In the mid-1990s, BMW introduced laser welding robots to assemble the first weld of the BMW 5 Series sedan, with a total weld length of 12 meters. By July 2003, the cumulative length of laser-welded seams had reached an impressive 1.5 million meters. This marked a significant shift in automotive manufacturing, as laser technology began to play a more central role in the industry.
The growing competition in laser technology has led to its increased adoption in car production. According to Christian Elsner, head of the welding (equipment and parts) technical group at Daimler Chrysler, the primary applications of laser welding are in the assembly of transmission systems and vehicle frames. Although laser welding wasn't widely used for many years, advancements in power supplies and higher laser output have allowed it to take over areas traditionally dominated by conventional methods.
The widespread use of laser technology in the automotive sector wouldn’t have been possible without the efforts of researchers and engineers. At Daimler Chrysler, the Institute of Production Technology and Materials Technology is working closely with the Institute of Physics to improve sensor integration in the welding process. Strengthening collaboration between manufacturers, application companies, and research institutions leads to better innovation and more efficient outcomes.
New developments in laser welding solutions are emerging. One such example is the transistor-pulsed Diode Pumped Disk Laser (Diodengepumpte Scheibenlaser), developed by the Stuttgart Laser Tools Institute (IFSW). This new technology offers high efficiency and excellent focusing capabilities. The laser medium is an extremely thin reflective disk, just a few percent to a few hundredths of a micron thick. The pulsed laser beam is refracted multiple times through a compact system before exiting via a crystal. Despite its small thickness, the reflectivity is very high, resulting in excellent overall efficiency.
As noted by Mr. Hügel, this technology combines the best features of CO₂ and Nd:YAG lasers, opening up new possibilities for future applications. The use of laser welding continues to grow, with the Volkswagen Touran being a prime example. In this model, there are 1,400 laser welds totaling 70 meters in length. For open-top vehicles, VW's engineers partnered with Austrian company Fronius to develop laser hybrid welding technology. On the doors of premium convertibles, the hybrid weld reaches 3,570 mm—three times longer than a standard laser weld.
Laser hybrid welding has proven to be highly effective, especially when joining sheet metal components. It enhances the gap tolerance compared to pure laser welding, allowing for greater stability during high-speed welding. Another application involves the aluminum alloy baffle on the BMW 5 Series, which is joined to the internal high-pressure deformation bracket using this advanced technique. As the automotive industry continues to evolve, laser technology remains a key driver of innovation and precision.
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