Direct-Diode Industrial Systems

Transcription

1 Direct-Diode Industrial Systems Laser Systems for High-Power Materials Processing Applications Superior Reliability & Performance

2 Focus on High-Power Direct-Diode Laser Technology Products HighLight series of high power direct diode laser (HPDDL) systems are simple to use and have a proven track record in industrial environments. These systems consist of a light weight, rugged laser head, a user friendly control unit with a Graphical User Interface (GUI) and a chiller. The compact size of the laser enables mounting the head on a robot or a gantry type system. The lightweight and rugged design is employed in production sites worldwide processing everything from small hand tools to massive steel shafts and heavy truck axles. The types of industrial production processes include surface cladding for remanufacturing of engine components, heat treating of drive train components and hermetic welding of large pressure canisters. The compact size and ease of installation makes these systems extremely flexible and capable of solving your production challenges. The HighLight is a solid-state laser system based on laser diode bars with beam shaping optics and either a fiber optics or free space beam delivery system. The spot formed by the laser can be tailored to the application and is ideal for processing large surface area parts with localized and minimal heat input. Applications Materials Examples Cladding Stainless steel alloys 316L, 420 Heat Treating Carbon steels Gray cast iron Cast iron 4140, 1045 Stainless steel alloys 420SS, 440SS Metal Welding Mild steels, Stainless steel alloys 1010, 1020 Titanium 304SS, 316SS Plastics Welding Thermoplastics Polypropylene Thermosets Acrylic HDPE Nylon Polycarbonate Soldering and Brazing Lead based PbSn, SnAg, CuSi Silver based Copper based

3 Cross-section of HPDDL vs. Induction Hardened (inset) Crankshaft High-power diode lasers for localized, high-speed hardening with minimal distortion, pre-processing or post-processing required. Focus on Heat Treating Heat treating a surface with a laser is as simple as point the laser, heat the surface, and let it cool. HPDDL s are ideal for performing laser-transformation hardening in a manufacturing environment because of the superior heat treat characteristics, the flexibility of the process, the compatibility with a lean manufacturing environment, and fast cycle time for processing the parts. When comparing yields, operating expenses, and environmental impact, this method is the most cost-effective laser heat-treating process. With their high edge definition and 805 or 940 nm wavelength, HPDDL are highly absorptive and require no pre-coating of the work piece to achieve absorption. They feature greater wear resistance and, under certain conditions, increase the fatigue strength. High processing speed 3X over induction hardening Low or negligible distortion No pre-processing or post-processing required Precision heating control Flexibility easily handles any work piece shape/geometry Higher hardness capability over Rockwell C 60 without cracking or spalling Fatigue life improvement on powder metal parts and drive train components Bearing Surfaces Hand Tools, Needles, and Pins Cutting Surfaces and Forming Tools Pumps and Stamping Dies Valve Seat and Seal Surfaces Turbine Blades Drive Train Components Powder Metal Parts Gears and Cams

4 7 6 5 Efficiency lb/kw*hr Heat Input/Distortion HPDDL CO 2 Plasma GTAW The optimum cladding solution when weld metallurgy, consumables cost, distortion, and thickness control are important. Focus on Cladding Cladding is the deposition of material on a base part for the purpose of rebuilding the part or improving the material properties of the base material. The HighLight series based HPDDL cladding process is the most cost effective process available today for the production environment. This laser process has the highest material capture efficiency in the industry with >95% of the powder material being deposited on the surface of the work piece. The lesser the wasted material, the lower the costs. The HighLight series is an all solid state system delivering outstanding reliability and efficiency compared to all other types of laser systems. The HighLight system uses a unique beam profile to paint the surface in a continuous line as the cladding material is deposited on the surface. This large area cladding provides the lowest dilution and smoothest cladding surfaces compared to all other processes. This process is significantly more efficient than the processes that can be performed with a Nd:YAG, CO2 or fiber laser because of the unique beam shape. When comparing to the initial capital cost, the low cost of ownership and the high performance of the process, the HighLight laser system delivers the best price performance of any of the laser based cladding processes. Large-area cladding with minimal scanning Excellent cladding metallurgy High efficiency process lower thermal input and lower powder consumption Minimal pre-processing and post-processing Precision control Significantly lower consumable cost High-resolution process ability to deposit thinner clad layers Lower residual stress and distortion Super Alloys for CFB Components Water Walls and Water Tanks Hard-Facing of Valve Seats Bearing Shafts Bearing Seats, Cylinder Liners, and Pins Hydraulic Shafts Earth Moving Equipment Agricultural Equipment Remanufacturing

