Press Release

ROFIN Profile Welding System



Weld Sensor

ROFIN at the TUBE 2012


Hamburg, 23 March 2012 – From 26 to 30 March, the international tube branch meets at the TUBE 2012 in Düsseldorf. The ROFIN Laser Macro Group will show its range of possibilities in the area of laser welding in Hall 5, booth F22, and presents laser based products and solutions for the processing of tubes and profiles.

Process safe laser welding of tubes and profiles for 25 years

For the past 25 years, the ROFIN Macro group has delivered laser system solutions for the welding of tubes and profiles. At the TUBE 2012 ROFIN presents the well-proven Profile Welding System (PWS) – a complete laser welding system with an integrated process sensor.

ROFIN does not only provide the necessary laser equipment, but also develop new processes together with the customers like e.g. the welding of deep-water tubes made of Duplex material or the welding of titanium tubes or filler wires. At the TUBE fair, ROFIN is exemplary showing the welding results of smallest tubes with 2-6 mm in diameter and wall thicknesses from 0.1 mm up to 0.5 mm, welded with the Fiber laser of ROFIN’s FL Series.

Laser welding of tubes and profiles provides very narrow seams with fine-grain structures and narrow heat effected zones. This means the heat treatment needed for further processing is often not required. In contrast to conventional TIG welding, non-contact laser welding can achieve significantly higher process speeds. The welded seams withstand even very high stress levels without tearing.

The Profile Welding System consists of a beam guidance and sensor system with PC-controlled linear axes, which is needed for reliable laser welding. All the func-tions required to operate the laser system can be controlled using an integrated PLC controller. These functions include the introduction of process gases, the monitoring of the optical safety circuit, the complete system monitoring of the laser, and the associated cooling system. The moveable display unit attached to the support arm makes operation easy and clear.

Sensors for gap position recognition and seam tracking can detect even the slightest discrepancies in the seam position. This ensures that the laser beam always follows the seam, guaranteeing high process reliability. Thanks to high-speed pre-cision linear drives, the PWS achieves position accuracies of a few µm at production speeds of up to 60 m/min.

Standardized interfaces and compact dimensions enable simple integration – even into existing systems. The tried and tested beam guidance system provides safe operation under industrial conditions. The PWS is virtually maintenance-free and is not sensitive to oil, dirt, dust, damp and electrical interference – the best prerequisites for use even in tough industrial environments.

Thanks to the modular system, adaptations to customer-specific requirements and local circumstances can be made easily. This means, the beam guidance system can be adapted with a beam switch box or a beam splitter to enable simultaneous operation on various systems or at various welding points. Depending on the requirements, the PWS is fitted with optimized jet geometries in order to achieve the best possible application results. A special weld head allows drag welding, which optimizes the process for high welding speeds. Other features, such as documentation of process data for quality monitoring purposes, can also be integrated on an optional basis.

The perfect partners – ROFIN’s CO2 Slab Lasers and Fiber Lasers

For welding tubes and profiles, our CO2 Slab lasers or Fiber lasers are the ideal beam sources, which in various versions complete or replace conventional laser beam sources.

The highly efficient CO2 Slab lasers of the DC Series with up to 8 kW output power and an excellent beam quality of K = 0.95 are the first choice for highest weld seam quality from medium to thick wall thicknesses. These extremely durable lasers operate with only a few moving components and do not need conventional gas recirculation, which leads to a considerable reduction in maintenance, service and gas consumption. A real advantage for an efficient process! A further plus of the proven CO2 Slab laser is the security aspect: Due to the longer wavelength less security measurements have to be taken.

The highly-brilliant Fiber lasers out of ROFIN’s FL Series are the ideal addition to the well-proven Slab lasers. The Fiber lasers are available with currently up to 4 kW output power and used for welding applications in material thicknesses in the range of 0.01 mm up to 2 mm.

During the welding process of thin materials, only small weld pools are developed and due to this, processes can be realized that are not possible with conventional welding methods. Given the fact that existing machine and production concepts are adjusted accordingly, extremely efficient processes can be achieved by using the highly focusable Fiber lasers. For example, these processes can be used in the pipeline construction, e.g. for composite tubes, or in the medical device industry for the production of smallest cannulas.

At the TUBE show, ROFIN is presenting the Compact Version of the Fiber laser, the ROFIN FL 030 C, which can be integrated into existing machining concepts with ease. This laser is also an interesting solution for plant and system manufac-turers.

The Fiber lasers of the FL Series offer high efficiency, long inspection intervals and high welding speeds. 

For a perfect process monitoring – the Weld Sensor
At the TUBE 2012, ROFIN presents the Weld Sensor in combination with the Pro-file Welding System. This sensor system allows the operator to “watch the weld”. In addition to the fully automatic correction of the welding position, the sensor ensures demonstrably higher process reliability. The Weld Sensor is available as an option – instead of the Standard Tracking System – and has been developed for CO2 and Fiber lasers, whereas in case of CO2 lasers the same safety class can be maintained. Even existing ROFIN Profile Welding Systems can be upgraded with this new sensor system.