IMTS High power solid state lasers and their

TUSD
IMTS
High power solid state lasers and
their applications
Tracey Ryba
Ryba, Product Manager - Lasers
9/9/2014
IMTS, Tracey Ryba
Confidential
■■ Confidential
9/9/2014
1
High power solid state lasers and their applications
1.
2
2.
3.
4.
5.
6.
Why so many laser choices
T Di k and
TruDisk
d its
it applications
li ti
TruFiber and its applications
TruDiode and its applications
PFO and its applications
Summary
y
IMTS, Tracey Ryba
Confidential
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9/9/2014
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1
High power solid state lasers and their applications
1.
2
2.
3.
4.
5.
6.
Why so many laser choices
T Di k and
TruDisk
d its
it applications
li ti
TruFiber and its applications
TruDiode and its applications
PFO and its applications
Summary
y
Confidential
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IMTS, Tracey Ryba
9/9/2014
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Selecting the right laser
Application
Welding Cutting
Engineering and
machine technology
Hardening…
Choose beam source
Disk
Fiber
Diode
CO2
=> Optimal solution regarding quality, costs
and productivity
IMTS, Tracey Ryba
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2
Selecting the right laser
Some of the influencing factors
• Production volume / throughput / cycle time
• Networkability
N
k bili
• Existing installed base
• Use of resources (electricity, gas, water / cooling, space)
• Available budget
.
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Selecting the right laser source
Absorption curve
IMTS, Tracey Ryba
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CO2 Lasers
Disk
Diode
Fiber
Micro
Mark
Cutting
Welding
Plastic
Welding
Brazing
Cladding
Hardening
H d i
Ablating/
Drilling
Marking
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IMTS, Tracey Ryba
Confidential
9/9/2014
World Wide Installations
> 55,000 Fabrication & Laser Machines
> 24,000 CO2 Lasers
> 16,000 Solid State Lasers
> 11,000 Marking Lasers
IMTS, Tracey Ryba
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4
High power solid state lasers and their applications
1.
2
2.
3.
4.
5.
6.
Why so many laser choices
T Di k and
TruDisk
d its
it applications
li ti
TruFiber and its applications
TruDiode and its applications
PFO and its applications
Summary
y
IMTS, Tracey Ryba
Confidential
■■ Confidential
9/9/2014
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Disk / fiber laser strengths
• Fiber optic delivery
• Excellent beam quality
• High speed cutting / welding of thin-medium materials
• Cutting / welding of highly reflective metals (e.g. copper,
aluminum)
• No plasma suppression necessary & argon can be used for
shielding gas for oxidation critical welds (instead of He)
• High wall plug efficiencies
IMTS, Tracey Ryba
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5
Why did Trumpf choose the disk laser architecture over the fiber
laser architecture for high power?
 Both are solid state
 Both are diode pumped with long life diodes
 Both are fiber optic delivered
 Both have excellent BPP
 Both are compact
 Both have excellent WPE
 Both are “non-monolithic” for industrial applications
 Only the disk laser is truly modular:
-
Field upgradability of power with no splicing required
The disk laser yyields the minimum risk & downtime
There are no potential failure modes that require factory repair
Therefore, no need for the laser itself to be a “spare part”
Diode replacement without splicing
 Only the disk laser has uncritical power densities on the active medium
 Only the disk laser is insensitive to back reflections
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IMTS, Tracey Ryba
Confidential
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Disc vs Fiber
Diode modules / bars
(modular)
Single emitter diodes
(spliced)
Yb:YAG disk
(modular)
Yb:Quartz fiber
(spliced)
Non-monolithic
beam delivery
Feed fiber
RM & OC mirror
(modular)
Beam combiner
(spliced)
RM & OC – Bragg
gratings (spliced)
IMTS, Tracey Ryba
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1um Wavelength
TRUMPF TruDisk
IMTS, Tracey Ryba
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TruDisk – 1um wavelength laser
• Economical, efficient. compact
• High output power (up to 16 kW standard) custom lasers over 60kW
• Wavelength 1.03 micron
• Extremely high diode life time
• Insensitive to back reflections
• Field upgradable (e.g. power and number of outputs)
• Plug & play of delivery fiber
• If ever needed, easy and fast exchange of every component.
