At the midpoint of the Soni-Shape-Laser project, focused on developing welding techniques for aluminium 6000 grades without filler wire, Hydro Aluminium has joined as an advisory board member. Hydro Aluminium Extrusions, a well‑known extruder in the UK with a long history of production. Hydro brings a wealth of experience about the manufacturing capability of aluminium extrusions and the industrial standards required for lightweight automotive structures.
Welding aluminium extrusions is traditionally a skilled task, requiring precise arc or laser welding with filler wire. Soni-Shape-Laser aims to deliver a reliable solution for welding Al6000 aluminium using laser technology, simplified into a de-skilled, button-press operation. Alloys such as Al6082 highlight the challenge: they crack under pulsed YAG welding and soften locally around the weld.
With Hydro Aluminium’s involvement, we gain an industry partner invested in solving these issues. Their customers demand extrusion welds that are simple, robust, and free from cracks—exactly the outcome we seek.
The Soni-Shape-Laser project proceeds to plan, exactly halfway through the 2 year program. Phil Carr was presenting at the MTC Coventry in the West Midlands at the Lasers Matter show. An event designed to show how lasers are in every part of the supply chain.
Soni-Shape-Laser project partners went to see PowerPhotonic Ltd in Dalgety Bay, Scotland in August. My thanks to Emma Modrate who hosted our visit during the aftermath of hurricane Floris. Key staff at PowerPhotonic were also available to meet the soni shape team including representatives from finance and management alike.
A tour of the facilities showed a modern working environment, where the beam shaper optics are cut by laser and then polished by the IP protected technique special only to PowerPhotonic. An antireflective (AR) coating is then applied by a specialised wavelength specific coating supplier and this reduces the reflection, protect against laser damage and extend the life of the optic. These optics are then inserted straight into the laser head section of the welding system, exact position dependant on need and design. This optic then gives the desired beam which is hopefully in line with the previously predicted simulation.
We await the results of the latest test and trials.
Welding trials with the new beam shaper optics
Watch the 17 minute SoniShapeLaser presentation given by Phil Carr at ILAS.