Professional Documents
Culture Documents
a laser manufacturer
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multiple lasers
Welding
- Hot strip
- Batteries
Lasers in China
Laser/punch
combo in the shop
Cleaning
productivity
Airbus
flies with
additive
manufacturing
SEPTEMBER\
O C T O B E R 2 0 17
P.
5 application report
5
Additive manufacturing makes
headway in aircraft production
Reduced ecological and environmental 21 user profile
footprint opportunities are big PETER SANDER Laser machine provides
9 technology report speed, flexibility, and higher
Industrial lasers in China: productivity
An observer’s perspective Laser/punch combination meets
product fabrication challenges
Chinese laser manufacturers respond
ROBERT J. KOLCZ
to changes in the market environment
24
DAVID A . BELFORTE
application report
Departments
16 application report
W W W. I N D U S T R I A L- L A S E R S . C O M
ANALYZING
THE BUSINESS OF
PHOTONICS
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our field. Delegate benefits include:
• First look at the 2018 Worldwide Laser Markets Report, as • $1,000 discount on the full Worldwide Laser Market Report
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• Continental breakfast, catered lunch, coffee breaks, and
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global laser and photonics companies
Additive
manufacturing
makes headway
in aircraft production
REDUCED ECOLOGICAL AND ENVIRONMENTAL
A
irbus’ investigations into addi- Materials, processes, and machines
tive manufacturing processes Materials. Because of future business cases, Airbus first
started more than 20 years ago, focused on titanium (Ti6-4), followed by Inox, and is planning
first with plastics and rapid pro- on aluminum applications by the end of 2018. LBM/EBM-based
totyping applications and a few additive manufacturing on Ti6-4 has been on Technology-
years later on laser beam melting Readyness-Level (TRL) 6 since the end of 2015, and the first
(LBM) and electron beam melt- low-rate serial parts were delivered by Premium Aerotech (a
ing (EBM) for metal applications. A problem that still some- subsidiary of Airbus) at the end of 2015.
what exists for the company is coming to additive manufac- One additional opportunity will be available for serial appli-
turing solutions with a solid business case, and how to start cations in 2018 onwards with Scalmalloy, a high-performance
if nearly every industrial decision is driven by business-case aluminum alloy managed by the Airbus subsidiary AP-Works.
discussions. From 2018 onwards, the company will have a first set of additive
Ninety-five percent of the time, additive manufacturing
makes it easier, cheaper, and faster to jump into a project,
rather than trying to get permanently improving basic figures
through deep investigations for future decisions.
manufacturing materials available to start real serial have been extremely useful for the future of additive manufacturing at Airbus,
production. One of the biggest challenges for future as they have demonstrated technical feasibility and future opportunities for
additive manufacturing serial applications is the avail- real industrial usage of additive manufacturing from 2016 onwards.
ability of low-cost metal powders, so it is good to see There are demonstrated additive manufacturing capabilities in flight safe-
all activities all over the world following that future need. ty-relevant hydraulic components. Up until now, mostly LBM projects have been
Processes. Fused deposition modeling (FDM; using produced—95% of which were manufactured by Airbus partners Laser Centre
Stratasys Fortus machines) has been in serial mode North (LZN), Hofmann Innovation Group, Toolcraft, and AP-Works, among others.
for two years now on Airbus A350 parts. Selective
laser sintering (SLS) with polyamide (PA) has Application examples
been used on demonstrator parts and High-speed development process. The Testing High-tech
first serial applications on helicop- Objectives in Reality (THOR) aircraft, a 3.7m flyable plat-
ters and brackets for the com- form almost completely printed out of plastics and a
pany’s new Beluga transport few aluminum parts, has an in-flight weight less than
aircraft. Because of limited 25kg. The target was to demonstrate additive man-
fire resistance capabil- ufacturing capabilities in competition with theo-
ity, this has not yet been retical investigations. FIGURE 2 shows a success-
applied on passenger fully demonstrated THOR aircraft in service.
aircraft up to now. Flight test LBM hardware. Titanium, Inox,
LBM and EBM with and aluminum parts were tested in service on
metals is now in first several A350/A330NEO test aircrafts, includ-
serial applications, with ing an aluminum camera cover for a vertical tail
wire- and powder-fed plane (FIGURE 3).
high deposition rate (HDR) First serial titanium use on aircraft systems.
processes to mill parts out First delivered in 2016, a Premium AEROTEC
of massive plates targeted for (PAG) titanium double-walled fuel connector that
the end of 2018. replaces a welded cast part assembly had a cost
Machines. The number of addi- reduction of around 50% because no casting tools
tive manufacturing machine suppliers is were needed and lead time was reduced from
increasing rapidly, which leads to competition in FIGURE 2. A Testing months down to 11 weeks (FIGURE 4).
the worldwide market. From an industrial view, in-pro- High-tech Objectives in First serial topology-optimized titanium
cess quality tools play a key role for future automated Reality (THOR) aircraft, brackets. First serial PAG additively manufac-
additive manufacturing facilities. In 10 years, we will produced entirely using tured parts for the A350 aircraft with a weight
see a bundle of different machine sizes and part-spe- additive manufacturing, reduction of 30% will be delivered in the fourth
cific additive manufacturing machines, as well as is shown in flight. quarter of 2017.
multifunctional additive manufacturing systems. For
example, an additive manufacturing machine sup-
plier in The Netherlands offers a machine with inte-
grated heat treatment, and the DMG Mori milling
center integrates an HDR powder-feed additive man-
ufacturing tool.
