Shipbuilder Fincantieri and Castellini Officine Meccaniche have conducted an extensive study utilising Civan Lasers’ 28kW Dynamic Beam Laser (DBL). DBL technology was found to offer significant benefits for welding of thick steel sections.
The technology allows for a forty per cent increase in welding speed, allowing Fincantieri to complete projects more efficiently. DBLs can also weld steel sections over twice as thick as those handled by current methods, expanding possibilities for ship design and construction.
In addition, there was a reduction of distortion and heat-affected zone (HAZ). Pure laser welding transfers significantly less heat into the workpiece, minimising distortion and substantially reducing the size of the HAZ, which leads to better mechanical properties.
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Energy and cost savings
At the same time, DBL technology offers significant energy savings of up to sixty per cent and requires ninety per cent less filler material usage, thereby also reducing costs. The requirement for protective gases, a major cost factor in traditional welding, has been reduced to a minimum as well.
This research exemplifies how Civan’s DBLs can be integrated into Fincantieri’s production processes, setting a new standard for welding thick steel sections and making shipbuilding faster, more efficient, and environmentally sustainable.
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Dynamic beam lasers versus hybrid welding
Dynamic Beam Laser (DBL) technology is revolutionising the field of welding, offering solutions to some of the most challenging welding problems and unlocking new opportunities for industries. One of the most promising applications of DBL technology is in the welding of thick sections, where traditional methods fall short.
Currently, the most advanced approach for thick section welding in shipyards is hybrid welding, which combines laser and MIG/MAG technologies. However, even this method faces significant challenges. These include high heat input, which can cause material distortion, reliance on consumables, such as filler rods and protective gases, and the need for complex joint preparation through bevelling.
Key advantages of DBLs over hybrid welding are:
- Minimal heat input, reduced distortion, and better mechanical properties: DBL technology introduces far less heat into the welding process compared to hybrid methods, resulting in significantly reduced distortion. This minimises the need for large fixturing and mitigates the risk of misalignment, simplifying the process. Additionally, the smaller HAZ ensures superior mechanical properties in the welded material, enhancing the overall quality of the weld.
- Higher penetration depth in a single pass: DBLs offer greater penetration depth, allowing thick materials to be welded in a single pass. In hybrid welding, a single-pass hybrid weld typically needs to be followed by multiple MIG or MAG passes to achieve the desired thickness. With DBL technology it is possible to reach up to 30mm in a single pass.
- No pre-heating, faster process, and lower power consumption: DBL technology reduces the need for pre-heating, which is often necessary in hybrid welding to ensure proper hardness when welding thick sections. By reducing this step, DBL technology speeds up the process and reduces energy consumption, making it both cost-effective and energy-efficient.
Picture (top): Illustration of welding ship panels with Dynamic Beam Laser (by Civan Lasers).
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