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Lasers in
Manufacturing
Present: Erfan Zaker Esfahani
Email: aref_z_e@yahoo.com
Number: 09131299216
Lecturer: Dr. saebnoori
University: najaf abad
Number of student: 890914688
Course: Surface Engineering
Introduction
 Laser Welding
 Laser Cleaning
 Surface treatments
 Laser Cladding
 Direct Laser Fabrication
 Selective Laser Sintering
 Laser Forming - an emerging process
Laser Welding
 Established in the early 80’s
 Now used on many production lines
 Low volume applications and
subcontract limited to niche areas such
as mould tool repair, jewellery and
dentistry
Welding
Key features of deep penetration laser welding include:
 High energy density – Keyhole welding Less distortion
 High processing speeds High throughput
 Rapid start / stop Unlike arc processes
 Welds at atmospheric pressures Unlike EB welding
 No filler required But good fit up is essential
 Narrow welds Less distortion
 Very accurate welding possible Good fit up & fixturing needed
 Good weld bead profiles
 No beam wander in magnetic fields Unlike EB
 Little or no contamination Depending on gas shroud
Welding
A 10 kW fibre laser used in
shipbuilding
A hybrid laser welding system
Spot and MicroWelding
 Repairing mould tools
 Medical devices
400 m spot welds on a
orthodontic bracket
Sensors
 Read / Write heads
Orthodontic Bracket
Other Laser Welding applications
Plastics and Polymer Welding
Possible to use laser to weld transparent plastic to
opaque plastic (n.b. “transparent and “opaque”
refer to laser wavelengths)
Clear weld®
Uses absorbing dye in joint interface to weld two
nominally transparent polymers
Can even be used for clothing!
Laser Welding Developments
Hybrid Welding
Uses combination of arc and laser processes
More tolerant to poor fit up
Filler metals can positively modify weld metal
Over performance better than expected for this
combination
“Remote Welding”
Use high beam quality “slab” and fibre lasers
coupled to a scanning head to weld at multiple x-
y-z positions
Cleaning
Emerging process, particularly driven by art and
monument restoration (I.e. National Museums and
Galleries on Merseyside (NMGM) conservation centre.
Engineering applications are being identified – dry
cleaning of metal components prior to welding and
PCB’s and component leads prior to soldering.
Cleaning
Advantages of laser cleaning
 Laser Cleaning does not damage
 No abrasive effect (No abrasive)
 No mechanical contact
 No heat effect
 Laser cleaning does not pollute
 No solvents
 No polluted effluents
 Fumes extracted easily
The operator protection is reduced to a simple eye protection
 Engineering applications of laser cleaning
are being developed.
 Applications include mould tool cleaning
Stripping of paint from aircraft
Cleaning
Surface treatments
 Three main processes –
hardening, melting and alloying.
Aim to improve surface properties
such as wear and corrosion
resistance, one can:
 Temper
 Laser Hardening
 Laser fusing / cladding
(depositing a hardwearing
corrosion resistant surface)
 Alloying surfaces
 Nitrate
 Treat many different materials
Laser hardening
Laser Alloying
Surface treatments
Special hardening process for titanium
 Surface is laser heated.
 Nitrogen is blown over the surface forming
titanium nitride under on the surface.
 The surface hardness is increased many times
compared with the parent material.
Laser Cladding
Deposition of wear and corrosion resistant
materials.
Reduced heat input gives lower distortion.
Direct Laser Fabrication
DLF combines 4 common technologies
 CAD
 CAM
 Powder Metallurgy
 Laser Technology
 A high powered laser creates a melt pool
 Powder is deposited into the melt pool
 Moving the laser beam in a prescribed pattern a component is
traced out layer by layer
Direct Laser Fabrication
General set-up of Direct Metal Deposition
Direct Laser Fabrication
 Tool repair
 Mould repair
 Turbine blade repair
 Rapid Prototyping
Selective Laser Sintering
 Parts built up layer by layer
 A CO2 laser beam selectively melts powder into a designated
shape
 The component sinks into the bed, a layer of powder is
deposition above the component
 The process repeats until the component is finished
Laser and laser cladding
Laser Forming - an emerging
process
 Bending metal with light
 Laser beam induces thermal stresses
 The plate expands, cools and
contracts
 The flat plate deforms into a new
shape
Industrial sectors
 Aerospace
 Automotive
 Marine
Structuring and texturing
 Periodic Structures (with period <1um) machined into metals
and ceramics, and also produced by material modification in
polymers
Direct writing in Fused
Silica
Pulse duration 100fs,
Wavelength 400nm,
Pulse energy 0.8μJ
Scan speed 200 μm/s
10 μm pitch, 0.5NA
CW Fibre laser generation
of Nanoparticles
High intensity laser beams vapourise materials
that then condense as sub-micron powders.
CW fibre laser combine high intensity with high
intensity
pS fibre lasers
 Fianium laser system:
 Pulse Length 20ps.
 Wavelength 1064 nm.
