1. B3 Sustainable welding production – Challenge Page 1 ► Task orientation: Sustainable welding process concerning: ► Sheet thickness ► Quality requirements ► Joint preparation ► Resource efficiency ► Application of high power welding processes for thick metal sheet structures ► Savings in base/filler material, consumables and energy regarding the whole product life cycle ► Increased weldability of high strength steels for reduction of sheet thicknesses ► Simulation based optimization of weld process ► Working conditions and training ► Ergonomy oriented & feed back enhanced training for manual welding processes ► Decrease health risks for welder by means of automatization

2. B3 Sustainable welding production – Approach Page 2  Welding task defines constraints for suitable process selection  Suitable process depending on the requirements of the task  Simulation based optimization  Sustainable weld defined by product/process quality, ressource efficiency and social aspects *Gas metal arc welding welding task features Sheet thickness Quality requirements Availabilty welders Base material Accessibility weld Weld in position Energy consumption Consumables consumption Process capability hazards for the welder Sustainable weld features Number of defects Energy input

3. B3 Sustainable welding production – Results 2012 Page 3  Influence factors for welding in sustainable manufacturing  Contributions regarding the three sustainability dimensions  Potentials of improvements in specific factors  Determination of dominant factors:  Reduction of base metal sheet thickness  Reduction of filler wire consumption  Application of laser hybrid welding  Extended root face width  Welding of higher strength steel grades  Reduction of welding passes from 8 to 4  Reduction of filler wire consumption by factor 2.8 in a demonstrator weld root pass Initial weld design root face width New weld design Laser-arc hybrid weld Reduction of welding passes from 8 to 4