LASER BEAM WELDING AND CUTTING

Laser & EB Welding

Wide & partial fusion Narrow & deep fusion
Conventional welding
Why LASER ?
INCANDESCENT Vs. LASER LIGHT
LASER WELDING
S

CHARECTERISTICS OF LASERS
Common light : incoherent & varied lengths in different directions
Laser Beam is a coherent light waves are identical & parallel
Temporal coherence
How long a wave train is continuous?
Ordinary light ~ few tens of microns
Lasers ~ from 20 cm to few tens of mt
DIRECTIONALITY
It is the spread of the beam when its travels
Divergence is of the order of 1 milliradian
i.e , when the beam travels for 1m, the beam diameter
increases by 1mm.
.
Semi conductor lasers : Laser diodes
Gas lasers : He- Ne, CO
2

Chemical Lasers : Hydrogen Fluoride
Liquid lasers : Organic dye
Excimer lasers : Rare gas mixtures
Solid state lasers : Nd:YAG, Ruby
LASER SYSTEMS
LASERS FOR MATERIAL PROCESSING
Gas lasers : up to 45kwatt

Solid state lasers:up to 4kwatt

Semiconductor lasers: up to 40watt

CW lasers welding, cutting & surface modification
Pulsed lasers drilling & welding

Circular and linear beams

E
1
E
1
E
1
E
2
E
2
E
1
E
1
E
1
E
2
E
2
E
2
Stimulated absorption
Spontaneous emission
Stimulated emission
Energy-state transition diagram
E
2
Initial state Final state
CO2 Laser Theory
Total Lasing (Light Amplification)
Laser medium Laser output
Excitation
source
Mirror
(100% reflective)
Mirror
(partially transparent)

Generation of laser beam
CO
2
Laser principle
Concentrating light waves into narrowly defined highly intense beam that impart
tremendous energy on a small area to produce fusion
CARBON DIOXIDE LASERS
CO
2
: Lasing gas, 1-9% of the gas mixture

N
2
: Efficient excitation of CO
2
molecules,
10-55% of the gas mixture

He : For conducting heat out of resonator
and emptying the lower CO
2

energy level, balance of gas mixture
In ICF , MS 20 , SS 15 & AL 11 MM
Laser cutting is a technology that uses a laser to cut
materials, which is used in the production line and is
typically used for industrial manufacturing
applications.
Laser cutting works by directing the output of a high
power laser, by computer, at the material to be cut.
The material then either melts, burns, vaporizes away,
or is blown away by a jet of gas, leaving an edge with
a high quality surface finish. Industrial laser cutters are
used to cut flat-sheet material as well as structural and
piping materials.
25
L as er cutti ng
N :
0 0 3 / 1
2 1
0 1 T R
0 0 2
P r i n c i p l e o f
l a s e r c u t t i n g
4
1
2
3
5 8 7 9 6
1 . A u x i l i a r y g a s

2 . C u t t i n g h e a d

3 . P r o f i l e f o l l o w e r

4 . F e e d r a t e

5 . C a s t M a t e r i a l
6 . S c a l e s ( f r o m
c a s t i n g )
7 . C u t t i n g f a c e
8 . Z A T
9 . C u t t i n g w i d t h
D o c .
R o f i n
S i n a r
29

