Plastic Welding

with Diode Lasers

June 2005

Laserline GmbH ! Muelheim-Kaerlich ! Germany www.laserline.de

Laserline GmbH, Germany
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Characteristics of Diode Laser

Advantages of Diode Lasers 1-step quick-welding Flexible, any desired welding contour Non-contact, fluff-free Easily automated, high process stability Low thermal and mechanical stress Top-Hat-beam profile w/o intensity peaks Applications Gas-/fluid proof containers, electronic/sensor-housings, automotive parts, etc.
Direct diode laser on robot in production. Photo: Toyota Laserline GmbH, Germany
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Plastic Welding with Diode Lasers

Joining of Plastics with Diode Laser " An Industrially Proven Process ! Content
Basics Types of Welding Processes Joining Techniques Examples Outlook

Laserline GmbH, Germany

Welding of Plastic: Principle

Laser Beam Transmits Top Shell

Laser Beam F translucent

Absorption in the Welding Zone Bottom Shell

Movement Direction

Melting of Both Parts by Heat Convection

Weld-Seam absorptive F
Laserline GmbH, Germany

Invisible Weld-Seam No Damage to the Surface

Welding of Plastic: Basics

Polymers for Plastic Welding Thermoplastics (Amorphous or Partially Crystalline) but not Duroplastics or Elastomeres Overlapping Melting-Temperature Comparable Melt Behaviour (Polarity etc.) Transmission / Absorption Characteristics for Laser Wavelength: One Transparent, One Absorbing Layer Mechanisms of Connection Intermolecular Forces Between Molecule Chains Mechanical Attachment by Macro-Molecules That Diffuse from one Part to the Other
Laserline GmbH, Germany
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Main Parameters
Parameters " Welding System Laser: beam forming, wavelength, optical power, spot size, energy distribution Machine concept: laser, manipulating system (positioning), cooling unit, electrics, other external components Parameters " Parts Combination of thermoplastics (thermal, mechanical and optical properties " additives!) Type and positioning of weld seam, thickness, parts design Parameters " Process Welding speed, cycle time, absorption of heat / reaction time
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Weld Results Width of the seam (HAZ) Optical results Resulting strength Internal strains

Welding of Plastic: Basics

Source: VDI Kunststofftechnik/BASF Laserline GmbH, Germany

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Welding of Plastic: Basics

Source: VDI Kunststofftechnik/BASF

Laserline GmbH, Germany

Welding of Plastic: Basics

Laser

F
translucent Weld Joint

Transmission welding Quality of weld depends on:

absorptive

Welding pressure Flatness of parts-surface Thickness of transparent welding partner

Laserline GmbH, Germany

Welding of Plastic: Basics

Typical Part Design with Process Control by Welding Path Laser F

Setting Path

Visible Notch

F
Laserline GmbH, Germany
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Plastic Welding: Typical Data

1000 Beam quality [mm mrad]

Hr
n ihc eie w t af ltstosfsc ing Ps ld n Ku We

te n

100

H a rtl
S

te n

Au
schw

ssc ftra g

hw e

i e n

Laser DioScan, Direct, Fiber-Coupled and Multi-Diode Lasers Power 50 W to 800 W

te n

en chwei

Hybrid
Schne

eien
T ie f we sch i e n

iden

10 10 100 Power [W] 1000 10000

Beam quality < 150 mm mrad Spot dimensions 0.5 to 5 mm Material - Thermoplaste

Electronics housings

- Thermoplastische Elastomere (TPE)

Laserline GmbH, Germany
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Diode Laser Types for Plastic Welding

Direct diode laser, LDL 40 Multi diode laser system (100 diode laser sources)

DioScan F
Laserline GmbH, Germany

Fiber-coupled diode laser LDM

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Plastic Welding: Options

DioScan: beam scanner with PC or stand-alone control, scanner software and integration for plastic welding Optics with different beam dimensions and working distances 1-inch or 2-inch optics Ring focus optics for simultaneous welding of circular seams Circumferential weld optics for welding of tubes Pyrometer and CCD camera for process monitoring

Laserline GmbH, Germany

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Variants of Welding Processes

I. Quasi-Simultaneous Welding (QS): Uniform, step-by-step heating of the weld zone Rotation symmetric parts or any desired 2D-contour II. Contour Welding: One-step-welding process Any desired geometry, 3D contour

Laserline GmbH, Germany

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Special Variants I

Multi-Laser-System: Rotation symmetric parts Uniform, simultaneous heating of different weld zones Shortest cycle time Cost reduction due to less process stations

Laserline GmbH, Germany

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Special Variants II

Simultaneous Welding: Uniform, simultaneous Heating of the Weld Zone No internal strains, any part geometry Reduced cycle time Low flexibility, high complexity

Laserline GmbH, Germany

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Special Variants III

Scheme: Special Optics

Laser-light-cable

Laser beam Collimating optics

Circular focusing optics

Special focusing optics for circular focus geometry AXICON Parabolic mirror

Rotation symmetric part

Laserline GmbH, Germany

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Systems Advantages
Weld Geometry \ Laser Spot Welds Contour Welds Multi-Spot Welds Step Welds Direct & Fiber-Coupled Scan-System (QS) Multi Diode (simultaneous)

Laserline GmbH, Germany

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I. System Concept: Multi-Laser

Multi-Laser-System Redundant system Shortest cycle time

100-Laser-System

Applications Structures Foils Rotation symmetrical parts

Twin-Laser-System

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II. System Concept: QS-Welding

