INDUSTRY TRENDS & DEVLEOPMENTS. Rick Neff. CINCINNATIR cincinnati incorporated

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1 INDUSTRY TRENDS & DEVLEOPMENTS Rick Neff CINCINNATIR cincinnati incorporated

2 The Industrial Laser Community Promoting Laser Technology to Help SME Members Meet, Know & Grow

3 FANTASTIC GROUP

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5 ILC ACTION - WEBINARS Laser Micromachining 101 Remote Scanning Applications & Technologies Laser Plastic Welding Laser Beam Delivery Optics for All Processes Laser Heat Treating Hardening of Metals Industrial Laser Cutting 101 Laser Metal Deposition 101 Laser Processing in the Medical Industry 101 Industrial Laser Marking 101 Industrial Laser Processing 101

6 ILC ACTION - SME Member Experience Fabtech Mfg4 MD&M Omaha Products Show Fabtech Canada Laser and Photonics Marketplace IMTS Photonics West AeroDef SALA Houstex ALAW EASTEC WESTEC Laser World of Photonics SME Annual Conference CMTS ICALEO LME

7 NEW LASER TECHNOLOGY Fiber Delivered Lasers for Cutting Flat Sheet Metals Hot Formed High Strength Steel Fiber Delivered Lasers Coupled with Scanners Welding Cutting Laser Micromachining Short pulse lasers Plasmonic Devices Laser Paint Stripping

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9 FIBER LASER CUTTING

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12 POWER DENSITY COMPARISON Sunlight.1W/cm 2 Light Bulb 1W/cm 2 Soldering Iron 100 W/cm 2 Unfocused Beam 2,000W/cm 2 4,000 Watt Resonator Focused Beam 30 Million W/cm 2 4,000 Watt CO2 Resonator Steel Vaporization 2 Million W/cm 2

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14 C02 LASER

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18 FIBER DELIVERED LASERS YAG Nd:YAG (neodymium-doped yttrium aluminium garnet; Nd:Y 3 Al 5 O 12 ) Disk Yb (Ytterbium) Fiber Yb (Ytterbium) Direct Diode

19 FIBER DELIVERED LASERS YAG Nd:YAG (neodymium-doped yttrium aluminium garnet; Nd:Y 3 Al 5 O 12 ) Disk Yb (Ytterbium) Fiber Yb (Ytterbium) Direct Diode

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22 Industrial Grade kw Fiber Lasers

23 WHY FIBER?

24 POWER DENSITY COMPARISON Sunlight.1W/cm 2 Light Bulb 1W/cm 2 Soldering Iron 100 W/cm 2 Unfocused Beam 2,000W/cm 2 4,000 Watt Resonator Focused Beam 30 Million W/cm 2 4,000 Watt CO2 Resonator Focused Beam 100 Million W/cm Watt Fiber Resonator Steel Vaporization 2 Million W/cm 2

25 ENERGY SPECTRUM U. V. I. R. F. M. Rays (Heat) Radio X Rays Visible Micro- A.M. Light Waves Radio Fiber Laser CO 2 Laser 1.0 Micron 10.6 Microns Short Wavelengths High Frequency Long Wavelengths Low Frequency

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28 BEAM DELIVERY

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34 CAPACITIES Mild Steel O2 Stainless N2 Aluminum Watt CO Watt Fiber 4000 Watt Fiber

35 FRESNEL ABSORPTION OF FIBER AND CO2 LASERS As presented by Achim Mahrle, Dresden University of Technology and Eckhard Beyer, Fraunhofer IWS Dresden at ICALEO 10/2-5/2009

36 Photos courtesy of PRC and The Fabricator

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38 Nominal Hazard Zone Radius = P O Cos O M P E = (1) 4000 (1) 3.14(0.1) = 113 cm = 44 in.

