Fraunhofer scientists are to demonstrate the new laser production technologies for the automotive industry at the 2011 Laser trade fair to be held from 23 to 26 May. Lasers can be used to produce more-efficient engines, powerful batteries and fiber-composite components.
Energy efficient, less polluting cars are needed to address the global environmental demands and the rising cost of fuel. Lasers have unique properties to help address this demand. They are universally applicable, wear-resistant and have the capability to cut, shape, drill, and join any type of material.
Laser
Automotive manufacturers use fiber-reinforced plastics to reduce the overall weight of the vehicles, and thereby reduce energy consumption. These plastics, though lighter than metal by 30% to 50%, are brittle and normal tools get worn out fast during processing. Lasers can be used to cut and join fiber-reinforced plastics, and ablate and weld components. They can also join plastics strengthened by fiber to metals. Fraunhofer’s scientists have developed new integrated laser tools that can weld different material combinations without any cracks or fissures. The scientists are to demonstrate a new precise laser welding head that delivers a stable bond, at the Laser 2011 fair.
Low friction improves the efficiency of engines. Components made of high-performance ceramic coatings are wear-resistant, smooth and generate less friction. These components are currently manufactured through plasma chambers and are very expensive. Scientists at Fraunhofer have developed a quicker and more economic process, through which ceramic nano-particles are coated onto the work pieces and then treated with laser to achieve the desired finishing. Friction occurs between engine pistons and cylinder walls. To protect these components a film of oil must constantly coat the cylinder wall. Laser can be used to improve the adhesion of the oil through special structuring processes, thereby leading to lesser energy consumption and wear and tear.
Laser technology can be used to increase the durability, life-span and efficiency of electric batteries, while reducing their cost of manufacture. They can be used to form long-lasting connections between electrodes, while avoiding creation of brittle alloys that break easily. The batteries would also require less cooling as less electrical energy is converted into heat.
In the tool design, laser technology can be used to directly transfer a CAD model design onto a tool surface. For producing surface designs that have the appearance of leather, lasers can be used instead of the tedious etching process using steel tools.