Flight safety-relevant additively manufactured hydraulic component. On The goal is to make full use of the free room for mul-
March 30, 2017, the first flight of a flight safety-relevant additively manufac- tifunctional and highly integrated “clean-sheet-de-
tured component on an A380 aircraft enabled 35% weight reduction (FIGURE 5). signs” enabled by additive manufacturing. This could
be a hydraulic unit or bracket with a three-part assem-
From first parts to clean sheet designs bly that had previously been made from 126 parts and
The first step into a new area of additive manufacturing is a 1:1 exchangeable addi- rivets. This means no costs for the roughly 120 parts,
tively manufactured part, while the next step is to rethink the complete component. which leads to 95% less assembly (and no tooling
maintenance, stock, and logistics). Such cases are
under investigation for serial use in 2019 onwards.
FIGURE 4. This titanium double-walled fuel connector that replaces a welded FIGURE 5. This flight safety-relevant additively
cast part assembly had a cost reduction of around 50% because no casting manufactured component enabled 35% weight
tools were needed. reduction on an A380 aircraft.
BeamCheck™ measures
•
Focal spot size at the build plane
•
Laser power at the build plane
The First 3D-Printed Aircraft Airbus
debuted Thor in June 2016, •Laser power density at the build plane
a mini-plane which is the first of • Changes in spot size & power density over time
its kind to fly successfully.
Call for an on-site measurement of your lasers performance
Question:
How much does Thor weigh?
46 pounds.
Additive manufacturing allows us to really rethink a product, such as copy- demonstrates capabilities of generic design
ing a giant water lily structure into a spoiler or transferring the growth of a slim methods linked with future additive manufactur-
mold into design mathematics, as demonstrated by a Bionic-Partition project ing production, leading to a 45% weight reduc-
with 3D design software company Autodesk and other partners. The project tion and therefore saving around -3 tons of fuel/
year for an A320 aircraft (FIGURE 6).
FIGURE 6. The Bionic-Partition project demonstrates capabilities of generic design PETER SANDER (peter.sander@airbus.com) is VP of Emerging
methods linked with future additive manufacturing production, saving around -3 Technologies & Concepts Germany at Airbus Operations GmbH,
tons of fuel per year for an A320 aircraft. Hamburg, Germany; www.airbus.com.
Industrial lasers
in China: An observer’s
perspective
CHINESE LASER
INDUSTRIAL EXPORTS
MANUFACTURERS RESPOND
LASER
TO CHANGES IN THE SYSTEMS
MARKET ENVIRONMENT
IMPORTS
DAVID A. BELFORTE
I C
n the view of industrial laser
processing system manufac-
turers in the Western world, H
China is the single largest mar- I N
ket for their products and, poten- A
tially in the near future, a significant
competitor in their home markets.
The estimated market for industrial laser material
processing equipment in China was about $3.8 billion in 2016,
showing a 12.51% compound annual growth rate (CAGR) over the
last five years. Growth in 2017 is expected to be in the 22% range
to an estimated $4.6 billion. Putting this into perspective, the total
global market for laser systems used for material processing was
about $12.6 billion in 2016, so the China market alone represents
one-third of all global system revenues. The hot markets for these
laser systems are in manufacturing operations for smartphones, are about 150 of these companies with annual rev-
sheet metal cutting for fabricated products, batteries for electric enues of more than $5 million.
vehicles, and display panels—the latter an application sector that These domestic suppliers have, since 2010,
vaulted micromaterials processing up by a strong 23% in 2016. exported at a 22% CAGR to an estimated $480 mil-
In 2016, China imported $640 million of industrial laser sys- lion in 2017. The bulk of these system exports have
tems, down from a high in 2014 of almost $1 billion—about a 30% been to other Asian markets in Korea, Taiwan, and
decline. This slowing of imports is expected to continue in 2017 by Vietnam, as well as markets in countries with rap-
another 18%. FIGURE 1 suggests the crossover point for laser sys- idly developing manufacturing industries such as
tems exports vs. imports that may occur in 2018. India and Malaysia.