 Rep Rate 200kHz or 500kHz
 Maximum Pulse Energy 6 J
 Laser Power 2.1W
 Experimental Spot Size 26 J
DTI Funded project “Ultrafast” completed at LLEC – scored 56/60 in final assessment
Tanks for attention

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Laser and laser cladding

  • 1. Lasers in Manufacturing Present: Erfan Zaker Esfahani Email: aref_z_e@yahoo.com Number: 09131299216 Lecturer: Dr. saebnoori University: najaf abad Number of student: 890914688 Course: Surface Engineering
  • 2. Introduction  Laser Welding  Laser Cleaning  Surface treatments  Laser Cladding  Direct Laser Fabrication  Selective Laser Sintering  Laser Forming - an emerging process
  • 3. Laser Welding  Established in the early 80’s  Now used on many production lines  Low volume applications and subcontract limited to niche areas such as mould tool repair, jewellery and dentistry
  • 4. Welding Key features of deep penetration laser welding include:  High energy density – Keyhole welding Less distortion  High processing speeds High throughput  Rapid start / stop Unlike arc processes  Welds at atmospheric pressures Unlike EB welding  No filler required But good fit up is essential  Narrow welds Less distortion  Very accurate welding possible Good fit up & fixturing needed  Good weld bead profiles  No beam wander in magnetic fields Unlike EB  Little or no contamination Depending on gas shroud
  • 5. Welding A 10 kW fibre laser used in shipbuilding A hybrid laser welding system
  • 6. Spot and MicroWelding  Repairing mould tools  Medical devices 400 m spot welds on a orthodontic bracket Sensors  Read / Write heads Orthodontic Bracket
  • 7. Other Laser Welding applications Plastics and Polymer Welding Possible to use laser to weld transparent plastic to opaque plastic (n.b. “transparent and “opaque” refer to laser wavelengths) Clear weld® Uses absorbing dye in joint interface to weld two nominally transparent polymers Can even be used for clothing!
  • 8. Laser Welding Developments Hybrid Welding Uses combination of arc and laser processes More tolerant to poor fit up Filler metals can positively modify weld metal Over performance better than expected for this combination “Remote Welding” Use high beam quality “slab” and fibre lasers coupled to a scanning head to weld at multiple x- y-z positions
  • 9. Cleaning Emerging process, particularly driven by art and monument restoration (I.e. National Museums and Galleries on Merseyside (NMGM) conservation centre. Engineering applications are being identified – dry cleaning of metal components prior to welding and PCB’s and component leads prior to soldering.
  • 10. Cleaning Advantages of laser cleaning  Laser Cleaning does not damage  No abrasive effect (No abrasive)  No mechanical contact  No heat effect  Laser cleaning does not pollute  No solvents  No polluted effluents  Fumes extracted easily The operator protection is reduced to a simple eye protection
  • 11.  Engineering applications of laser cleaning are being developed.  Applications include mould tool cleaning Stripping of paint from aircraft Cleaning
  • 12. Surface treatments  Three main processes – hardening, melting and alloying. Aim to improve surface properties such as wear and corrosion resistance, one can:  Temper  Laser Hardening  Laser fusing / cladding (depositing a hardwearing corrosion resistant surface)  Alloying surfaces  Nitrate  Treat many different materials Laser hardening Laser Alloying
  • 13. Surface treatments Special hardening process for titanium  Surface is laser heated.  Nitrogen is blown over the surface forming titanium nitride under on the surface.  The surface hardness is increased many times compared with the parent material.
  • 14. Laser Cladding Deposition of wear and corrosion resistant materials. Reduced heat input gives lower distortion.
  • 15. Direct Laser Fabrication DLF combines 4 common technologies  CAD  CAM  Powder Metallurgy  Laser Technology  A high powered laser creates a melt pool  Powder is deposited into the melt pool  Moving the laser beam in a prescribed pattern a component is traced out layer by layer
  • 16. Direct Laser Fabrication General set-up of Direct Metal Deposition
  • 17. Direct Laser Fabrication  Tool repair  Mould repair  Turbine blade repair  Rapid Prototyping
  • 18. Selective Laser Sintering  Parts built up layer by layer  A CO2 laser beam selectively melts powder into a designated shape  The component sinks into the bed, a layer of powder is deposition above the component  The process repeats until the component is finished
  • 20. Laser Forming - an emerging process  Bending metal with light  Laser beam induces thermal stresses  The plate expands, cools and contracts  The flat plate deforms into a new shape Industrial sectors  Aerospace  Automotive  Marine
  • 21. Structuring and texturing  Periodic Structures (with period <1um) machined into metals and ceramics, and also produced by material modification in polymers
  • 22. Direct writing in Fused Silica Pulse duration 100fs, Wavelength 400nm, Pulse energy 0.8μJ Scan speed 200 μm/s 10 μm pitch, 0.5NA
  • 23. CW Fibre laser generation of Nanoparticles High intensity laser beams vapourise materials that then condense as sub-micron powders. CW fibre laser combine high intensity with high intensity
  • 24. pS fibre lasers  Fianium laser system:  Pulse Length 20ps.  Wavelength 1064 nm.  Rep Rate 200kHz or 500kHz  Maximum Pulse Energy 6 J  Laser Power 2.1W  Experimental Spot Size 26 J DTI Funded project “Ultrafast” completed at LLEC – scored 56/60 in final assessment