Welding requires acceptable quality along the entire weld. In particular, the weld surface geometry has a vital role in ensuring an adequate fatigue life. This paper describes the results of a case study of laser hybrid arc welding of a structural vehicle component of complex geometry. By isolating the various weld geometries along with systematic experimental studies by using a scanner and high speed imaging, the whole chain of the welding process can be analyzed and controlled. The component is made of two types of 7 mm and 20 mm thick high strength steel, requiring butt joints and T-joints, with 7 mm penetration. Cold Metal Transfer is compared to the more common spray mode of the arc, as it offers reduced spatter, undercuts and distortion. The study demonstrates the suitability of this new systematic procedure for controlling the whole welding process under industrial production conditions.
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