Looking at this from another perspective, Chinese suppliers of Exports of Chinese laser material processing sys-
laser systems for material processing experienced a 16% CAGR tems to the US and Europe are now in an advanced
in revenues over the past five years. According to sources, there introductory role, as exporters to these markets
grapple with safety and reliability standards. This is especially dif- cutting, and 60,000 units into systems requiring pulsed laser out-
ficult in the Western world, which has established demands for put (<1kW) for marking and microprocessing applications. Of note,
rapid service response and expedited replacement part supply. about 60% of high-power continuous-wave fiber lasers and 30% of
Chinese system suppliers are realizing that the overriding concern lower-power pulsed fiber lasers were from non-Chinese suppliers.
of buyers in the US and Europe is for equipment reliability, even Now, the kicker in the competition situation is that successful
more than system selling price. international industrial laser and systems manufacturers invest
Somewhat mitigating the service and reliability issues is the use of a significant percentage of revenues in product research and
fiber lasers as the power source in many industrial laser systems on development to gain or retain market share in this very compet-
the market. The fiber laser is an itive global market. Two exam-
energy-efficient, long-time-be- China - Import/export industrial laser systems ples include IPG Photonics,
tween-replacement, and easy- 887 911 which reinvested about 7.9% of
to-maintain device that ensures 794 sales (FY17, Q1), and TRUMPF,
724
the prospect of cost-effective 695 660 which reinvested about 10.5%
Import 639
operation in the manufacturing (FY15/16). The result—invest in
525
environment. Long-time reliabil- research & development and
ity has been a major factor in $ million 480 attendant intellectual property
392
boosting fiber lasers to about a 306 338 (IP), and you get positive return
third of the installed base of all 202 223 on your investment.
Export 134
industrial lasers sold. 98 This was not lost on China’s
In 2016, Chinese system man- 2010 2011 2012 2013 2014 2015 2016 2017 government when they drafted
Estimate
ufacturers integrated 70,000 Source: Han's Laser the 13th Five-Year Plan, which
fiber lasers into the units sold. seeks to set a high 6.5% growth
Of these, 10,000 went into high- FIGURE 1. By the end of 2017, exports of Chinese industrial laser rate to improve the average per-
power (>1kW) applications such systems may show a 21.9% CAGR, while imports of equivalent son’s quality of life and for man-
as welding and sheet metal systems may show a -3.4% CAGR since 2010. ufacturers to foster innovation
ACKNOWLEDGEMENT
Valuable assistance in preparing this perspective was provided by
Dr. Qitao Lue (Han’s Laser), Dr. Bo Gu (BOS Photonics), and Allen
Nogee (Laser Markets Research).
REFERENCES
1. See www.news.cn/english.
www.scanlab.de
2. C. Holton, “China’s Belt and Road Initiative presents serious challenges and opportunities for
photonics companies,” Laser Focus World online (Mar. 2, 2017); https://goo.gl/bxqJiZ.
3. J. Perlez and Y. Huang, “Behind China’s $1 trillion plan to shake up the economic order,” New
York Times (May 13, 2017); https://goo.gl/EJzF86.
P
ower electronics constantly pres-
ent packaging technologies with
new challenges to handle ever-
larger currents. At the semiconduc-
tor level, the most important inter-
connection technology by far is wire
bonding with aluminum-heavy wires
in diameters up to 500µm, welded directly onto a bond pad of
the semiconductor chip by an ultrasonic friction welding pro-
cess. These wire bonds have a fuse current of up to 35A for
a wire measuring 20mm in average length. For considerably
higher currents found in today’s power modules, several wires
are bonded in parallel on the chip.
Wire bonding features enjoy major advantages: the bonds are FIGURE 1. The battery cells wired together by a
highly reliable and have long lives; the process is very flexible LaserBonder contains variety of interconnection technol-
because distances and positions of the bonds can be freely pro- a wire-bonder base ogies. At present, the dominating
grammed and adapted; and it is a very cost-efficient process. (left) and a standard battery type is the 18650 lithium-ion
However, two drawbacks to wire bonding are that the bond- fiber laser with a (Li-ion) consumer battery, which is
ing surfaces must be very clean, and the bond pads on chips control unit (right). especially well suited for wire bond-
or substrates must be held rigidly and stably. The thicker the ing with heavy aluminum wire. Here,
bonding wire, the more ultrasonic energy must be employed, the advantages of the continuous bulk joint regarding life-
making it progressively more difficult to clamp the parts rig- time and stability combine with excellent ease of automati-
idly. The bond forces also must increase with thicker wires. zation. This is the reason why wire bonding is by far the lead-
Taken together, these factors set a practical limit to about ing interconnection process for battery cells, for example, at
500µm-diameter wire, as thicker wires pose a danger to sen- Tesla Motors.
sitive chip surfaces. Even here, ultrasonic wire bonding is running into limitations
Nonetheless, larger connector cross-sections have been of manageable currents. 18650 Li-ion-type consumer battery
processed for a few years now using ultrasonic wire bonding. cells are operated with cells below about 20A, allowing a sin-
These are usually rectangular ribbons measuring 2mm wide gle wire to connect a cell to, for instance, a busbar. To connect
and 0.2mm thick, replacing three 500µm-diameter wires. The several cells directly with a bond wire, however, the maximum
main area of application is automotive electronics, especially current carrying capability is soon reached. Moreover, newer
in e-vehicles. cells at the same approximate size are designed for currents
up to 45A and would require several wires in parallel.
Wire bonding The alternative, using the aluminum ribbon mentioned ear-
A further application has developed in the field of e-mobility lier, is not really feasible: on the one hand, these ribbons are
for storage batteries. Depending on their design, they contain still quite expensive, and on the other it is difficult to clamp
Laser welding
Laser welding is an alternative. In sev-
eral regards, it is almost a perfect com-
plement to wire bonding, as it has no
trouble with lower-quality surfaces and
it does not need substantial forces to
clamp the parts during the process.
