Laser welding in transmission manufacturing opens up completely new kinds of product solutions with excellent properties in terms of wear, corrosion resistance and service life. Current welding designs are characterized in particular by difficult-to-weld material combinations (e.g., steel vs. cast iron) and a high component stiffness for load transfer, that is typically correlated with high residual welding stresses. The major challenge for these welded structural components remains both their crack-free weldability and their complex cyclic load capacity.
In this frame, the subject of this contribution is the presentation of a simulation-based strategy for process- and load-compatible laser welded transmission components. Specifically, a systematic study is being conducted to understand and qualitatively evaluate effective methods for reducing residual weld stresses in circumferential welds. The recommendations developed as part of this study take particular account of the influence of process modifications, material conditions and geometric aspects on weldability and component distortion. In this context, the residual stresses can be reduced by up to 30 % using suitable modifications. In particular, structural welding simulations are performed and verified by experimental welding trials including metallographic examinations. To ensure the required component fatigue strength, a practical concept for determining Wöhler curves is presented.
The simulation-based development methods enable the production of load-transmitting components in the fields of e-mobility, aerospace and industrial engineering. In particular, time-consuming and cost-intensive iterations of laser welding tests can be significantly reduced. Furthermore, the systematic investigations provide effective recommendations for phenomenological understanding and solving typical welding challenges in practice.