Laser welding 201

Laser welding technology has evolved significantly, making it easier to optimize both equipment and processes. This advancement leads to higher profits and a competitive edge in global manufacturing. The key to optimization lies in utilizing accurate and reliable laser beam diagnostic and process-monitoring devices. Proper training is essential for safe and effective operation of these devices to ensure full optimization.

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To stay competitive locally and globally, merely running the laser welding process is not enough. Equipment can often deliver higher productivity and better-quality products at no extra cost by optimizing the laser operation to suit the welding process. Most laser beam diagnostic devices operate in an open-loop mode but can be set to trigger alarms when preset limits are exceeded.

Optimization: A Real-World Example

For optimum weld quality and productivity, certain laser beam characteristics must be fine-tuned using diagnostic devices. These parameters include:

• Temporal profile (pulse shape) of pulsed lasers
• Temporal behavior of the laser (such as ramping and modulating)
• Spatial profile of the laser beam for both pulsed and CW lasers. This involves the distribution of laser energy or power across the beam, affecting the focusability of the laser.

An electrical appliance manufacturer optimized the temporal profile of a pulsed laser, significantly enhancing weld quality and reducing consumables costs. Using an electrically pulsed Nd:YAG laser with pulse-shaping capabilities, they achieved remarkable results in lap welding of chrome-plated carbon steel with minimal gap tolerance. However, they encountered issues such as lack of fusion and burn-through, caused by excessive gaps, leading to high rejection rates and shortened flash lamp life.

To resolve these issues, a specific pulse shape was employed, bridging gaps as large as the top plate's thickness. An energy meter was used to measure and adjust the actual pulse shape, ensuring accurate alignment with the programmed shape. This adjustment reduced the rejection rate and increased peel test force, leading to significant cost savings due to extended lamp life.

Additional resources:

Cereal/Corn Puff Snack Extrusion Line
5 Must-Have Features in a Fabric Laser Cutting Machine
Beginners Guide To Gold Plating

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