Also, the connector elements can have FIGURE 2. The LaserBonder’s bonding
large cross-sections to conduct very head with its laser scanner. ends up in a galvanometer scanner that
large currents. Finally, the requirements contains optics generating a very sharp
on the bulk properties of the connectors focus of about 35µm in diameter. The
are lower, leading to lower material cost. optics move the focused laser beam on the bond ribbon, just
As with wire bonding, there are also a few disadvantages— in front of the bond tool.
notably the more difficult automatization compared to wire This bond tool is a modified type of bond wedge from ultra-
bonding. In wire bonding, the connector (wire or ribbon) is sonic bonding. Its main purpose is to hold down the bond rib-
reeled from a spool in a virtually endless manner; is handled bon properly on the contact pad. The rest of the bond head is
solely by the bonder; can be attached in any position and direc- unchanged from the ultrasonic bonder, including the wire or
tion (also with tolerance compensation by pattern recognition ribbon guide and the cutting unit, which indents the ribbon after
systems); and can be cut at any length as needed. the second weld step prior to tearing it off (FIGURE 2).
Laser welding is more complex—a pre-fabricated connect-
ing element must be positioned on the contact points and held Aluminum and copper connectors
there for welding. Therefore, the connector must be handled Ribbon-shaped connectors are preferred over wires for laser
as a separate part and needs to be precisely positioned before bonding. Thanks to their rectangular cross-section, they feature
the laser beam can start working. Furthermore, the connec- a constant profile and, therefore, constant thickness of metal.
tor must be pre-fabricated to the right dimensions, usually as Aluminum is easily processed, as is copper. The latter is
a punched part. Tolerances and height variations in the con- preferred on battery cells because of its higher conductivity.
tact positions cause extra work during process automation. The bonder setup used is still largely restricted to the ribbon
dimensions also used in the ultrasonic bonder—approximately
Laser bonding 2mm wide and up to 0.3mm thick. Larger ribbons don’t pres-
Combining laser welding and wire bonding offers the best of ent a challenge for laser welding, but they do require a differ-
both worlds, and it has now been accomplished within a joint ent layout for feeding and cutting, both of which are under
research project supported by the German Federal Ministry development now.
for Education and Research (BMBF) called RoBE (Robustness In general, copper is considered much harder to process
for bonds in e-vehicles). Besides F&K Delvotec Bondtechnik by laser welding than aluminum because at 1µm wave-
(Munich, Germany) and the Fraunhofer Institute for Laser length, it has poor absorption. One alternative is a green
Technology (ILT; Aachen, Germany), the consortium included laser, which has much better absorption, but a much higher
Audi, Continental, Infineon, and the Fraunhofer Institute for investment cost.
Reliability and Microintegration (IZM; Berlin, Germany). At Fraunhofer ILT, a technology was used that takes advan-
Developed within the RoBE project is the LaserBonder sys- tage of a very small focus spot. The extremely high energy
tem, which consists of two main components: a standard wire density at this local spot permits deep-penetration welding
bonder base from F&K Delvotec and a near-infrared fiber laser instead of heat conduction welding, generating very deep
with 1kW power in a separate unit (FIGURE 1). The laser beam and steep welding zones by internal multiple reflections. It
is brought into the bond head through an optical fiber, and is also termed keyhole welding because of this behavior.
The side effect of a small connection This is an aspect where laser bonding is needed and the bond ribbon is simply
area would normally be a narrow weld- is highly advantageous, as it can make left out. The main advantage of the equip-
ing seam and, therefore, an undesirably the connection on top of the rolled rim of ment is that it can push the connector ele-
high transition resistance. However, this the cell, right next to the plus pole. Having ment down to the contact block, ensuring
is easily avoided by “wobbling” the laser both connections on the top side of the cell a zero welding gap and making the clamp-
beam, superimposed on the linear motion leaves the entire remainder of the cell free ing setup much simpler.
across the ribbon. Because of the programmable laser
An additional beam pattern, a welding interface of any
advantage is that shape within a window about 10mm in
the heat emerging diameter can be formed, allowing large
from the laser spot operating currents. The downward push
is not just dissipated force and required distance can be con-
on both sides of the trolled and monitored, allowing additional
welding seam, but process and parts control. For some
is used efficiently to application areas, it may also be attrac-
melt the area inside tive to have equipment that is capable
the circular move- of both processes with extremely sim-
ment ( FIGURE 3). FIGURE 3. A schematic of the deep-penetration welding process. ple changeover.