DioScan Simple manipulation system Laser safety box Short cycle time Application Sensors, electronic housings, etc.
DioScan Circular table Laser safety feature

Part holder

Laserline GmbH, Germany

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Joining Techniques - Comparison

Ultrasonic
1-Step-Process Mechanical Force Transmission US-Frequency in Weld Zone All Thermoplastics

Vibration
1-Step-Process Mechanical Force Transmission Vibration Forces in Weld Zone All Thermoplastics

Laser
1-Step-Process No Touch IR-Radiation in Weld Zone All Thermoplastics (optically suited)

Glueing
Multi-Step-Process Glue Application through Nozzles Most Plastics

Heat Plate
1-Step-Process Global Heating through Heat Plates All Thermoplastics

Laserline GmbH, Germany

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Joining Techniques - Comparison

Diode Laser
Highest welding quality (visible joints, fluff free) Highly flexible (robot, axis-system, quasi-simultaneous welding) Availability 99.5 % Gap-bridging Wear-resistant tool
Part damage
0 50

Availability
100

Laser US VIB Gluing Flexibility

Gap-bridging
Scan system Direct diode laser
Laserline GmbH, Germany

Joint-quality

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Requirements from Industry

Vibration

Requirements
Failed parts 0 ppm Gap bridging Gas proof No damage to the part No fluff in weld Any desired contour Sensitive electronic parts

Gluing

Characteristics
Process control Check of melting path Endless weld-seams Non-contact No vibrations Maximum flexibility Local heat input

Laser
Ultrasonic

Heat Plate

Laserline GmbH, Germany

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Weld Seam Geometry YAG vs. Diode Laser

Diode Laser Nd:YAG Laser w = weld zone

Diode Laser Top-hat beam profile " Homogeneous weld over entire width of weld seam Good weld seam control Ideal for welds > 0.25 mm width and larger areas Nd:YAG Laser Gau beam profile: High central intensity limits max. power Higher risk of parts damage Less homogeneous weld Ideal for micro structures < 0.25 mm width
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Weld seam dimensions. Advantages and disadvantages of the different systems < 0.25 mm. !-Structures, etc. 0.25 ...1.5 mm Sensors, small housings, welding with setting path < 1.5 mm Large housings, broad area connections, contour welding Large area welds Plastic layers, plate material, foils

Diode + +++

Nd:YAG +++ ++

+++

++

--

Laserline GmbH, Germany

Influence of Power on Productivity

total time for weld [s]

15 10 5 0

3 2 1 0 50 150 250 laser power [W] 350

High flexibility AND high productivity

Laserline GmbH, Germany

speed [m/s]
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Quasi simultaneous welding Almost constant path energy without damage to components Higher power and scan speed result in reduced welding time

influence of laser power, material: PA6, weld seam length: 250mm

25 20 5

time for weld Potenziell (Ges.-Zeit [s]) scan speed Polynomisch (v [m/s])

Scan Software
Laser control by scan software Graphical view of settings User-/ Operator surface Special mode for easy operation (e. g. operator mode for 3-shift production) Contour flexibility, import of dxf, wmf, bmp, plt, ...

Laserline GmbH, Germany

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Prozess Monitoring

Mechanical

Thermal

Optical

Software

Visual
CCD-Camera Alignment beam

Setting path sensor

Pyrometer

Back reflection diagnoctics

Frame-Grabber

Laserline GmbH, Germany

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Examples: Automotive Industry

Air Flow Sensor

Car Key
Laserline GmbH, Germany

Schaltbox
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Examples: Automotive Industry

Electronic Housings

Automatic Gear Box

Laserline GmbH, Germany
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Plastic Welding: Examples

Mats from plastic material

Invisible weld seam in PMMA

Liquid pouring device

Laserline GmbH, Germany

Weld of foam on plastics

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Example: Magnetic Sensor

Welding seam

Photo: Laserquipment

Tyco Electronics AMP GmbH

Integration in a system with round switch table
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Example: Movement Sensor

LDL 40-100 - Direct Diode Laser Contour Welding Opaque Material

Source: Laserquipment
Laserline GmbH, Germany
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Example: Hydraulic Tank

Welding of hydraulic tanks DioScan 200 Result: Excellent welding seam Single step process Highest process-stability Non-contact process No fluff development
Source: branson
Laserline GmbH, Germany
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Example: Ostomy Bags

LDF 600-300 Fiber-Coupled Diode Laser Medical Industry Contour welding of concentric Circles Soft-to-soft welding

Laserline GmbH, Germany

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Example: Filter Element

(1)
Medical Industry Contour welding of transparent material Clear weld (1) Black absorbing foil (2)

(2)

Source: Leister
Laserline GmbH, Germany
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Reference Customers (selection)

Automotive - Bosch - Bremi - Daimler Chrysler - Geigertechnik - Grau - Mendiguren - Siemens VDO - VAW Others - Boeing - Colbond - Erlas - Philips - Thyssen - TRW

Sensors Metal Welding Plastic Welding Electrical-Mechanical Components Valves Housings

Metal Welding Plastic Welding Pump-Module for Fiber-Laser

Laserline GmbH, Germany

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Outlook Plastic Welding with Diode Laser

Highest Quality-Requirement for Joining Techniques in Automotive Industry Easily Integrated in Full-Automation Systems Customers-Specific Solutions

Laserline GmbH, Germany

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