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Metal laser welding markedly improved with beam forming

Researchers at the Fraunhofer Institute for Material and Beam Technology IWS in Germany have worked out a way to eliminate filler wire in the laser welding of metals while improving quality, energy efficiency, and production.

"We demonstrate that even the most demanding welding tasks -- such as joining of difficult-to-weld material alloys or welding of heavy sections -- can be performed robustly and productively with less energy, material, and rework," said Dr. Axel Jahn, head of the Joining Department at Fraunhofer IWS. "The combination of high-frequency scanner technology, flexible power modulation, and our open system control enables design options and application perspectives that conventional arc welding cannot provide."

Laser-welded aluminum battery housing at full component scale; this piece combines die-cast elements with extruded profiles in a lightweight design. [Credit: ^® Rene Jungnickel/Fraunhofer IWS]

 

 

 

 

Application: Aluminum battery housing that is crack-free, pore-minimized, and made without wire
In a European Union-sponsored electric vehicle (EV) project dubbed "ALBATROSS," Fraunhofer IWS developed an innovative, laser-fabricated battery housing for EVs and successfully demonstrated it at full component scale. The lightweight design combines aluminum extrusion profiles with die-cast aluminum parts, featuring walls up to 5 mm in thickness.

Conventional approaches reach physical limits with this pairing: Die cast tends to form pores, while aluminum extrusion alloys of the 6000 series are prone to hot cracking. "Our solution relies on targeted oscillation of the laser beam, which moves the melt pool, reduces pores, and produces metallurgically stable welds," explained Jahn. "This allows us to generate high-quality aluminum welds without the filler material usually required."

The housing has already been integrated and tested in a real vehicle model. Within the Fraunhofer flagship project called "FutureCarProduction," the technology is being advanced for secondary aluminum and cast-to-cast joints, alongside a sustainability assessment.

Laser welding with dynamic beam shaping produces tight, low-distortion seams on this rotationally symmetric aluminum tank structure without using filler wire. [Credit: ^® Rene Jungnickel/Fraunhofer IWS]

 

 

 

 

Application: 3D tank bottom boasts crack-free welds for demanding conditions
For aerospace applications, Fraunhofer IWS has developed a laser welding process with dynamic beam shaping to produce closed tank structures from high-strength, 2000-series aluminum alloys. Since these alloys tend to form hot cracks, conventional welding typically requires the use of filler wire to adjust the alloy composition. In contrast, the new laser process operates without filler material and achieves stable, low-heat welding -- even on three-dimensional contours. "The process is ideal for closing rotationally symmetric containers and is also under study for pipe welding," Jahn said. "It delivers tight, mechanically strong joints with minimal distortion and high seam strength."

The demonstrator is being developed within an aviation project funded by the German Federal Ministry for Economic Affairs and Climate Action (BMWK). In parallel, Fraunhofer IWS is testing friction stir welding (FSW) for sheets and electromagnetic pulse welding (EMP) for hybrid pipe joints.

Application: Crane boom is a productivity boost for steel construction
Manufacturers of large steel structures now have a new option for joining thick profiles with wall thicknesses over 20 mm. Fraunhofer IWS demonstrated this on a 4-m-long crane boom. The process uses high-performance multilayer welding in a single clamping with up to 24 kW of laser power. V-groove preparation has been optimized to opening angles below 5 degrees. "As a result, we reduce weld volume, save up to 90 percent filler material, and largely eliminate distortion," Jahn noted. "Straightening large assemblies -- often an energy-intensive manual step -- becomes unnecessary in many cases."

The project aims to transfer its findings into bridge building, wind energy, and shipbuilding. Initial industrial feedback confirms strong interest in integrating the technology into existing production lines.

Conclusion
These demonstrators illustrate how material science, process know-how, and system integration come together. Fraunhofer IWS not only develops joining technologies but also supports their transfer into production environments. "We bring our solutions into application with integrated sensors, advanced control, and continuous process quality evaluation," said Jahn.

VIDEO: Overview of laser welding development at Fraunhofer IWS. [Credit: Fraunhofer IWS]

Want more information? You can contact Dr. Axel Jahn at Axel.Jahn@iws.fraunhofer.de or by phone at +49 351 83391-3237.

Learn more about Fraunhofer IWS's customized laser processes, system solutions, and component concepts at www.iws.fraunhofer.de/en/technologyfields/cutting-and-joining/welding.html.

Source: Fraunhofer Institute for Material and Beam Technology IWS

Published September 2025

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