A dual solution for improving welding efficiency and quality

Innovative welding technology New era

Optimize the welding process to improve product performance

Technical Parameters

serial number

projects

parametric

1

laser power

20KW

2

Applicable welding products

H-beam, box-type columns, etc.


3


Maximum welding thickness

Single-sided welding：≤18mm

Double-sided welding：≤30mm

4

Welding speed

≥1.6 metres/minute

5

Maximum welding length

24000mm

6

Repeat Positioning Accuracy

≤0.1mm


H-beam welding samples

H-beam welding samples

Welding samples of box columns

Flatbed welding samples

Welding Cost Analysis for Box Columns

Box column: size 400*400*12000mm, thickness 14mm, weight 845KG Welding seam length: 48 metres then the welding cost per 100 tonnes of output is as follows

cost item

Laser Arc Composite Welding

Gas Shielded Welding/

Submerged Arc Welding

Bevel form

未标题-8.png

未标题-9.png

Total length of weld (m)

100÷0.845×48m=5680.5

100÷0.845×48米=5680.5

Welding man-hours (h)

5680.5m÷1.6m/min÷60=64

680.5m÷0.5m/min÷60=190

Turnover, preparation man-hours (h)

10

20

Total labour hours (shifts)

9

26.5

Labour cost (CNY)

3700 (400/shift for general labour)

68166 (welder 12/m)

Welding wire consumption (CNY)

2272 (0.4/m)

7953 (1.4/m)

Electricity per hour (CNY)

150

90

Total electricity cost (CNY)

9600

17100

Welding cost per 100 tonnes (CNY)

3700+2272+9600=15572

68166+7953+17100=93219


Technical Advantage

A leap in welding efficiency - laser arc composite welding technology

- Increased Depth of Melt: Laser-arc interaction attracts and compresses the arc, increases current density, and increases the depth of weld.Single-sided welding, double-sided moulding. - Low cost: no bevelling welding, reduced wire filler. - High adaptability: laser-arc composite heat source welding is conducive to reducing the sensitivity to gaps, alignment and misalignment. - High efficiency: the auxiliary heating of the arc can improve the speed of laser welding; laser-guided arc can achieve high-speed welding.

Welding Performance Comparison

Welding method

submerged arc welding

gas welding

Laser-Arc Composite Welding

Bevel form (up to 14mm)

V-shape

V-shape

No bevelling required

Bevel form (over 14mm)

V- or U-shaped

V- or U-shaped

Y-shape

morph

large‍

large

small

Thermal impact

large

large

small

Weld quality

excellent

excellent

excellent

Welding wire consumption (14mm plate thickness)

RMB 1.5/m

RMB 1.5/m

RMB0.4/米

Weld width

10～16mm

5～10mm

3～8mm

Weld height margin

5～10mm

3～8mm

2～8mm

Welding speed

0.6 ~1 metre/minute

0.5～0.8metres per minute

1.5～2metres per minute

Welding Depth

5～12mm

3～8mm

5～18mm


Welding Process Comparison

Comparison of welding process of H-beam, comparison of welding process of box-type column (product with thickness of 14mm), comparison of welding process of box-type column (product with thickness of 30mm)

Welding process

Welding & Straightening Machine

Gantry submerged arc welding

Laser-Arc Composite Welding


schema

示意图-1.png

示意图-2.png

示意图-3.png

Welding speed

0.6 to 1 metre/minute

0.3 to 1 metre/minute

1.5 to 3 metres/minute


       Welding method

Gas Shielded Welding/

Submerged Arc Welding

Laser-Arc Composite Welding

               schema

示意图-4.png

示意图-5.png

       Welding process

Blunt edge leave 4mm

bottom welding, bevel filler welding

Without bevelling


Single-sided welding and

double-sided moulding

         Welding speed

   0.3～1 metre/minute

1.5～2.5metre/minute

       Welding method

Gas Shielded Welding/

Submerged Arc Welding

Laser-Arc Composite Welding




      schema

示意图-6.png

示意图-7.png

       Welding process

Blunt edges are left 4mmfor bottoming and welding.

Bevel filler weld

Blunt edge left 16mm bottom welding, bevel filler welding

       Welding speed

   0.3～1metres per minute

1.5～2.5metres per minute


Weld performance testing

Weld flaw detection, weld mechanical properties testing, welding impact testing

★ Weld flaw detection test results：

Ultrasonic flaw detection test grade 1 pass.
X-ray flaw detection test grade 1 pass.
★Weld mechanical properties test results:
The tensile test was passed and the parent material broke. Passed bending test, no cracks in welds.
★Weld mechanical properties test results: Q235 material impact performance requirements > 27J, the actual test results of the weld: 47J ~ 120J.
much higher than the material impact performance requirements.

Act now to start the journey to efficient production

Don't wait any longer, choose our laser-arc composite welding line today for both productivity and safety. We look forward to working with you on your journey to efficient, cost-effective production.

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