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44 STAINLESS STEEL WITH N2 MATERIAL THICKNESS inch/m m 2000 W 4000 W 4000 W CO2 FIBER FIBER ipm ipm ipm m/min m/min m/min 20 ga. 450 [800] (0.036 /0.9m m ) ga. 375 [735] (0.048 /1.2m m ) ga. 330 [700] (0.060 /1.5m m ) ga (0.075 /1.9m m ) ga (0.105 /2.7m m ) ga (0.120 /3.0m m ) ga (0.135 /3.4m m ) / (0.188 /4.8m m ) / (0.250 /6.4m m ) / (0.375 /9.5m m ) / (0.500 /12.7m m )

45 MILD STEEL WITH NITROGEN Material 4000 W 2000 W 4000 W Thickness CO2 FIBER FIBER in/mm IPM IPM IPM M/MIN M/MIN M/MIN 20 ga. 440 [800] / ga. 405 [700] / ga / ga / ga / ga / / / / /

46 MILD STEEL WITH O2 MATERIAL THICKNESS (in./mm) 4000 W CO2 FEED RATE (ipm) 2000 W FIBER FEED RATE ipm m/min 4000 W FIBER FEED RATE ipm m/min 10 ga /16" / / /

47 ½ STEEL

48 OPERATING COSTS

49 WALL PLUG EFFICIENCY Lamp-pumped YAG 1.5% - 2% Diode-pumped YAG 10% - 20% CO2 5% - 15% Disc 15% - 25% Fiber Laser Ytterbium (Yb) 28%-35% Direct Diode 40%-60%

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51 OPERATING COSTS 16 GA MILD STEEL N W CO W FIBER 4000 W FIBER Electrical $6.04 $2.93 $3.43 Consumables Resonator Gas $0.14 $0.00 $0.00 Assist Gas $2.22 $2.62 $2.84 Purge Gas $0.42 $0.29 $0.29 Internal Optics $0.66 $0.00 $0.00 External Optics $0.78 $0.00 $0.00 Lenses $1.62 $0.82 $0.82 Nozzles $0.02 $0.02 $0.02 Long-term Maintenance Blower replacement $0.40 $0.00 $0.00 Glassware replacement $1.00 $0.00 $0.00 Preventative Maintenance $1.22 $0.61 $0.61 Total Hourly Cost $14.58 $7.29 $7.72

52 COST PER 100 INCHES OF CUT 16 Gage Mild Steel with Nitrogen 16 Ga. Mild Steel Cost Per 100 Inch of Cut at Max Speed Model 4000 W CO W FIBER 4000 W FIBER Cutting Speed (N2) Hourly Cost $14.58 $7.29 $7.72 Cost per 100 inches $ $ $0.0114

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59 LOTS OF MACHINES

60 HIGH STRENGTH STEEL HOT STAMPED PARTS TRIMMING

61 AUTOMOTIVE CAFE STANDARDS Automotive average today 25 mpg By 2016 average to be 35.5 mpg

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64 SCANNER SYSTEM

65 Reduction of flange width Resistance Spot Welding Remote Welding 1,1 2 14,5 1,1 2 1,25 1,25 8,0 3, , REP 1,1 1,1 6 6 v min 1,0 17,5

66 Elimination of lower electrode (hole)

67 REMOTE WELDING Cylinder head gasket CrNi Overlap joint 0.1 mm onto 0.3 mm seal weld Scanner optics PFO 33 field size: 140 x 240 mm² TruFiber W 20 m/min

68 Welding-on-the-fly with PFO

69 Remote Vapor Pressure Melt Cutting: - Remote cutting without process gas nozzle - Steel up to 4 mm thickness in one single run - Melt expulsion along the laser beam direction - For cutting stationary or on-the-fly - Focus diameter ~ 0.6 mm (same as for welding) - Good cutting quality Higher System flexibility for production Principle of Melt pressure cutting t = 2 mm; v = ca. 3 m/min; P = 4 kw t = 3mm; 3.5 m/min; P = 6 kw Laser beam melt

70 LASER MICROMACHINING Feature sizes and material thickness are less than 1 mm Usually much less.

71 ULTRA SHORT PULSED LASERS

72 Advantages of USP Ultra-short pulses (ps and fs) open up a wide range of applications. Wavelength independent absorption, even in transparent materials Non-thermal interaction and ablation Virtually no HAZ, no micro-cracks Laser development is moving fast!