Advantages of laser cutting over mechanical cutting vary
according to the situation, but two important factors are the lack
of physical contact (since there is no cutting edge which can
become contaminated by the material or contaminate the
material), and to some extent precision (since there is no wear on
the laser). There is also a reduced chance of warping the
material that is being cut, as laser systems have a small heat-
affected zone. Some materials are also very difficult or
impossible to cut by more traditional means. One of the
disadvantages of laser cutting includes the high energy required.
Comparison to mechanical cutting
OPTICS
Collimating Optics: Plano-convex lenses; copper total
rflectorReflective and transmissive collimating optics are
used in beam delivery systems to maintain beam
collimation between the laser resonator and the focusing
optics. Reflective collimators typically use Cu total
reflectors, while transmissive collimators typically use
ZnSe lenses.
P has e Retar der s
Ragged Cut: produced by linearly
polarized light
Clean Cut: produced by circularly
polarized light
Ref l ec t i v e phas e r et ar der i nt o
t he beam del i v er y pat h
el i mi nat es k er f v ar i at i ons by
c onv er t i ng l i near pol ar i z at i on
t o c i r c ul ar pol ar i z at i on.
Ci r c ul ar pol ar i z at i on c ons i s t s
of equal amount s
PROTECTIVE WINDOWS
It protectS scan lenses from backsplatter
and other workplace hazards,
PARABOLIC MIRROR
Par abol i c mi r r or s ar e des i gned
f or r ef l ec t i ng and f oc us i ng t he
l as er beam t hr ough 90 degr ees .
N :
0 0 8 / 1 2 1
0 1 T R
0 0 7
P e r f o r ma n c e s of a CO2 l aser
of 3000 W
STEEL 2 0 mm
STAI NLESS STEEL 1 0 mm
BRASS 3 mm
ALUMI NI UM 8 mm
CERAMI CS 8 mm
P. M. M. A. 5 0 mm
POLYCARBONATE 2 5 mm
WOOD 3 0 t o 5 0 mm
A d v a n t a g e s o f t h e l a s e r c u t t i n g u s i n g
C O 2
No s t r e s s / l o a d o n t h e c o mp o n e n t
No t o o l we a r
No d e f o r ma t i o n o f t h e ma t e r i a l s
Hi g h f l e x i b i l i t y o f u s e
P r e c i s i o n o f 0 , 1 mm
Ve r y h i g h r e p e a t a b i l i t y
S a v i n g o f ma t e r i a l
L a r g e r a n g e o f ma t e r i a l s f o r c u t t i n g
Hi g h c u t t i n g s p e e d
Re d u c e d c o s t o f u s e
N : 011/121
01 TR 010
D r a w b a c k s o f C O 2 l a s e r c u t t i n g
Hi g h c o s t o f e q u i p me n t
Lo w yi e l d
Di f f i c u l t y o f u s e
Co n s i d e r a bl e r e f l e c t i o n r a t e f o r c e r t a i n
ma t e r i a l s o f 1 0 , 6 m
Di s e n g a g e me n t o f f u me s a n d v a p o u r s
Ri s k o f c a r b o n i s a t i on f o r c e r t a i n ma t e r i a l s
38
Welding
In laser welding we must distinguish between two main processes: thermal conductivity welding and deep
penetration welding. In thermal conductivity welding, the materials to be joined melt as a result of absorption of
the laser beam on the surface of the material, and the associated conduction of heat. The solidified smelt joins the
materials. The depth of the weld in this process is typically < 1 mm.
Deep penetration welding, which begins at an energy density of approx. 10
6
W per cm
2
, is based on the creation of
a vapor capillary in the material. To achieve this, it is necessary to heat the material locally to its evaporation point.
The resulting vapor pressure in the material creates a capillary approx. 1.5 times the diameter of the focal spot of
the laser beam, which is moved through the material by the movement system, following the contour to be welded.
The hydrostatic pressure, the surface tension of the smelt, and the vapor pressure in the capillary compensate
each other, so that the capillary (often referred to as the "keyhole") does not collapse. The total reflection within
the keyhole guides the applied laser beam deep into the material, in such a way that today, given sufficient laser
power, weld depths of up to 25 mm (steel) can be achieved.
Steels and aluminum are the classic area for laser welding. But in principle, all materials that can be welded using
traditional methods can also be welded with lasers, often at higher speed and quality compared with the traditional
processes.
LASER CUTTING AND WELDING MACHINE
Sequence of operation

The Loading System
The loader takes a sheet from the stack and loads it on the loading
table in front of the clamping bench. The sheet is taken by means
of suction cups connected to a vacuum system. A hydraulic
cylinder drives the vertical movements; an electrical motor drives
the horizontal movement.
1.The Loading System

The unloader takes parts from the cutting area and drops them on the
unloading conveyor. The sheet is taken by means of suction cups
connected to a vacuum system. A pneumatic cylinder drives the vertical
movements of the entire unloading platform.
1.a.The Unloading System
Whenever a sheet feed-in cycle is
commanded, a sheet will be transported from
the loading table in front of the clamping bench
to the appropriate position where cutting can
start.

2.Feeding FirstSheet into the Clamping
Bench
As soon as the first sheet has been fed in, and the transport rolls have been moved
DOWN, the cutting cycle starts:

The U-axis moves to its end position with the unloader platform above the unloading
conveyor. This allows the Y-axis to be set at "full stroke".
The Y-axis moves to the edge of the first sheet on the exhaust table, and the edges
of the sheet are cut away, as are the window holes.
When cutting on the exhaust table is finished, the Y-axis moves to its position above
the clamping bench. Unloading of the window cutouts can start (also refer to "The
Window Cut-out Unloading Cycle"). The unloading cycle runs in channel 2, allowing
channel 1 to continue trim-off and welding.
The cutting head cuts (trims) away the edges in the clamping bench of the first
sheet. Then a second sheet is fed in the clamping bench, after which its edges in the
clamping bench are also cut (trimmed) away.
A head change is performed, rotating the cutting head away, and replacing it by the
welding head.
The clamping bench closes (moves OUT), and the two sheets are welded to each
other: first some points are welded, afterwards the entire weld seam.

