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    Figure 2a: AMET’s experience in the welding market together with its expertise in designing and manufacturing high-precision welding systems and controls makes them the ideal partner to build a Civan DBL-based system that will offer a turn-key welding solution for thick metal sections.
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    New Solution for Welding Thick Metal to Hit the Market Early Next Year

    Nov. 2, 2022
    Collaboration between AMET and Civan Lasers will introduce a breakthrough system for single-pass welding of 25 to 50-millimeter-thick metals.

    Civan Lasers’ novel dynamic beam laser (DBL) technology promises to enable single-pass laser welding of 25 to 50-millimeter-thick metals. The DBL’s megahertz-level frequencies, which expose a broader set of parameters for enhanced control of laser welding processes by using unlimited beam shaping and up to 20 millimeters of focus position—influence how much control laser welders have over keyhole and melt-pool dynamics.

    Civian
    Figure 1a: In contrast to existing thick joint welding methods—which require the costly and time-consuming forming of bevel grooves, chamfers, and subsequent filling with extra material—laser welding saves time and money by conducting deep-penetration welding in a single pass, eliminating the need for multiple runs, layering, filler material, and extra steps such as beveling, all the while minimizing the heat affected zone (HAZ) to improve joint strength.
    Figure 1a: In contrast to existing thick joint welding methods—which require the costly and time-consuming forming of bevel grooves, chamfers, and subsequent filling with extra material—laser welding saves time and money by conducting deep-penetration welding in a single pass, eliminating the need for multiple runs, layering, filler material, and extra steps such as beveling, all the while minimizing the heat affected zone (HAZ) to improve joint strength.

    “These capabilities enable new applications for lasers,” explains Dr. Eyal Shekel, CEO of Civan. “DBLs are similar to electron-beam technology in its ability to wobble the beam in megahertz regimes. However, DBLs can do so without requiring a vacuum environment.”

    A common process for welding thick sections is submerged arc welding (SAW). Typically, SAW and other processes require beveling the workpiece to allow the torch access to the joint root. The multipass process requires high heat input to the weldment and can generate a large heat-affected zone (HAZ) along with distortion.

    Civian
    Figure 1b: Deep penetration weld illustration

    Laser welding can focus a large amount of energy on a small spot. However, existing lasers are limited in welding thick sections and therefore are not commonly used.

    The unique capabilities of the DBL enable thick-metal laser welding for the first time, bringing all the advantages of laser to metals in the thickness of 15 to 50 millimeters. These advantages include eliminating the need for beveling and reducing HAZ and distortion along with vastly higher welding speeds.

    Civian
    Figure 2a: AMET’s experience in the welding market together with its expertise in designing and manufacturing high-precision welding systems and controls makes them the ideal partner to build a Civan DBL-based system that will offer a turn-key welding solution for thick metal sections.
    Figure 2a: AMET’s experience in the welding market together with its expertise in designing and manufacturing high-precision welding systems and controls makes them the ideal partner to build a Civan DBL-based system that will offer a turn-key welding solution for thick metal sections.
    Civian
    Figure 2b: AMET welding solution for thick metal sections

    To offer a turnkey solution, Civan Lasers and AMET have collaborated to develop a laser welding system aimed at thick metals. The companies have partnered to develop the most advanced laser welding system for welding 15 to 50 millimeters metals.

    The project has won a prestigious grant from the Israel-U.S. Binational Industrial Research and Development Foundation (BIRD Foundation) which aims to support collaboration between Israeli and U.S. companies.

    Civian
    Figure 3: This cross-section of a 25-millimeter weld performed by Civan’s DBL on S355JR steel illustrates how reduced HAZ can improve joint integrity in very deep welds.
    Figure 3: This cross-section of a 25-millimeter weld performed by Civan’s DBL on S355JR steel illustrates how reduced HAZ can improve joint integrity in very deep welds.

    The project began in March 2022, and the companies will present the first system in February 2023. The system will be produced in AMET’s Idaho factory. In parallel to building the machine, Civan Lasers is developing welding processes in their application lab in Israel. Civan has already demonstrated a 25-millimeter weld and is aiming to present 50 millimeters by the end of 2022.

    Civan Lasers was established in 2008 and is the only company to offer dynamic beam lasers. Civan’s dynamic beam lasers allow manufacturers to control beam shape, frequency, and sequence and to focus steering, eliminate spatter, increase welding power, and increase speed. Through their advanced capabilities, dynamic beam lasers open the door to countless new applications. Visit Civan.

    AMET was established in 1989 and has developed, produced, and supported automated welding systems throughout the world. AMET's focus on providing completely integrated welding systems controlled via a single operator interface has allowed our systems to be an integral part of manufacturing crucial components for a broad range of industries.