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For a better world: OCT unlocks real-time quality control during oscillation welding

Compared to conventional laser welding with a static focal spot, welding with an oscillating laser beam results in better weld quality. However, to ensure the broad industrial application of this technique, an easy-to-handle integrated system for precise seam tracking and quality monitoring is required. OCT can be applied to a welding process with an oscillating laser beam to influence the process by improving control of the weld position, depth and geometry. This is done by compensating the oscillating laser movements. Hence, laser welding of power storage and electric engine components using an oscillating beam can become more robust using a highly dynamic OCT system. OCT enables fast, precise and omnidirectional online detection of varying seam joint location, focal position, weld penetration depth, as well as weld faults.

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OCT für das Schweißen von Hair Pins

Wegen der immer strengeren Anforderungen an den Umweltschutz müssen die Automobilhersteller den Kraftstoffverbrauch ihrer Fahrzeugflotten reduzieren. Der Übergang zur emissionsfreien Elektromobilität ist ein globaler, technologischer Trend. Der schnell wachsende Markt für Elektromobilität erfordert präzise geschweißte Funktionskomponenten. Das Laserschweißen leistet zusammen
mit Präzisionssensorsystemen wie OCT (Optische Kohärenztomografie, auf Englisch Optical Coherence Tomography) einen großen Beitrag zur Entwicklung von elektrischen Komponenten für voll- oder teilelektrifizierte Fahrzeuge, aber auch für die Batterien selbst.

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Optical Coherence Tomography (OCT) Allows Sophisticated Trajectories while Producing High-Quality Laser Welds

Better-quality welds, reduced cost per part, and shorter cycle times are industrial goals that can be achieved by using highly focused laser light. Precise and reliable dynamic sensing technology is required to operate the automated processing laser without direct human manipulation to accomplish safety requirements.
Today, optical coherence tomography (OCT) has gained acceptance as a measurement technique with high precision and reproducibility. OCT as applied to laser welding has already made a step beyond laboratory use, being widely adapted to various laser heads in different branches of the joining industry. OCT brings laser welding to its proper target, ensuring high-quality welds and enabling the reduction of cycle times during welding along sophisticated trajectories or during positioning at challenging joints or low-dimensional e-mobility elements. OCT is beneficial for online omnidirectional seam tracking, exact nondestructive measurement of keyhole depth, and identification of faults and defects at the resulting seam.

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Implementing OCT for industrial weld monitoring

Dr. Nataliya Deyneka-Dupriez describes the benefits that OCT can bring to weld monitoring, and highlights how the technology is starting to find applications in e-mobility.

"OCT technology can be successfully used for fast and exact localisation of hairpins, and fast quantitative quality assessment of the weld bead during processing."