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TruDisk – solid state laser
Cutting
• Quality cuts up to 12 mm
us o cu
cuts
s up to
o 25
5 mm
• Fusion
• Flame and fusion cuts
• Mild steel, stainless steel, aluminum,
copper, copper alloys
• Highly productive for thin sheet
• Variable series size
• Networkability
IMTS, Tracey Ryba
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TruDisk – solid state laser
Fine Cutting
• Fine and thin sheet from 0.5 - 2 mm
e co
contours
ou s
• Fine
• Mild -, stainless steel, aluminum, copper,
copper alloys
• High productivity
IMTS, Tracey Ryba
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8
Best in class cutting quality with Bright Line Fiber
Powered by TruDisk 5001
Standard
CO2 (10 µm)
BrightLine
SSL (1 µm)
CO2 (10 µm)
TruDisk 5001 (1 µm)
VA 12mm
Bild fehlt
St 25mm
IMTS, Tracey Ryba
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TruDisk – solid state laser
Welding
• Deep welding and thermal conduction
welding
• Welding depth up to 12 mm
• Large working distance possible (remote
processing)
• Mild steel, stainless steel, aluminum,
copper, copper alloys
IMTS, Tracey Ryba
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9
TruDisk – solid state laser
Fine Welding
• Sheet metal thicknesses up to 3 mm
e oep
processing
ocess g
• Remote
• Welding speeds up to 40 m/min in
continuous process
• Mild steel, stainless steel, aluminum,
copper, copper alloys
IMTS, Tracey Ryba
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TruDisk – solid state laser
Deposition Welding
• Production of wear and corrosion
protection layers
• Repair jobs
• Individual layer thickness 0.1 to 2 mm
• Material deposition rate up to 2 kg/h
Filler materials: steels, nickel, cobalt and
titanium alloys
• Substrate: steel, gray cast iron, titanium,
nickel
IMTS, Tracey Ryba
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10
Welding of tailored blanks
Boron Steel 22MnB5
1.
Removal of AlSi-layer as weld preparation
with TruMicro 7060

850 W average power, 30 ns pulse
l d
duration
ti

Special focusing optics used to generate a
line with aspect ratios of 1 :10

2.
Ablation rates > 5 cm²/s
Welding of tailored blank typ. with TruDiode or
TruDisk
IMTS, Tracey Ryba
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High power solid state lasers and their applications
1.
2
2.
3.
4.
5.
6.
Why so many laser choices
T Di k and
TruDisk
d its
it applications
li ti
TruFiber and its applications
TruDiode and its applications
PFO and its applications
Summary
y
IMTS, Tracey Ryba
Confidential
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9/9/2014
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11
Fiber Lasers
TRUMPF TruFiber
IMTS, Tracey Ryba
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TruFiber – 1um wavelength laser
• Impressively high processing speeds
• Narrow cutting kerfs and thin weld seams
• Laser outputs of 500 and 1000 W
• Single mode beam quality
• Ideal for precision processing.
IMTS, Tracey Ryba
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TruFiber – 1um wavelength laser
Fine Cutting
• Foil materials and thin sheets from 0.05
to 2.4 mm (500 watts)
• Ultra-fine contours Filigree structural
components
• Mild steel, stainless steel, aluminum,
copper, copper alloys
• High productivity
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IMTS, Tracey Ryba
Confidential
9/9/2014
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High quality cutting of thin sheets
CW Single Mode Fiber Laser
 Sheet thickness typ. < 1 mm
 400 W Laser
L
power applied
li d
 High quality cut with Software
“Cutassist”
 Even at fine contours and
small geometries
 Laser power and power mode (cw /
Pulsed) automatically synchronized
to feed rate
Without Cutassist
With Cutassist
Principle also applied for welding applications!
