Technology Focus Joining

Joining

Fraunhofer ILT develops laser beam sources and laser-based joining processes for numerous applications in micro and macro technology. It focuses on extending current process limits, for example, to increase processing speed and precision and to improve weld seam quality. By implementing specific optical systems, nozzles, processing heads and control systems, the institute puts efficient and reliable processes for joining identical or dissimilar materials into practice.

Metals and plastics as well as material combinations such as silicon-glass or plastic-metal can be joined reliably with laser radiation. At the same time, laser processes are suitable for materials that are difficult to process, such as ultra-high-strength steels, high-strength aluminum alloys or (fiber) composite materials.

High accuracies and qualities in weld seams can be achieved through targeted beam shaping and guidance as well as application-specific controls. The institute is continuously developing and adapting processes such as precision welding of metals, plastic welding or glass and ceramic processing for industrial applications. It also focuses its research and development on integrated applications that combine welding, cutting and additive powder processes.

Laser welding machine for the production of battery modules.
© Fraunhofer ILT, Aachen, Germany.
Laser welding machine for the production of battery modules.
Efficient processing of copper materials with blue laser radiation for modern battery technology.
© Fraunhofer ILT, Aachen, Germany.
Efficient processing of copper materials with blue laser radiation for modern battery technology.

In addition, Fraunhofer ILT is developing high-performance energy storage systems. In this area, it is continuing to develop the micro joining of copper materials and dissimilar metal combinations to produce particularly reliable electrical connections with high current carrying capacities. These safe connections are used, for example, in the construction of battery modules or packs of various types. Fraunhofer ILT is also advancing laser processes in hydrogen technology, which are used, among others, to produce bipolar plates for fuel cells economically.

Stable and functional plastic-metal joints are in demand, for example, in automotive engineering or in the aerospace sector. With special tunable lasers, these materials can be welded particularly well, which opens up new possibilities for lightweight construction. In addition, Fraunhofer ILT is developing processes and algorithms for process control and quality control for laser material processing, which also make use of artificial intelligence methods. Inline detection and power controls allow joining processes to be monitored and automatically adjusted in real time.

Fraunhofer ILT has many years of experience and comprehensive know-how in the field of joining technology and develops efficient and process-reliable laser methods and systems for customers from industry and research.

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