Research Projects

Our goal at BBW is to fulfil our customers’ requests without compromise. The increasing performance required of products often dictates exceptional design in terms of materials and wall thickness. This often pushes existing manufacturing processes to their limits. In order to be able to offer solutions for new materials and challenging product designs, we strive to stay one step ahead. This includes research projects in cuttingedge laser processes that are possible with modern laser systems; as well as independent development of advanced systems that allow for great flexibility combined with a high degree of automation.

 

Laser processes

Modern laser sources with high beam quality and performance allow for laser processes that were previously unthinkable, even as recently as a few years ago. This, in combination with fast deflection systems, results in the ability to quickly oscillate the laser beam and thereby adjust the weld seam shape and the solidification rate. Because the relation between laser parameters and weld quality has not yet been completely researched, BBW is investing in the testing of this technology in order to be able to reliably use it in the near future.

 

 

Aluminium welding seam produced by laser beam oscillation

Another goal of our internal research and development is to be able to produce new or difficult-to-weld materials and compounds. This includes aluminium alloys and hightemperature steels and coated copper materials. Process stability and the susceptibility to cracks and pores is analysed and improved on different systems and with different beam sources. BBW relies on inhouse testing methods and uses state-of-the-art equipment from partner institutes for research and laser welding development.

Cross-section of a mixed joint of steel and copper
Cross-section of a mixed joint of steel and copper
Image of spot welding process on aluminium
Image of spot welding process on aluminium

Systems technology

As a service provider, BBW works hard to process customer enquiries as quickly as possible. Short system setup times and low manufacturing process cycle times in a single or multiple systems are essential. Because a system is sometimes refitted several times a day, it is necessary to have a high degree of flexibility coupled with a high level of automation.
In order to fully tap into the potential of cooperating systems in the future, BBW participates in a consortium to increase machining accuracy of remote laser cutting processes. To achieve a precise manufacturing result despite an imprecise handling system, one has to know the exact position of the machining head relative to the work piece. For this purpose, BBW is developing a device with integrated sensors that enables communication between the device and the handling system.

Cooperation with universities and institutes

Although much of our development work is done inhouse, BBW also takes advantage of opportunities to work with universities and research institutes. This allows us to participate in multiyear research projects to fundamentally investigate processes and explore the capabilities of modern laser systems. As a member of Technical Committee 6 (beam processes) of the Deutscher Vereins  für Schweißen und verwandte Verfahren (German Welding Society ), BBW regularly supervises  interesting research projects. In addition, BBW participates in bi- and multilateral research projects to eliminate deficiencies discovered, or to a priori develop more efficient processes for future uses.
BBW offers students the opportunity to write their thesis in various areas (process or automation engineering, quality and construction), conduct internships or work with us as a student trainee. Tasks are chosen together with students and solutions for existing challenges are developed. Our offering is aimed especially at students of the HS Rosenheim, but students from other colleges and universities are welcome to apply. Current student paper assignments can be found here.

 

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