IMTS, Tracey Ryba
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13
TruFiber – 1um wavelength laser
Fine Welding
• Thin sheet up to 2.0 mm (500watts)
e oep
processing
ocess g
• Remote
• Ultra-fine weld seams
• Filigree and temperature-sensitive
structural components
• Mild steel, stainless steel, aluminum,
copper, copper alloys
IMTS, Tracey Ryba
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Welding of aluminum to copper
Tap Welding
 Requirements:
 No spatters
 High
Hi h productivity
d ti it
 High quality at repetitious results
 Solution:
 TruFiber + Scanner PFO
 Power at workpiece: 400 W
 Speed: v = 6 m/min
 Welding depth: 0.6 mm
geometry:
y spiral
p
 Wobble g
IMTS, Tracey Ryba
14
High power solid state lasers and their applications
1.
2
2.
3.
4.
5.
6.
Why so many laser choices
T Di k and
TruDisk
d its
it applications
li ti
TruFiber and its applications
TruDiode and its applications
PFO and its applications
Summary
y
IMTS, Tracey Ryba
Confidential
■■ Confidential
9/9/2014
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Diode Lasers
TRUMPF TruDiode
IMTS, Tracey Ryba
Confidential
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Direct diode laser strengths
• Fiber optic delivery
• Conduction welding
• Welding, brazing & laser hardening
• Welding of highly reflective metals (e.g. copper, aluminum)
• No plasma suppression necessary & argon can be used for
shielding gas for oxidation critical welds (instead of He)
• Very high wall plug efficiencies
IMTS, Tracey Ryba
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TruDiode – 1um wavelength laser
TruDiode
• Extremely energy efficient
• fiber delivered
• 150 – 6000 watts
• Beam quality ranging from 8 – 50 mm * mrad
• Modular diode assemblies
IMTS, Tracey Ryba
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TruDiode – 1um wavelength laser
Welding & Brazing
• Thermal conduction welding
IMTS, Tracey Ryba
•
Deep welding to 6 mm
•
Soldering & Brazing
•
Deposition welding
•
Mild steel, stainless steel, aluminum
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TruDiode – solid state laser
Welding
• Deep welding and thermal conduction
welding
• Welding depth up to 6 mm
• Mild steel, stainless steel, aluminum,
copper,
pp , copper
pp alloys
y
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Further application fields for Laser Metal Deposition
Coating
g
Coating
Repair
8,5 mm
By courtesy of MWS
Schneidwerkzeuge
(Germany)
4,5 mm
By courtesy of: Gall & Seitz
Systems, Germany
Coated blade
Coated cutting disc
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IMTS, Tracey Ryba
Confidential
9/9/2014
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Trend: Lightweight design
Innovative Ideas
Lightweight Materials
Boron Steel 22MnB5
Aluminum
Plastics
CFRP
Spot Welding
Laser Welding
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Welding of aluminum or steel to plastics (1)
Welding of plastics
existing technology
State of the art
Welding of metal:
existing technology
State of the art
Joining of metal with plastic?
 2 step process (TruMicro &
TruDiode)
 Solid weld, like typical metal
welding base material will
break before the actual weld
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IMTS, Tracey Ryba
Confidential
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Joining of aluminum to steel
1xs
 Joining of aluminum and steel using Laser Metal Deposition
 Application tests show very good results
 Actual several tests for finding the best metal-powder for joining and the best joining
strategy
IMTS, Tracey Ryba
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Welding technologies (Aluminum - Steel)
Laser Metal Deposition
Laser, focusing head and powder nozzle
Laser Metal Deposition used
as joining technology
IMTS, Tracey Ryba
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9/9/2014
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High power solid state lasers and their applications
1.
2
2.
3.
4.
5.
6.
Why so many laser choices
T Di k and
TruDisk
d its
it applications
li ti
TruFiber and its applications
TruDiode and its applications
PFO and its applications
Summary
y
IMTS, Tracey Ryba
Confidential
■■ Confidential
9/9/2014
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20
Taking advantage of the fiber delivery
Programmable Focusing Optics (PFO)
PFO 33
PFO 20
 2D scanner, max. 0.7 kW  2D scanner, max. 8 kW
 Product since 2004
 Product since 1999
PFO 3D
 3D scanner, max. 8kW
 Product since 2007
TRUMPF has sold over 2000 scanners worldwide
IMTS, Tracey Ryba
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Taking advantage of fiber delivery
Programmable Focusing Optics PFO
2D:
PFO 20
PFO 33
IMTS, Tracey Ryba
3D:
PFO 3D
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Taking advantage of fiber delivery
What makes remote welding more productive?