The result is a weld
seam in which welding depth and seam of connecting leads, enabling simpler man- Other applications
width can be controlled independently, ufacturing because there is no need to flip There are several further potential appli-
and that delivers consistently shallow the battery assembly, and far more space cations beginning to take shape. The
welding depths into the lower contact pad. available for thermal management of the lower demands of laser bonding regard-
cell to help increase cell lifetime. ing surface quality make it possible
High current capacity/ to bond aluminum ribbons directly to
low weld penetration Different approach for
FIGURES 4 and 5 demonstrate how the larger currents
mechanical strength of the weld seam and Larger prismatic battery cells where much a)
its width can be controlled by the advance larger currents are employed and where
speed and oscillation amplitude of the there are dedicated connector blocks on
laser beam. Under optimized conditions, the battery cell require even larger ribbons.
they can be more than doubled without First steps are under development for rib-
increasing the process time and, there- bons up to 10mm wide and 1mm thick
fore, the energy input. This is also attractive within the framework of FlexJoin, a joint
because the metallurgical properties of the research project funded by the Federal
welding zone depend strongly on the ther- Ministry of Economy and Energy (BMWi). b)
mal load to which it is exposed. An alternative to this is using pre-
Laser bonding allows creating a con- punched connector elements as in con-
necting interface of practically any size ventional laser welding. However, in the
(and correspondingly high current-car- LaserBonder, only a different bond tool
rying capacity) while keeping the weld
penetration depth low. This approach is
Tensile strength (N)
extremely attractive for battery cells. In
small 18650 Li-ion battery cells, the plus 700
P: 400W c)
pole is a hat-shaped, punched sheet 600 df: 30µm
Material: CuFe2P (0.2/0.4mm)
metal disk that is contacted in the cen- 500
ter by a copper ribbon without large 400 50mm/s
forces (FIGURE 6).
300
The second bond to the minus pole, the 100mm/s
200
battery can, is even more advantageous.
The container is made of thin sheet metal 100
measuring 250 to 300µm, which carries 0
0.0 0.1 0.2 0.3 0.4 0.5
considerable risk of excessive heat input Amplitude (mm) FIGURE 5. Wide welding seams at
if it is penetrated by the welding step. Any low welding penetration depth are
uncontrolled heat input would risk degrad- FIGURE 4. Seam strength and oscillation shown with no oscillation (a), at 0.2mm
ing the battery lifetime. amplitude are compared. amplitude (b), and at 0.3mm amplitude (c).
die-cast aluminum housings, without circuit boards (PCBs) and the outer shell Long-term objective
prior surface preparation. This is perfect of many automotive aggregates such as The long-term goal of laser bonding, how-
for ground connections between printed starters or generators, as these should be ever, is bonding directly on semiconduc-
continuous bulk connections without any tors—for example, copper ribbons for high
mechanical or corrosion vulnerabilities for currents on high-temperature wide-band-
a very long lifetime. gap semiconductors such as silicon car-
Those are difficult and expensive to bide. The welding depth and thermal energy
accomplish at present because bolting or input are still too high, creating a high risk of
crimping typically suffer from slow corro- damaging the semiconductor, even where
sion or oxidation. Also, ultrasonic bond- thick copper buffer layers are provided.
ing requires local surface preparation by A novel approach called laser impulse
milling, which generates conductive alu- metal bonding (LIMBO) is under develop-
minum dust and requires expensive dust ment at Fraunhofer ILT, which is designed
removal. Relatively thin (1500 × 100µm) to bond across a defined small gap
aluminum ribbons are perfectly sufficient between the two welding partners. This
for the small grounding currents required, approach decreases the amount of heat
and they can be laser-bonded easily on impinging on the semiconductor surface
the untreated cast aluminum surface. The to a fraction of the regular technology, and
second bond is made directly on a cop- shows great promise for rapid progress in
per landing area on the PCB. If the copper the next few years. ✺
layer on the PCB is very thin, it can easily
be reinforced by soldering an extra copper BENJAMIN MEHLMANN (benjamin.mehlmann@de.fk-
delvotec.com) oversees laser bonding applications
pad to this spot during the standard sur-
and Dr. JOSEF SEDLMAIR handles technical mar-
FIGURE 6. An 18650 consumer battery face-mount device placing process, caus- keting, both at F&K Delvotec Bondtechnik, Ottobrunn,
cell with a laser bond is shown. ing very little extra cost. Germany; www.fkdelvotec.com.
SYSTEM CAN
INTEGRATE FIBER
LASER SOURCE
FIGURE 3. A principle representation of the welding process, which incorporates five main steps.
postponed until the next scheduled main- seam, as well as the power, are variable. Weld seam quality assurance. An inte-
tenance shutdown, as certain misalign- This means that the treatment time and grated, automated weld-seam quality
ment can be compensated by the welding temperature are adjusted flexibly in the assurance system with two cameras eval-
traversing unit. most suitable way for each seam. uates the entire process. The first camera
In case of hard-to-weld material, the The highly efficient deep heat treat- positions the welding head on the middle
weld seam is subjected to inductive heat ment with medium-frequency induction of the joint, and the second camera checks
treatment (pre- and post-treatment) to allows thorough heating of the material and rates the quality of the welded seam. If
obtain a homogeneous hardness profile in the shortest possible time, thus pre- everything passes inspection, the system
across the weld seam. venting a hardness increase on the weld automatically approves (FIGURE 6).
