AILU Technology Workshop

Transcription

1 AILU Technology Workshop Welding of metals using high power fiber delivered diode laser beams Dipl.-Ing. Mark Daichendt Laserline GmbH Mülheim-Kärlich Germany 1

2 Outline Laserline company State-of-the-art high power diode lasers Diode lasers in welding applications Future trends Conclusion 2

3 Laserline - Company Leading company in high power diode lasers for industrial use Offering laser products application feasibility after sales service Head office near Koblenz Subsidiary San Jose, CA, USA More than 700 lasers world wide installed Continuous growth since foundation in employees 3

4 Laserline - Company 2. New Facility 1. Facility Production area Production area New Training center Office building Laserline total: m² Production: m² Clean room: 800 m² Application and training center: 300 m² Offices: m² 4

5 Laserline - Worldwide Distributors Laserline, Germany Headquarter Marubun, Japan Eurovision, Korea Apricon, Finland ILS, France Laser lines, GB Raymax, Australia Laserline Inc., CA 5

6 Outline Laserline company State-of-the-art high power diode lasers Diode lasers in welding applications Future trends Conclusion 6

7 Operating Principle: Diode Laser Head Modular Product Easy exchange and repair of stacks and other components inside the head Exchangeable further components (optics etc.) Easy upgrade in output power Polarisation coupling Diode laser stack Wavelength coupling Laser diodes µ-optics 7

8 Beam Quality vs. Laser Power Fiber Diameter µm Laser power [W] µm 600 µm 400 µm µm 200 µm

9 LDF Product Specification VG4L output power fiber diameter µm µm µm µm µm 2-4 exit beam switch size: 80 x 140 x 170 cm³ moveable Standard optical and electrical interfaces electrical efficiency > 35% for LDF

10 Laser Type Efficiency 4 kw Lasers LPSS Disc Laser Fiber Laser Diode Laser Laser System 125 kw 17 kw 17 kw (5kW laser) 12 kw Cooling Unit Water/Air 70 kw 7 KW 7 kw 5,5 kw Total consumption 195 kw 24 kw 24 kw 17,5 kw Total efficiency 2 % 16 % 21 % 23 % Diode Laser has highest efficiency 10

11 Outline Laserline company State-of-the-art high power diode lasers Diode lasers in welding applications Future trends Conclusion 11

12 Welding Diode lasers attain typical welding spot of 0,4 mm to 0,6 mm Output power in multi kw range Replace most of applications of lamp-pumped solid state laser Welding results from solid sate lasers are directly transferable in case of identical laser power and focus Diode lasers are predestinated for demanding welding tasks Diode lasers for aluminum and galvanized sheet metals 12

13 Welding with Top Hat profile Material thicknesses from about 0,1 mm upwards Welding depth of more than 3 mm in production Stable output power and Top Hat intensity profile Diode lasers achieve high welding seam qualities, free from pores and cavities 13

14 Welding Requirements I Requirements in welding applications: High Level process stability Low distortion Excellent weld seam surface Consistent product quality => Laser is the right tool 14

15 Welding Requirements II Low thermal load and low distortion Smooth, regular and pore-free welding High process stability at high welding speeds Keyhole welding and heat conduction welding Reduced costs for investment and operation Highest reliability for serial production 15

16 Options Integrated weld monitor Ccd camera Cover slide monitor Cross jet Shield gas nozzle Pressure finger or pressure roll Unmatched welding surface 16

17 Diode Lasers for Welding fiber diameter min. f=100 mm max. output power 200 µm 0.2 mm W 400 µm 0.4 mm W 600 µm 0.6 mm W 1,000 µm 1.0 mm W 17

18 Diode Lasers for Welding Low operating and investment costs for diode lasers 100 W up to 8 kw using different fibers and optics Diode laser equipped with various options like beam switch New applications for diode lasers which were up to now in the domain of conventional welding systems are possible 18

19 Applications: Spot Requirements 1000 Beam quality [mm mrad] Laser power [W] Spot: 0,6-2 mm Spot: 0,5-3 mm Diode Laser can meet most of spot requirements Rectangular spot: 3x3 10 x 60 mm Spot: 1,5-3,5 mm Spot: 1-6 mm Spot: 0,6-3 mm Spot: 0,3 0,8 mm Spot: 0,2 0,6 mm Not yet possible with diode laser 19

20 Market Movement for Diode Lasers Beam quality [mm mrad] Laser power [W] Diode Applications since 1999 Diode Applications since 2002 Diode Applications since 2004 Diode Applications since 2007 Still mainly YAG Applications 20

21 Welding with Laser Laser beam Pool crater Solidified Pool Crater Laser beam Plasma Keyhole Metal vapor Pool crater Solidified Pool Crater Schweißrichtung Laser movement Conduction welding Keyhole welding 21

22 Welding tests Optics with CCD- Camera Welding results 22

23 Welding of stainless steel Laser spot: 0,6 mm welding speed [mm/min] ,2 kw 4 kw 3,4 kw penetration [mm] 23

24 Welding depth Different welding results 24

25 Welding Diode lasers are used in various application areas of mass production Precision and spot welding of electronic components Welding of car body parts in automotive industry Heat conduction welding of consumer goods Welding of pipes 25

26 Outline Laserline company State-of-the-art high power diode lasers Diode lasers in welding applications Future trends Conclusion 26

27 Body in White Welding Requirements Laser power 2-4 kw Spot size 0,6 mm Focal lengths > 200 mm Diode laser fulfill requirements LDF standard optics f > 150 mm Highyag optics comparable WD as LP-YAG 27

28 Laser Welding of Zink Coated Steel Overlap joint with: 4 kw, 400 µm fiber, spot 0,6 mm 6 Welding speed [m/min] Through welded Partly through welded zink coated overlapped sheets with total thickness [mm] 28

29 Laser Welding of Aluminium Aluminium (AL 5083) welding with: 4 kw, 400 µm fiber, spot 0,6 mm 12 Welding speed [m/min] Welding depth [mm] 29

30 Body-in-White Welding Trends Welding of Zink-Coated Steel Aluminum Direct Welding Laser power 4-6 kw Spot size 0,6 mm Remote Welding Laser power 4-6 kw Spot size 0,6 mm Welding Laser power 4-6 kw Spot size 0,6 mm Focal lengths = 200 mm Photo: Irepa Focal lengths > 400 mm Focal lengths = 200 mm Diode Laser Fiber Laser Disc Laser Diode Laser 30

31 Products Today and Future Diode bar improvement Actual status Fiber coupled Diode Lasers 300 µm 300 W* W W 400 µm 2500 W W W 600 µm W W W 1000µm W W W 31

32 Outline Laserline company State-of-the-art high power diode lasers Diode lasers in welding applications Future trends Conclusion 32

33 Future Lasers for Metal and Alu Welding LP YAG Disc Laser multi kw diode laser 30 mm mrad Fiber Laser Diode Laser Remote Disc Laser Remote Fiber Laser cost reduction of multi kw diode laser 33

34 Welding with Diode Laser: Conclusion Low thermal load and low distortion Smooth, regular and pore-free welding High process stability at high welding speeds Keyhole welding and heat conduction welding Reduced costs for investment and operation Highest reliability for serial production 34