Process Start
Home
Welding 8
Positioning 7
Welding 7
Positioning 6
Welding 6
Positioning 5
unproductive
travelling times
Welding 5
Positioning 4
Welding 4
Welding 3
Positioning 3
Positiotning 2
Welding 2
Positioning 1
approach
Welding 1
Conventional Laser Welding
Process End
Laser Scanner Welding
g
Process Start
travelling times
 Maximization of beam-on share
Home
Welding 8
Welding 7
Welding 6
Welding 5
Welding 4
Welding 3
Welding 2
Approach
Welding 1
 Elimination of non-productive
Process End
IMTS, Tracey Ryba
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Taking advantage of fiber delivery
What makes remote welding more productive?
Customized weld patterns allow for optimum strength of the
joints and increased design flexibility due to:
 virtually any weld seam shapes
 virtually any orientation of weld seams
 user defined distribution of weld seams
 optimum flow of forces
➩ reduced flange width
➩ material, weight and
cost savings
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Taking advantage of fiber delivery
Reduction of flange width
Remote Welding
Resistance Spot Welding
8,0
1,1
14 5
14,5
2
1,25 1,25
2
3,5
1
1,1
11
8
16
2,25
6
3
REP
11
1,1
1,1
vmin
6
6
17,5
1,0
➩material, weight and cost savings
IMTS, Tracey Ryba
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Taking advantage of fiber delivery
Elimination of lower electrode (hole)
IMTS, Tracey Ryba
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PFO case study
Comparison of RSW with Laser Remote Welding
Resistance Spot Welding:
 34
+ shift
hift mark
k
 4 robots, 5 weld guns
 additional tool for shift mark
 processing time: 35 sec
Laser Remote Welding:
 34
+ shift
hift mark
k
 1 robot, 1 scanner optics
 processing time: 13 sec (with 4 kW)
 processing time reduction: factor 3
Laser shift mark:
Source: Volkswagen AG
IMTS, Tracey Ryba
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PFO case study
Comparison of RSW, conventional laser & remote welding
Comparison of
Technologies:
Processing
time
Resistance spot
welding
30 sec
Laser welding
(conventional)
23 sec
Remote welding
5 sec
Source: BMW
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PFO case study
Remote Laser Welding on the Audi A4 / Q5
Processing Parameters:
Laser
Joint Geometry
Material Thicknesses
Number of straight stitch welds
Location of laser nubs
TruDisk 4002 (4 kW)
overlap
0.7 / 0.6 mm
45 – 49 per door (25 – 40 mm length)
straight line aside of stitches
Remote Welding Time
(Resistance Spot Welding Time
< 20 s
> 135 s)
41
42 6
7
43 8
44
45
11
12
9
10
13 15 18
14
IMTS, Tracey Ryba
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3
40 4
5
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20 21
2
36 35
1
34
33
31 32
30
29
28
26 27
25
22 24
23
16 17 19
Confidential
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9/9/2014
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High power solid state lasers and their applications
1.
2
2.
3.
4.
5.
6.
Why so many laser choices
T Di k and
TruDisk
d its
it applications
li ti
TruFiber and its applications
TruDiode and its applications
PFO and its applications
Summary
y
IMTS, Tracey Ryba
Confidential
■■ Confidential
9/9/2014
50
25
Summary CW Lasers
IMTS, Tracey Ryba
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Summary
• Many styles of modern 1um wavelength lasers Disc, Diode, Fiber, Short Pulse
• Differences
• Beam
B
quality
lit
• Variable wavelengths +/- 100nm around 1um
• CW vs Short Pulse
• Applications
• Welding (thin to thick)
• Remote welding
• Cutting (.001” to 1.0”)
• Brazing
p
• Deposition
• Heat treating
IMTS, Tracey Ryba
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TUSD
QUESTIONS?
Tracey Ryba
Ryba, Product Manager - Lasers
9/9/2014
IMTS, Tracey Ryba
Confidential
■■ Confidential
9/9/2014
Confidential
■■ Confidential
9/9/2014
53
TUSD
YOUR CONTACT
Tracey Ryba
Product Management - Lasers
734-454-7216
[email protected]
IMTS, Tracey Ryba
54
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