to 30 mm, due to the limited welding depth, which limits the productivity of the process due to the high welding times. In addition, the welding process is characterised by a high heat input. Alternative welding processes, such as laser hybrid welding, are limited in their industrial application due to some process-specific challenges: increased risk of drop formation at the weld root due to the gravity; limited gap bridgeability; risk of hardening and deterioration of the mechanical properties of the weld due to high cooling rates. However, the great advantage of laser hyrbid welding technology would be that this technology would allow a significant increase in process speed and cost savings for the welding process. In this talk, we will show how we have managed to weld such components in only a single pass for the first time thanks to an innovative approach. To overcome the challenges mentioned above, a contactless electromagnetic weld backing is used, which is based on externally applied AC magnetic fields. With this bath support, the disadvantages mentioned can be eliminated and the full potential of laser beam welding can unfold. This leads to a eightfold time saving and a cost saving of over 90%. This development and the presentation vividly shows that the industry is far from having exhausted the full technical optimization potential and is intended to encourage the participants to break new ground in the field of technical innovation as well.