5 More flexibility in terms of gap tolerance than other keyhole welding processes such as CO 2 lasers, disk lasers, fiber lasers and E-beam processing. Focus on Welding HPDDL provide a high quality, conductionstyle weld in most metals. Typical autongenous laser welding requires very tight fit-up, similar to E-beam processing. The gap fit-up tolerance required is approximately 3% of thickness, which eliminates the use of most low-cost parts because they need a machined interface fit-up. Therefore, the industry defaults to TIG and PTA processes in order to achieve a robust production weld process. HighLight HPDDL achieve process speeds 3X faster than Tungsten Inert Gas (TIG) or Plasma Transfer Arc (PTA) laser welding. Because the HPDDL weld nugget is smaller then TIG or PTA, there also is less distortion and, no post-processing. In addition, the line beam allows for filler wire to achieve optimum weld bead geometry. Overall, our HPDDL make production welding much faster and improve part quality without changing upstream stamping or fixturing processes. More forgiving gap tolerance Increased throughput Less weld distortion Excellent reliability Low maintenance Flexibility Wire feed compatible Automotive Body-in-White Metal Housings and Enclosures Chain Assemblies Automotive Fluid Assemblies Tube Mills Zinc-Coated Steels

6 Brazing with Silicon Bronze Feed Wire Radiator panel wire feed welding Customized line beam creates smooth bead geometry and spatter-free process with lower heat input than other methods. Focus on Brazing The HPDDL line spot makes feeding wire into the laser beam very easy. No expensive vision systems or precision alignment devices are required. The long beam, which is suitable for conduction-mode weld, "wets out" the weld and produces excellent weld bead profiles. For body-in-white brazing, our HPDDL create excellent braze joints that require no rework after brazing. Lower cost Low maintenance Non-plasma process Splatter significantly reduced Zinc fuming and sooting reduced No MIG/TIG fouling Lower heat input Faster brazing process Automotive Body-in White Plumbing Assemblies Air Conditioner & Cooling Systems Focus on Plastics Welding HPDDL are ideal for transmission welding various plastics for industrial applications. Our free-space and fiber-delivered products provide simultaneous, quasi-simultaneous or contour welding for a wide range of applications. The high brightness and custom beam-shaping capabilities of our HPDDL provide unmatched reliability and the highest throughput in the industry. High quality and high throughput transmission welding of plastics for automotive, electronics and industrial applications.

7 Si-Bronze wire feed welding Delivering high-intensity line beams for efficient removal of thin coatings on a variety of substrates. Non-contact, fast, flexible and no vibration Any desired weld-seam contour or large area Easily automated and high process stability Low thermal stress and low mechanical stress Control of melt geometry Electronics Housings Automotive Parts Fuel Pumps Focus on Other Industrial Processes HighLight HPDDL provide excellent results in a variety of surface engineering applications, such as large-area paint stripping. These lasers feature a line beam, which enables thermo-mechanical stressinduced dislocations and then physical ablation over a large area with minimal scanning. Unlike abrasive blasting, with its consumable blast media and disposal costs, laser processing requires only gas, electricity and disposal of the paint dust. Coatings easily removed by HPDDL include paint, adhesives, epoxies, and heavy rust or scale. Suitable substrates include plastic, metal, cloth, stone, ceramic, composites, and wood. Improved de-paint quality Less labor intensive Improved throughput removal rate of >40 square meters per hour No secondary waste Lower health risk no hazardous by-product Low noise and less dust Easy to automate Lower consumable and disposal costs PVDF coating removal application Paint-stripping Scale removal Rubber mold cleaning

8 Coherent as your partner. To compete and succeed in today s fast-paced research and manufacturing environments, you need a laser partner who understands your needs. A partner who can provide a wide range of technology solutions, and the support that goes with them. Since 1966, Coherent has been helping customers by providing complete laser-based solutions for a wide range of commercial and scientific applications. With a heritage of innovation and an uncompromising position on quality, Coherent is the most forward-thinking and diversified manufacturer of solid-state, gas, excimer and semiconductor lasers in the industry. For more information, visit us on the Web at Or call Coherent, Inc Patrick Henry Drive Santa Clara, CA phone (800) (408) fax (800) (408) tech.sales@coherent.com Benelux +31 (30) China +86 (10) France +33 (0) Germany +49 (6071) 9680 Italy +39 (02) Japan +81 (3) Korea +82 (2) UK +44 (1353) Printed in the U.S.A. MC C0607 Copyright 2007 Coherent, Inc. *All product names contained herein are the trademarks of their respective holders. Coherent s scientific and industrial lasers are certified to comply with the Federal Regulations (21 CFR Subchapter J) as administered by the Center for Devices and Radiological Health on all systems ordered for shipment after August 2, ISO 9001:2000 Registered