The Basics of Lasers

and Laser Welding & Cutting

Tim Morris
Technical Sales Manager
TRUMPF Inc., Laser Technology Center

Agenda

1. Basics of lasers
2. Basics of laser welding
3. Summary

Advantages of laser welding

Flexibility
> beam manipulation (beam switching and sharing)
> variety of product geometries and materials
> ease of back-up (especially YAG)

Often faster than other techniques ...
> high power density weld process
> high laser uptime (>98%)

Cost savings ...
> high productivity
> reduction of scrap and re-work
> reduction of manual labor
> reduction of component material and weight
> can eliminate secondary processes

Laser basics

LASER


Light Amplification by Stimulated Emission of Radiation

Active Laser Media



Nd:YAG (Rod Laser)



Yb:YAG (Disk Laser)



Neodymium Yttrium Aluminum Garnet

Ytterbium Yttrium Aluminum Garnet

CO2 (Gas Laser)

Laser basics

Nd:YAG (Rod Laser) = 1064 nm

Yb:YAG (Disc Laser) = 1030 nm
CO2 (Gas Laser)
= 10600 nm

Laser basics
Power supply
Laser pump
(e.g. lamp, diode, RF)

Mirror 1

Mirror 2

Laser beam
Laser active medium
(e.g. Nd:YAG, Yb:YAG, CO2)

Resonator

Characteristics of laser light

Many colors

Many directions

Many phases

Unfocused Power
Measurement

0.0008 Watts / cm2

100 Watt
light
bulb

One
color >>
select laser for application

One direction >> can capture all the beam energy

One phase >> maximum energy at workpiece

Spot size CO2

df = M2(4f/D)

Spot size - YAG

df

Incoupling lens
Laser

df = M2(4f/D)
df = 3BQ(4f/D)

dw = c(f/ fc)
Laser light cable
Collimation lens

dw
Focusing lens

Power density

Power density = power per unit area

Power density of an unfocused 6 kW CO2 HQ laser

is about 1,000 W/cm2

Power density of a focused 6 kW CO2 laser

(f200mm) is about 50,000,000 W/cm2

Effects of Beam Quality

Beamquality

Spotdiameter

Working
distance

Depth of focus

Optics

25 mm*mrad
(LP rod)

4-8 mm*mrad
(DP disk)

With same
Focussing optics

With same
Spot diameter

Working area
of a scanner optics

Focal length
Key advantages of short focal length:

Faster weld speed

Less heat input

Key advantages of long focal length:

Longer depth of focus

Further from weld spatter & smoke

CO2 vs. YAG

CO2 considerations ...

CO2 Laser

Higher powers

Better focusability

Higher weld speeds on materials non-reflective to CO2 wavelength

Deeper weld penetration on materials non-reflective to CO2 wavelength

Lower capital and operating costs

Less expensive safety precautions

CO2 vs. YAG

YAG considerations ...

YAG Laser

Fiber optic beam delivery

(esp. robotic applications)

Materials reflective to CO2 wavelength can often be welded

Easy beam alignment, beam switching and beam sharing

Argon can be used for shield gas (plasma suppression not required)

Long and varied fiber lengths with no effect on process

High peak powers with high energy per pulse

Heat conduction welding

Laser beam

Description
Heating the workpiece above the
melting temperature without vaporizing
Characteristics

Low welding depth

Small aspect ratio

Low coupling efficiency

Very smooth, highly aesthetic weld bead

Processing gas

Applications
Laser welding of thin workpieces like foils,
wires, thin tubes, enclosures, etc.
Welding seam
v
S

Melt

Workpiece

Keyhole welding

Laser beam

Description
Heating of the workpiece above
the vaporization temperature and
forming of a keyhole
Characteristics

High welding depth

High aspect ratio

High coupling efficiency

Processing gas

Laserinduced
plasma

Welding seam
v
S

Melt

Keyhole

Workpiece

Cutting
Description

Cutting:

Laser Beam

Heating of the workpiece above

the evaporating temperature and creation of a
keyhole because of the ablation pressure
of the flowing metal vapor,
power density of 105 - 106 W/cm2
Characteristics

High cutting depth

Fine cutting precision

Very low heat input

Assist Gas

Kerf
v
S

Melt

Keyhole

Workpiece
Absorption
front

Seam and joint types

Name

Seam weld on butt joint

Example

Characteristics
+ weld fusion area
- positioning tolerance

Lap weld on lap joint

+ positioning tolerance
- weld fusion area

Fillet weld on lap joint

+ weld fusion area

- positioning tolerance

Fillet weld on T-joint

+ weld fusion area

- positioning tolerance

Seam and joint types

Name

Example

Characteristics

Lap weld on T / border joint

+ positioning tolerance
- weld fusion area

Seam weld on flange

+ weld fusion area

- positioning tolerance

Lap weld on formed seam

+ positioning tolerance
- weld fusion area

Seam and joint tolerances

Butt joint configuration:

Gap: 3-5% thickness of thinnest sheet

Offset: 5-12% thickness of thinnest sheet

Overlap joint configuration:

Gap: 5-10% thickness of thinnest sheet

Why is this general guideline not absolute?

