Dynamic Beam Laser Technology: A Game-Changer for Welding Thick Steel Sections
The naval and shipbuilding industries have long faced challenges when it comes to welding thick steel sections. Traditional welding methods, particularly MIG/MAG welding combined with laser technologies, often encounter limitations when dealing with larger material thicknesses. These methods require multiple welding passes and specific joint preparations, both of which are time-consuming and expensive.
However, the Dynamic Beam Laser technology, developed by Civan Lasers, offers a groundbreaking solution that simplifies the welding process. The DBL technology uses a laser that can dynamically adjust its beam shape in real-time, optimizing energy distribution and increasing welding efficiency.
How DBL Technology Works
At the heart of DBL technology is its dynamic beam shaping, which is unlike traditional fiber lasers that use a fixed beam shape. The DBL system dynamically adjusts the laser beam based on the welding requirements, enabling more precise and efficient energy delivery. This innovation allows for faster welding speeds and a reduction in material waste, as it can weld steel sections in a single pass, even with thicknesses up to 25 mm, without needing special joint preparation.
As Simone Peli, a physicist at Castellini, explains, DBL technology can deliver higher performance by concentrating power during the welding process, bypassing the need for joint preparation, and reducing the number of welding passes. In essence, DBL is a purely laser-based welding process that overcomes the limitations of traditional hybrid systems, such as MIG/MAG lasers.
Why DBL is Revolutionizing the Welding Process
1. Speed and Efficiency: Up to 40% Faster Welding
One of the most compelling advantages of DBL technology is its ability to increase welding speed by up to 40% compared to traditional methods. For industries like shipbuilding, where time is of the essence, this significant increase in speed translates into shorter production cycles, allowing companies to meet tight deadlines and increase their overall productivity.
With the DBL system, the time required to prepare the material, apply filler materials, and complete the welding process is drastically reduced. The technology eliminates multiple welding passes, saving not only time but also material costs.
2. Sustainability: Reducing Energy and Material Consumption
In today’s industrial environment, sustainability is a critical concern. The DBL technology addresses this by drastically reducing the energy consumption and the need for filler materials. According to studies, the DBL welding process leads to up to 60% energy savings and 90% less filler material usage compared to traditional welding techniques. These reductions directly contribute to lowering the carbon footprint of the welding process, making it more environmentally friendly.
Additionally, the technology’s low heat input minimizes the heat-affected zones and plate distortion during the welding process. This is especially beneficial in industries like shipbuilding, where the quality of the weld is critical to ensuring the structural integrity and resilience of the finished product.
3. Improved Weld Quality: Enhanced Durability and Strength
The DBL technology excels in improving the overall quality of the welds. By reducing heat input, the process ensures that mechanical properties such as strength, ductility, and resilience are preserved. In addition, the laser focus control ensures that the base material maintains its integrity in both the molten and heat-affected zones, which is crucial for achieving high-quality welds in materials like AH-DH36 and S355J0-J2 steels, commonly used in shipbuilding.
The dynamic beam shaping process optimizes the energy distribution, enhancing joint properties and reducing the risk of defects like porosity and cracks. These improvements in weld quality are vital for ensuring that welded structures can withstand the extreme conditions faced in maritime environments.
4. Cost Reduction: More Economical and Efficient
The reduced need for joint preparation and filler materials makes DBL welding a more economical alternative to traditional welding methods. The elimination of additional steps such as filler material application and multiple passes means fewer materials are required and the overall cost per weld is lowered. This cost-efficiency is particularly important in industries with tight profit margins, such as shipbuilding, where cost-saving measures can significantly impact the bottom line.
Moreover, by reducing the energy consumption and increasing the speed of the welding process, companies can decrease their operational costs while increasing production output. This is crucial for maintaining competitive advantage in the global market.
5. Enhanced Safety and Reduced Maintenance Costs
The remote operation capability of DBL welding significantly enhances operator safety by minimizing exposure to welding fumes and reducing the risk of accidents. In addition, the use of long focal lengths with a working distance of over 1.5 meters reduces wear and tear on the laser equipment, resulting in lower maintenance costs and extended equipment lifespan.
The DBL system’s automation and remote monitoring features allow operators to manage the process from a safe distance, streamlining workflows and improving safety standards within the workplace.
The Future of DBL Technology in Shipbuilding and Beyond
While DBL technology has already demonstrated its ability to weld thick steel sections up to 25 mm in a single pass, the next frontier is to extend these capabilities to even thicker materials used in industries like offshore platform construction and industrial infrastructure. The next phase for DBL technology will focus on higher-powered lasers capable of welding materials up to 50 mm thick, which is common in industries such as offshore energy and heavy industrial construction.
For Fincantieri, the adoption of DBL technology represents a medium-term goal to integrate this revolutionary welding method into its production lines. The ability to handle increased weldable thickness and industrialize the process will ensure that shipbuilding projects can meet tight timelines and quality standards without compromising on cost-efficiency.
In the long run, DBL technology is poised to become a standard practice in global manufacturing. Its flexibility, speed, cost-effectiveness, and environmental sustainability make it an attractive solution for a wide range of industrial applications, including the construction of wind towers, offshore floating platforms, and marine vessels.
Key Takeaways:
• DBL technology increases welding speed by up to 40%, significantly improving production efficiency in industries like shipbuilding.
• The technology leads to 60% energy savings and 90% reduction in filler material usage, making it more sustainable and cost-effective.
• Dynamic beam shaping optimizes the energy distribution during welding, leading to improved weld quality and stronger, more durable joints.
• DBL welding eliminates the need for joint preparation, allowing the welding of thicker steel sections in a single pass with no special geometry required.
• Remote operation reduces workplace hazards and improves operator safety while extending equipment lifespan and lowering maintenance costs.
• The next step for DBL technology is to extend its capabilities to weld even thicker materials, such as those used in offshore platforms and industrial infrastructure.
• Fincantieri views DBL as a medium-term objective for integrating this technology into its shipbuilding production lines.
The Dynamic Beam Laser technology is set to reshape the future of welding in industries that require high-quality, efficient, and sustainable manufacturing processes. As this technology continues to evolve, it will not only enhance productivity but also contribute to the greener and more cost-effective future of industrial operations across the globe.