Upon completion of the welding pro- seam and the consequent risk of strip Calculation of welding parameters. The
cess, the edges are removed with a side breakage (FIGURE 5). The special inductor welder is adjusted by automatic adaptation
notcher to ensure reliable strip travel and design considerably reduces the hold- of the welding parameters. With this sys-
to allow the edge trimming shear down- ing time compared to conventional sys- tem, new material pairings can be welded
stream in the line to move into the contin- tems. This allows welding of hard-to-weld without extensive testing. It uses level 2
uous strip. The material cut-offs can also materials like martensitic or high-carbon/ data for cast analysis and thickness to cal-
be used for weld seam testing. silicon grades. culate carbon equivalents, and features a
database with suitable welding parameters.
Position 1 Position 2 Thanks to automatic calculation of the
welding parameters for every individual
material combination, even strip combi-
nations of unknown steel grades will be
welded. The correct welding parameters
for the combination to be welded are
determined immediately and reliably with-
out having to spend time on test welds
and lengthy searching in databases. All
Welding
it takes for the calculation are the geo-
Pre-heating Change of post-heating
start point possible metric strip data and analysis of the steel
melt of the two steel strips. These data are
usually stored in the production computer
Temperature
and can be transferred to the computer
of the welding machine. Therefore, test
welds on the production plant or prob-
Time lems when welding new material combi-
nations now are a thing of the past.
FIGURE 4. The system for pre- and post-heating of the weld seam with freely selectable Low cycle time. Another desired fea-
start points and temperatures. ture of the machine is its <60s cycle time,
Failures
Geometry
FREE
SUBSCRIPTION
Process emission
FIGURE 6. The welding machine’s quality assurance system enables automatic weld
release.
thanks to its simplified design for the pro- This extreme flexibility of the welding
cess. Most machine movements are per- machine guarantees that, for example,
formed linearly and are position-controlled, hybrid laser beam welding for joining stain- Industrial Laser Solutions is the
as encoders for all movements allow for less steel strips can be used without hav- leading media resource for laser
safe and fast positioning of the machine. ing to carry out major revamps.
materials processing and
The exchanging time for the machine’s
top and bottom knife cassettes in the shear Solid-state laser
manufacturing professionals.
is extremely short—they can be changed In former projects, SMS group installed Industrial Laser Solutions
in <20 min. This is a result of a smart multikilowatt CO2 lasers—either 12kW magazine, email newsletters
machine design, with no additional equip- (TRUMPF) or 8kW (Rofin-Sinar). For this and website deliver unique,
ment needed inside the machine to allow latest project, the company will install a unbiased, and in-depth technical
this quick-change procedure. solid-state laser for the first time—a 10kW
information about the
Selectable welding source. Thanks to fiber laser (IPG Photonics). When com-
the modular design of the welding machine pared to a conventional CO2 laser, the laser
innovations and challenges
and the consequent separation between beam is generated in a resonator with a specific to the industry.
weld seam preparation and the welding laser-active fiber. Thanks to its high wall-
process itself, the welding source can be plug efficiency and almost no power con- Request your
easily replaced. This allows use of a con-
ventional carbon dioxide (CO2) laser source
sumption in stand-by mode, operating
costs will decrease up to 90%.
FREE
or a solid-state laser source. With a solid-state laser, it is possible to subscription today!
The weld seam preparation with align- save or even avoid process gas (for exam-
ment, fine cutting, and joining of the ple, helium), and reduce the maintenance
Industrial-Lasers.com/
two strip ends is performed by separate effort. An excellent feature of the system
subscribe
machine modules. Subsequently, the weld- is its simple modular structure, which is
ing source is moved with a welding travers- almost maintenance-free. What’s more,
ing unit along the joint between the two solid-state lasers come with a compact
strip ends. In doing so, the position and design and small footprint with a flexible
traversing speed of the welding source process laser fiber, enabling plant con-
can be adjusted individually. This fulfills cepts to be kept simple.
an important condition for enabling other The solid-state laser process is rougher
welding sources to be used in the future. and more turbulent in comparison to a con-
Furthermore, various welding procedures ventional CO2 laser source with process
can be combined. stability, especially on thicker grades above
Installations
The X-Pro laser welder for a new pickling line/tan-
dem mill at Big River Steel (Osceola, AR) welds
almost 1.5 million tons of steel strips per year
(FIGURE 7). Commissioning took place in 2016.
After the welding process, the material, includ-
ing the welded joints, will not only be pickled,
but also rolled in a five-stand, four-high tandem
mill. This means the 1.4- to 5.0mm-thick strip will
be reduced to a final gauge between 0.27 and FIGURE 7. The X-Pro laser welder is integrated in the new pickling line/
1.4mm. Even steels with high silicon will be pro- tandem cold mill at Big River Steel.
duced on this line and, therefore, welded.
SSAB Europe has awarded SMS group an
order covering the modernization of a continuous pickling line With the installation of an X-Pro fiber laser welder and a high-per-
entry section in its Hämeenlinna, Finland plant. This moderniza- formance tension leveler, it will be possible to produce modern,
tion will significantly increase the line’s availability and its output, high-strength steel grades with high alloy contents. The conversion,
as well as the degree of automation and safety. including modification of the complete electrical and automation
equipment, will be accomplished in two phases, and is scheduled to
be completed by the end of 2018. With the new equipment, the line
will be able to process materials with yield points of up to 900MPa.
Higher capacity at lower operating costs will be a further benefit.
