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Laser Welding Succeeds with Dynamic Beam Shaping Without Filler Wire

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Productive welding alternative for thick steel profiles

Manufacturers of large-scale steel structures can explore an alternative for low-heat, resource-saving, and process-reliable joining of massive steel profiles with wall thicknesses over 20 millimeters in high quality, demonstrated through a four-meter-long crane boom. The core of the innovation, it is stated, is a powerful multilayer welding process with up to 24 kilowatts of laser power, functioning in a single clamping setup. The preparation of the selected V-groove was optimized to an opening angle of less than five degrees. This reduces the seam volume, saves up to 90 percent of filler material, and largely prevents distortion. Furthermore, straightening large assemblies—often an energy-intensive, manual task—becomes unnecessary in many cases, as noted by the Dresden researchers. This development was supported by an SAB project and is set to showcase advantages in bridge construction, wind energy technology, and shipbuilding in the future. Initial industrial feedback has confirmed strong interest in integrating the new welding technology into existing production lines.

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