73 MATH LESSON FEMTO = (One quadrillionth) PICO = (One trillionth) NANO = 10-9 (One billionth) MICRO = 10-6 (One millionth)

74 Material Interaction - USP-Laser Long Pulse [ns] Laser beam Ultra short Pulse [fs] Absorption Optical penetration depth Laser beam Heating Isother ms Electrons Absorption by free electrons, valence electrons Melting Evaporation Shock wave Metal vapor Melt Melt Energy transfer Energy transfer into the lattice, bond breaking Splashing Melt Shock wave Vapor cloud Melt splash Fast plasma expansion Melt

75 Nanosecond Laser Femtosecond Laser Chichkov, Appl. Phys. A 63 (1996) 109

76 LASIK laser assisted in situ keratomyleusis

77 Example - Raydiance fs laser Human Tooth Match Head Strengthened Glass PLGA Bio Degradable Stent

78 BIO-ABSORBABLE STENT No cleaning or postprocessing (some debris visible in photo) No change to material color or morphology

79 Nitinol Stents 150 m 0.2mm wall thickness Cut at 10w, 1.2m/min 40 x 0.5 mm 10 m RCL Courtesy LPL Systems

80 Polymer Stent SEM images of resorbable polymer stent machined with a femto laser system (top) and magnification of the cutting edge (bottom). Courtesy Admedes

81 X 100 Hypo-Tube Cutting 0.3mm diameter 75 micron wall thickness X 500 Stretched Higher magnification A human hair would only just fit inside this tube Courtesy LPL Systems

82 Hypotube Cutting Needle (OD 0.4mm), guidewires (OD 0.3 and 0.2 mm) Material: ST/Steel Pictures courtesy Swiss Tec Material: CrCO Pictures courtesy Swiss Tec

83 Heart Valve Material: Titanium Material: Titanium

84 Ti Cutting and Marking Material: Titanium Material: Titanium Bone Plate Marking on a titanium tube with a 100 W fiber laser. Width of the letters = 20 micron

85 UV Laser Drilled Microvias 30, 40, and 50 micron diameter vias in resin coated copper Oblique view of drilled via

86 Solder Mask Removal

87 Solder Mask Generation Fundamental YAG on SS 355 nm Polymeric Solder Mask

88 Aircraft Wire 248 nm Wire Stripping UV Wire Marking

89 Silicon Based Solar Cells

90 Organic Photovoltaics

91 Inkjet Printers

92 Dielectric Materials Ceramics Alumina AL µm thick Glass 150 µm Lumera ps Laser

93 Sapphire Patterning Sapphire material processed by LZH. Lumera ps Laser

94 PLASMONIC Nanoscale Devices Can transmit electromagnetic waves and electricity Can weld on nano level with femtosecond lasers No heat Maintains crystalline structure

95 Laser Coating Removal All debris collected by vacuum system Requires almost no operator PPE All byproducts cheap and easy to dispose Automatically segregates primer and top coat

96 PAINT REMOVAL

97 THANK YOU CONTRIBUTORS Christopher Jefferies, American Laser Enterprises, LLC Paint Stripping Dr. Ronald D. Schaeffer, PhotoMachining, Inc. High Speed Lasers Micro Machining Frank Geyer, Trumpf Remote Laser Processing Tracy Ryba, Trumpf 5-Axis Hot Stamp Cutting Anming Hu and Y. Norman Zhou, University of Waterloo Plasmonic Devices as published in LIA Today Order online at: *Use Promo Code 532AM to apply discount.

98 Thank you! Rick Neff SME INDUSTRIAL LASER COMMUNITY CINCINNATIR cincinnati incorporated