An essential element of the modernization is the X-Pro laser
welder with solid-state laser. In 2015, SSAB had sent diffi-
cult-to-weld, high-alloy plates from its own production to SMS
group, which have been welded with the machine using a fiber
laser source.
The line is designed for strips with thicknesses between 1.5 and
6.5mm and widths from 650 to 1650mm. In the processing sec-
tion, the strips will be pickled in the turbulence pickling tanks at a
speed up to 180m/min, whereas the maximum strip speed attain-
able in the entry section will be 400m/min.
Strip processing lines are facing several challenges when it
comes to flexible, economical, and safe welding of modern steel
grades. The X-Pro laser welder, which is easy to maintain and can
easily be integrated in existing lines, is able to produce hard-to-
weld strip materials.
The welding machine offers several beneficial features, includ-
ing patented inductive heat treatment, automatic parameter calcu-
lation, a quality assurance system, low cycle time, and exchange-
able laser sources. One special new feature is the integration of a
modern solid-state welder, which decreases operational costs. ✺
ACKNOWLEDGEMENT
X-Pro is a registered trademark of SMS group.
ROBERT J. KOLCZ
P
& A Metal Fab (Clackamas, OR) has been a suc-
cess story in the Pacific Northwest for decades.
According to industry observers, the company
has a winning business philosophy that is very FIGURE 1. Dan Aronson, president of P & A
straightforward: To provide everything a customer Metal Fab, and his research team purchased the
needs, charge a fair price, and deliver the job on Prima Power LPe6f laser/punch combination
time...every time. This dedication to service and machine that was installed in August 2016.
quality helps to explain the deep loyalty among customers and employees,
many of whom have worked for the company for over 20 years.
Phil Aronson, father of company president Dan Aronson, started P&A four employees to research the sheet metal fabri-
Metal Fab in 1978 out of a two-car garage a few blocks from its present loca- cation market to find a replacement. After talking
tion in Clackamas. “By 1991, the company grew into a fair-sized business,” to several machine builders, industry experts,
Dan Aronson explains. However, by that time, Phil Aronson was approach- and other fabricators, P & A Metal Fab pur-
ing retirement and later that year, he sold the company to the Kyoshin Giken chased a Prima Power LPe6f laser/punch com-
Company (Tokyo, Japan). His son Dan stayed on in senior management bination machine, which was installed in August
and later in 2007, he and another Japanese entity, Tsuguaki Takahashi, pur- 2016 (FIGURE 1).
chased the company and formed a new trans-Pacific partnership that offers
the partners greater reach and new opportunities. Combination machine
Today, P & A Metal Fab has evolved into a contract manufacturing pow- capabilities and features
erhouse with 90 employees, working in three facilities with over 75,000 The machine combines servo-electric punch-
sq. ft. of space. The company has also acquired an arsenal of laser cut- ing and fiber laser technology in a manufactur-
ting, fabricating, tube processing, welding, and powder coating to service ing solution that provides flexibility, speed, accu-
its diverse customer base, including air handling equipment and industrial racy, and productivity to fabricate challenging
and consumer products such as computer furniture, all-terrain vehicles, products (FIGURE 2).
and fitness equipment. The inherent benefit of integrated punching
Staying up to date with leading manufacturing technology has also been and laser cutting is high versatility. The turret
a long-term company goal. When the company decided to replace an older punch press can be used where it is easier or
model laser punch combination machine, Aronson put together a team of faster, and the laser where it is most flexible.
PROCESS MONITORING
DAVID GILLEN
U
ntil recently, laser cleaning has
been limited in application,
yet videos of handheld laser
cleaning systems generate
millions of hits on the Internet.
Therefore, laser cleaning is FIGURE 1. An
advancing and companies can range in power from 20 up to 1000W. example of rust
such as Blueacre Technology (SIDEBAR) are now implement- Laser cleaning systems with powers of removal from a steel
ing similar principles used in medical device and semi- 4kW are in development and will be on component using
conductor processing, where the laser process is supple- the market soon. Low-power laser clean- laser cleaning.
mented with ancillary processes to increase process yield ers tend to be portable and suitable for
and reduce overall production costs. handheld usage, whereas the higher-power laser cleaners are
integrated into 24/7 production environments with a high degree
Laser cleaning of automation (FIGURE 2).
At its most basic, laser cleaning is a process a) Remanufacturing is the process of returning a product
in which optical radiation is directed to a part to at least its original performance with a warranty that
to remove unwanted material from the surface. is equivalent to or better than that of the newly manufac-
The surface contamination tends to be rust on tured product. A recent study published by the EU shows
steel, oxide layers on aluminum prior to weld- a market of €30 billion in Europe, employing 130,000
ing, and coatings such as paint. people across many sectors, including aerospace, rail,
As shown in FIGURE 1, laser cleaning is very and automotive.
efficient at surface layer removal. Lasers
used for cleaning have high power and high b)
beam quality (M2) values, resulting in larger
spot diameters and a deep depth of focus.
Therefore, lasers can clean parts with mul-
tiple surfaces, each of which may be at a
significantly different
focal depth. FIGURE 2. Low-
Depending on the part power (a) and
to be cleaned and the high-power (b)
material to be removed, laser cleaning
laser cleaning systems systems.
