Laser welding is the future

Aart Aalbers and his successors—nephew Gijsbert and sons Kees and Niels—have long recognised the potential and benefits of laser welding for their products. As a metalworking company, AalbersIwico supplies complete products to OEMs and has become a global player in architectural security through its defence & security division. Aart Aalbers: “Especially for those products, laser welding technology allows us to deliver even higher quality.”

Meeting high standards

One of the first applications where AalbersIwico significantly improved both product quality and production efficiency using laser welding was in the circumferential welding of double-plated doors. “For the Eastern Scheldt storm surge barrier (OSK), for example, we manufacture doors that must be hot-dip galvanised due to saltwater exposure. We can now weld them seamlessly and completely shut all around, allowing galvanisation without compromising quality. Previously, we used plug welding and had to seal the seams with caulking. But that method isn’t suitable for galvanising. Now we can deliver these doors in higher quality and fully galvanised.”

Initial manual testing

To gain experience with laser welding technology, AalbersIwico initially imported a handheld laser welding system from China. “We carried out extensive testing with it, and the results were promising. The major advantage is that, unlike MIG and TIG welding, laser welding introduces virtually no heat, which prevents warping in flat products like the doors we make. You can even place a cold plate on a profile and weld it through completely. The welds are cleaner, and the quality is superb. However, the high welding speed is impossible to maintain manually. That’s where a robot becomes essential.”

Ferris wheel changeover System

“Given our long-standing collaboration and positive experience with Valk Welding, we sat down with them to discuss our idea of a robot on a track,” says Aart Aalbers.

Valk Welding proposed a different concept: a Ferris wheel-style changeover table housed within a fully enclosed cell. “Thanks to the Ferris wheel concept, you can ensure safety while also using a crane to load and unload heavier components,” explains Alex Hol from Valk Welding.

“It’s also the first cell we’ve delivered with a Trumpf laser source, integrated with a Panasonic welding robot.”