3.The Cutting and Welding
Cycle
3.e. Laser Head.
4.f.Welding Position
3.g.Cutting Position
As long as the Y-axis is positioned at the clamping
bench, the U-axis can move freely over the exhaust
table to remove the scrap parts (windows) from the
cutting area (U-axis is set at full stroke)

4.The Window Cut-out Unloading Cycle

5.Transporting the Sheets for the Next
Cutting and Welding Cycle
When the welding actions have been performed, and all window cutouts have been
removed, the joint sheets are to be transported further in the direction of the unloading
area, preparing for another cutting and welding cycle:
The transport rolls in the exhaust are moved UP.
The U-axis is moved to a position above the exhaust table where it is able and allowed
to grab a sheet. The rear gripper opens and moves OUT.
The front gripper opens and moves towards the sheet.
The front and rear gripper close and clamp the sheet.
The clamps at the loading side and the cutting side of the clamping bench move UP
(stop clamping).
The bench rolls are activated in forward direction, the unloading rolls are activated in
forward direction, and the U-axis pulls the clamped sheet over a defined distance
towards the unloading area.
The bench rolls and unloading rolls are stopped.
The transport rolls in the exhaust are moved DOWN.
The clamps at the cutting side of the clamping bench move DOWN
(start clamping).
The front and rear gripper open.
The U-axis moves to its end position with the unloader platform
above the unloading conveyor.
At this moment the cutting on the exhaust table can start, a third
plate can be loaded into the loading side of the clamping bench, and
cutting and welding the third plate to the second one can be
commanded.
When the final sheet has been welded to the previous one, the joint sheets are to
be transported further in the direction of the unloading area, preparing for the
final cutting:

The transport rolls in the exhaust are moved UP.

The U-axis is moved to a position above the exhaust table where it is able and
allowed to grab a sheet. The rear gripper opens and moves OUT.

The front gripper opens and moves towards the sheet.

The front and rear gripper close and clamp the sheet.

6.The Last Cutting Cycle
and Unloading the
Finished Part

The clamps at the loading side and the cutting side of the clamping bench move
UP (stop clamping).
The bench rolls are activated in forward direction, the unloading rolls are activated
in forward direction, and the U-axis pulls the clamped sheet over a defined distance
towards the unloading area. This time the final sheet is completely pulled out of the
clamping bench.
The bench rolls and unloading rolls are stopped.
The transport rolls in the exhaust are moved DOWN. Note that the gripper clamps
do not release the sheet this time.
At this moment the final cutting on the exhaust table can start.
After the cutting, the gripper clamps are opened, and the sheet is released. The
cutouts are removed as described in chapter 4.10.4 "The Window Cut-out Unloading
Cycle".
Finally, after the cutout removal, the gripper transports the joint sheets (and the
remaining scrap part of the last sheet) onto the unloading rolls. These rolls can then
transport the finished part to the point where the part will be removed from the
machine by means of external equipment.
There are a total of 5 scrap conveyors used on this machine.
The Bench Conveyor: The scrap parts resulting from cutting in the
clamping bench fall on this conveyor belt. The conveyor belt then pulls
the scrap out of the machine.
The Cutting Conveyors: The small scrap parts (resulting from cutting on
the exhaust table) are collected by a part collector (exhaust funnel) and
fall onto one of two conveyor belts. These conveyor belts transport the
scrap onto a third conveyor belt. This last conveyor belt then pulls the
scrap out of the machine.
The Unloading Conveyor: The window cutouts (larger parts) that are
unloaded via the unloader platform fall on this conveyor belt. The
conveyor belt then pulls the cutouts out of the machine.

7.The Scrap Conveyors
A gas circuit protects the optical path from dust. The gas supply for
this circuit is derived from the air dryer. During an X-, Y- or Z-axis
travel, a gas stream is blown under the bellows. This stream creates
an over-pressure in the optical path and this prevents dust from falling
down.

Purge Circuit for the Optical Path

Alignment Procedure for the Optical Path
The beam travel must be coaxial with the travelling-axes of the mirrors
along the machine axes X, Q, Y and Z. The laser-support and each
mirror on the machine should be aligned in order to obtain this situation.
A complete alignment (machine and laser) has been done when
installing the machine and should only be done in some particular cases
(e.g. after a service intervention on the laser cavity).
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