Fraunhofer Institute for Nondestructive Testing IZFP 
The “AkuProMoLaserbeam“ project is dedicated to developing user-friendly methods for acoustic process monitoring in laser beam welding.
Laser beam welding technology has established itself in recent years as one of the most efficient and precise methods for joining materials.
This technology is particularly valued in the automotive and aerospace industries, as well as in mechanical and plant engineering, due to its high processing speed and ability to process complex geometries. However, with the increasing use of laser beam welding, the need for reliable monitoring of the quality of weld seams is becoming more urgent. Seam defects such as spatter, pores, or “false friends” can have serious effects on the mechanical properties and tightness of the joints. Conventional process monitoring methods, such as optical or thermographic methods, often reach their limits, especially in harsh industrial environments. There is therefore a growing need for innovative approaches to acoustic process monitoring that are capable of overcoming these challenges.
AkuProMoLaserbeam aims to develop user-friendly methods for acoustic process monitoring in laser beam welding. The focus is on the simultaneous detection of various seam defects and the acquisition of acoustically relevant information generated during the welding process. Modern data processing methods, including machine learning, play a central role in this. The use of acoustic sensors will enable real-time monitoring of weld seams so that potential defects can be detected at an early stage. A key objective is to develop methods that are capable of detecting defects and identifying their causes, thereby enabling preventive measures to be taken. These approaches aim to increase the efficiency of manufacturing processes and significantly improve the quality of the components produced.
Potential benefits of the project results
The results of the project have the potential to significantly increase the competitiveness of small and medium-sized enterprises (SMEs). By implementing robust, user-friendly methods for acoustic process monitoring, SMEs can significantly reduce scrap and liability risks. The use of acoustic sensors provides a cost-effective and easily integrable solution that offers real-time inline monitoring of welding processes. This leads to improved product quality and reduced production costs. In addition, the methods developed in the project can be transferred to other laser material processing methods and even to related technologies, further increasing the benefits and applicability of the research results. The ability to respond preventively to quality problems further contributes to the optimization of manufacturing processes and promotes sustainable development in industry.
The project is being carried out in cooperation with the Department of Manufacturing Technology at the Technical University of Ilmenau. A project advisory committee consisting of 13 companies (including 6 SMEs) is supporting the project.