Welding of metals using high power fiber delivered … of metals using high power fiber delivered...

1Laserline GmbH, Germany

Dipl.-Ing. Mark Daichendt Laserline GmbH Mülheim-Kärlich Germany

www.laserline.de

Welding of metals using high power fiber delivered

diode laser beams

AILU Technology Workshop


Laserline company

State-of-the-art high power diode lasers

Diode lasers in welding applications

Future trends

Conclusion

Outline

3•Laserline GmbH, Germany

Laserline - Company

Leading company in high power diode lasers for industrial use

Offering laser products application feasibilityafter sales service

More than 700 lasers world wide installed

Continuous growth since foundation in 1997

65 employees

Head office near Koblenz

Subsidiary San Jose, CA, USA


Laserline - Company

• 1. Facility • Production area

• 2002

•Office building

•New Training center

• 2. New Facility • Production area

• 2007

• Laserline total:4.300 m²

• Production: 2.000 m²

• Clean room: 800 m²

• Application and training center: 300 m²• Offices: 1.200 m²

5

Raymax, Australia

Laser lines, GB

ILS, France

•Laserline GmbH, Germany

Distributors

Laserline Inc., CA

Laserline - Worldwide

Eurovision, Korea

Marubun, JapanLaserline, Germany

• Headquarter

Apricon, Finland


Laserline company



Future trends

Conclusion

Outline

7

Modular ProductEasy exchange and repair of stacks and other components inside the headExchangeable further components (optics etc.)Easy upgrade in output power

Operating Principle: Diode Laser Head

•Laser diodes•µ-Optics

•Diode laser stack

•Polarisation coupling

•Wavelength coupling


Beam Quality vs. Laser Power

0

2000

4000

6000

8000

10000

12000

1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009

Lase

r pow

er [W

]

•1500 µm

•1000 µm

•600 µm

•400 µm

•300 µm

•200 µm

•Fiber Diameter

9

LDF Product Specification VG4L

output power fiber diameter

2.000 W @ 300 µm

4.000 W @ 400 µm

6.000 W @ 600 µm

8.000 W @ 1.000 µm

10.000 W @ 1.500 µm

2- 4 exit beam switch size: 80 x 140 x 170 cm³moveableStandard optical and electrical interfaceselectrical efficiency > 35% for LDF 1000-8000


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


Laserline company



Future trends

Conclusion

Outline


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


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


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


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


Options

Unmatched welding surface

Integrated weld monitor

Ccd camera

Cover slide monitor

Cross jet

Shield gas nozzle

Pressure finger or pressure roll


Diode Lasers for Welding

fiber diameter min. focus @ f=100 mm

max. output power

200 µm 0.2 mm 100 - 1.000 W

400 µm 0.4 mm 100 - 4.000 W

600 µm 0.6 mm 100 - 6.000 W

1,000 µm 1.0 mm 100 - 8.000 W


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


Applications: Spot Requirements

•Spot: 1,5 - 3,5 mm

•Spot: 0,6 - 2 mm

•Rectangular spot: •3x3 – 10 x 60 mm

•Spot: 0,5 - 3 mm

•Spot: 0,3 – 0,8 mm

•Spot: 0,6 - 3 mm

•Spot: 0,2 – 0,6 mm

•Spot: 1 - 6 mm

•10

•100

•1000

•10 •100 •1000 •10000•Laser power [W]

•Bea

m q

ualit

y [m

m m

rad]

Diode Laser can meet most of spot requirements

•Not yet possiblewith diode laser


Market Movement for Diode Lasers

•Diode Applications since

2002

•Diode Applications since 1999

•Still mainly YAG Applications


2004•10

•100

•1000

•10 •100 •1000 •10000•Laser power [W]

•Bea

m q

ualit

y [m

m m

rad]


2007


Welding with Laser

Schweißrichtung

Laser beamLaser beam

Pool crater

Pool crater

Keyhole weldingConduction welding

Solidified Pool Crater

Metal vapor

Keyhole

Laser movement

Plasma Solidified Pool

Crater


Optics with CCD- Camera

Welding tests

Welding results


Welding of stainless steel

0

2000

4000

6000

8000

10000

12000

14000

16000

0 1 2 3 4 5 6 7 8penetration [mm]

wel

ding

spe

ed [

mm

/min

]5,2 kW

4 kW

3,4 kW

Laser spot: ∅ 0,6 mm


Welding depth

Different welding results


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


Laserline company



Future trends

Conclusion

Outline


Body in White Welding Requirements

Laser power 2 - 4 kW

Spot size 0,6 mm

Focal lengths > 200 mm

• Diode laser fulfill requirements

LDF 400-4000

standard optics f > 150 mm

Highyag optics comparable WD as LP-YAG


Wel

ding

spe

ed [m

/min

]

2 zink coated overlapped sheets with total thickness [mm]

0

1

2

3

4

5

6

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5

Through welded

Laser Welding of Zink Coated Steel

•Overlap joint with: 4 kW, 400 µm fiber, spot 0,6 mm

Partly through welded

29

0

2

4

6

8

10

12

0 0.5 1 1.5 2 2.5 3 3.5 4

Laserline GmbH, Germany

Wel

ding

spe

ed [m

/min

]

Welding depth [mm]

Laser Welding of Aluminium

•Aluminium (AL 5083) welding with: 4 kW, 400 µm fiber, spot 0,6 mm

30•Laserline GmbH, Germany

Body-in-White Welding – Trends

•Photo: Irepa

Laser power 4-6 kW

Spot size 0,6 mm

Focal lengths > 400 mm

Diode Laser

Direct Welding Remote Welding

Aluminum

Laser power 4-6 kW

Spot size 0,6 mm

Focal lengths = 200 mm

Laser power 4-6 kW

Spot size 0,6 mm

Focal lengths = 200 mm

Diode LaserFiber LaserDisc Laser

Welding of Zink-Coated Steel

Welding

31

Products Today and Future

300 µm 300 W* 2.000 W 4.000 W400 µm 2500 W 4.000 W 9.000 W600 µm 4.000 W 6.000 W 12.000 W1000µm 6.000 W 8.000 W 15.000 W

Fiber coupled Diode Lasers

Diode bar improvement

Actual status


Laserline company



Future trends

Conclusion

Outline


•Future Lasers for Metal and Alu Welding

•LP YAG

•Diode Laser

•Disc Laser

•Fiber Laser

•Remote Disc Laser

•cost reduction of multi kW diode laser

•multi kW diode laser 30 mm mrad

• 2000 2005 2010 2015

•Remote Fiber Laser


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

Welding of metals using high power fiber delivered … of metals using high power fiber delivered...

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