(What influences the amount of gap that can be bridged?)

Laser Welding & Cutting

Examples

Remote welding with Disk Laser

Register Enclosure

Material

 Stainless Steel
 Thickness 0.040

Laser Welding Strategy
 Heat Conduction Welding
 Shield Gas He

Register Enclosure

35
30

ca. 30 min.

Production time in [min].

40

25
20

24 min

15
10
5
0

10 min
4 min
3 min
2 min

3 min
2 min

Laser welding

MIG welding

4) Grinding and cleaning

3) Welding (with fixture)
2) Bending
1) Cutting out the blank

Example:

Housing 16x24x10

2. Elimination of Post Processing : OLYMPUS Display

Enclosure
Manual
Welding welding
time (manual 56
/hour)

10 Min

9.33

Grinding (manual 48 /hour)

24 Min

19.20

Sum
Laser welding
Welding time (automated 140
/hour)

28.53

4 Min

9.33

Incl. Load and un-load

Straightening

Non

Grinding

Non

Savings

19.20

in %

67%

Laser Welding in Sheet Metal Manufacturing

3-D Laser Cutting

Laser Welding
Keys to Success

Outline

Early involvement from production personnel

Creating a laser champion
Selecting partners for success
Considering the ambient environment
Design for maintenance and service
The making of exceptional operators and maintenance personnel
Commitment to training
Not sparing the spares
Conclusion

Early involvement from production personnel

Include plant personnel early in the process

> relational and philosophical disconnect between engineering and plant
personnel can result in implementation delays and reduced system
operational efficiency
> Early involvement is the key to ...

ownership
technology transfer
acceptance
integrating suggestions based on
plant experience

> In summary ...

involve
lead
listen
expect great things

Creating a laser champion

Appoint plant laser champion

> not having a laser champion at the using plant can increase system
downtime and reduce system operational efficiency

appointing a champion
characteristics of a champion
ideally a welding or mechanical engineer
> has an interest in laser technology
> will be around for awhile
> is teachable/trainable
> can teach others
>

shepherding the champion

instilling the vision
> provide and support key training
> enablement - authority and focus
>

The making of exceptional operators and maintenance personnel

Selecting and mentoring operators and maintenance personnel

> inappropriate selection of operators and maintenance personnel can
increase system downtime and reduce system operational efficiency

selecting (when allowed)

attitude
> aptitude
>

training
need to know how to safely operate and maintain the system in all modes
need to know how components function
> need to know when the system is not operating at optimal performance
> laser training at using site vs. TRUMPF
> supplemented by laser champion and LSO (on-going)
>
>

empowering
proportional to mentoring and training
> proportional to attitude and aptitude
>

Commitment to training

Training of laser personnel

> inadequate and improper training of key laser personnel can
increase system downtime and reduce system operational efficiency

commitment to training = commitment to quality

training requires investment
(time and money)

its more than just cranking

out parts (safety, operator,
maintenance, application, LSO,
technology transfer, etc.)

Not sparing the spares

In-house spares
> inadequate appropriation of spare parts can increase system downtime
and reduce system operational efficiency

Well take care of that later.

the role of tele-diagnostics

Advantages of laser welding

Flexibility
> beam manipulation (beam switching and sharing)
> variety of product geometries and materials
> ease of back-up (especially YAG)

Often faster than other techniques ...
> high power density weld process
> high laser uptime (>98%)

Cost savings ...
> high productivity
> reduction of scrap and re-work
> reduction of manual labor
> reduction of component material and weight
> can eliminate secondary processes

Conclusion

What I am NOT saying ...

ignore economics and cost justification

forget about the details of laser physics
dont bother with prototype parts and DOEs
underestimate the mechanical & electrical engineering
considerations

tooling and part fit-up are no big deal

part cleanliness doesnt matter

Conclusion

What I am saying ...

continue to do all these things better than ever before

re-emphasize and strongly consider these items
>

involve key people from production personnel early in the process

>

create a laser champion at the using plant

>

select partners that have proved themselves over and over again

>

consider the ambient environment

>

insure the issues of maintenance and service are not overlooked in the system design

>

be truly committed to training and mentoring operators and maintenance personnel

>

procure key spare parts before you need them

Thank you
TRUMPF Laser Technology Center
Plymouth, MI
(734) 354-9770