Not cleaned First pass Second pass Third pass Fourth pass
FIGURE 4. Examples of carbon steel laser-cleaned with 250W power, a 10kHz pulse rate, and Vgalvo = 2000mm/s.
FIGURE 6. The
remaining defects in
this stainless-steel
sheet laser-engraved
with the CE symbol
are easier to see after
laser polishing.
LASERBITS tial sites for failures. Laser polishing makes the inspection of such
defects simpler and more amenable to automated vision systems.
To demonstrate the effectiveness of this process, an area on
a stainless-steel sheet was laser-engraved with the CE symbol
(FIGURE 6). Prior to laser polishing, the surface of the stainless steel
Shop our expanded collection of laserable
had multiple scratches and blemishes. Laser polishing of the area
products at JPPLUS.COM.
with the CE symbol removes all but the deepest of scratches, but
the remaining defects are easier to visualize afterward. Also, as
laser polishing is automated, it produces consistent results and
the lighting parameters used in the vision system do not need to
be altered to suit the polishing.
With the current push for Industry 4.0, the ability to inspect parts
and gather data on defects allows models to be built up that can
predict when and where failures will occur. This allows for a reduc-
tion in downtime and for parts to be cleaned and repaired only
when required.
As laser average power continues to increase and laser cost
continues to fall, processes such as laser cleaning and laser pol-
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as well as being suitable for automation. Ongoing work with inte-
grated vision systems are offering increased functionality not seen
in the current market and have the potential to greatly increase
their productivity. ✺
JPPLUS.COM • 1-800-869-7800
DAVID GILLEN (dgillen@blueacretechnology.com) is the CEO of Blueacre
Technology, Dundalk, Louth, Ireland; www.blueacretechnology.com.
SEPTEMBER NOVEMBER
18-22 Laser Safety Officer with Hazard 1-2 Advanced Engineering 2017,
Group Publisher Alan Bergstein
(603) 891-9447 • alanb@pennwell.com Analysis Training, Rosemont, IL; www. Birmingham, England; www.easyfairs.
Editor-in-Chief David A. Belforte
lia.org/training/non-medical/classroom- com/advanced-engineering-2017/
(508) 347-9324 • FAX: (508) 347-7737 • belforte@pennwell.com courses/laser-safety-officer-hazard- advanced-engineering-2017
Associate Editor Lee Dubay analysis-training/2017-09-18
4-5 Medical Laser Safety Officer Training,
(603) 891-9116 • leed@pennwell.com
18-23 EMO Hannover 2017, Hannover, Miami, FL; www.lia.org/training/medical/
Editorial Assistant Virginia E. Belforte
Germany; www.emo-hannover.de classroom-courses/medical-laser-safety-
International Editorial
Advisory Board Tony Hoult – PhD, BSc (industrial applications for fiber lasers)
officer-training/2017-11-04
25-28 Canadian Manufacturing
Hua-Chung Man – PhD, MS, BS (laser processing in China) Technology Show 2017, Mississauga, ON, 6-9 FABTECH 2017, Chicago, IL; www.
Geoff Shannon – Ph.D., BS (laser welding, micromachining)
Stan Ream – MS, BS (laser materials processing) Canada; http://cmts.ca fabtechexpo.com
Ronald D. Schaeffer – PhD, MS, BS (laser micromachining)
Milton S.F. Lima – Ph.D., MS, BS (laser processing in South America) OCTOBER 6-9 The 30th International
Kunihiko Washio – PhD, MS (solid-state laser materials processing in Japan) 10-11 Special Interest Group Meeting: Microprocesses and Nanotechnology
Anant Deshpande – MS, MBA, M.Tech (laser processing in India) Conference (MNC 2017), Jeju, Korea;
Additive Manufacturing, Leuven, Belgium;
Creative Director Meg Fuschetti www.euspen.eu/events/special-interest- http://mnc2017.org
Production Manager Sheila Ward group-meeting-additive-manufacturing- 6-10 Laser Safety Officer with Hazard
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14-15 Medical Laser Safety Officer training/non-medical/classroom-courses/
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medical-laser-safety-officer- 8-9 MD&M Minneapolis, Minneapolis,
training/2017-10-14 MN; www.mdmminn.com/info
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16-20 Laser Safety Officer with Hazard 15-16 Industrial Laser Safety Officer
EDITORIAL OFFICES Industrial Laser Solutions For Manufacturing
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Business Solutions Manager, Samantha Forrest DECEMBER
Buyers Guide and Events (918) 831-9854; samanthaf@pennwell.com Processing with Laser Technology,
6-8 Additive Manufacturing Americas
North American: East & Central Jeff Nichols Porriño, Spain; www.aimen.es
2017, Pasadena, CA; www.amshow-
(413) 442-2526 FAX (413) 442-2527 • jeffn@pennwell.com
22-26 ICALEO 2017, Atlanta, GA; americas.com
North American: West & Mountain AnneMarie St. John-Brooks
(510) 606-0630 • annemarie@pennwell.com www.lia.org/conferences/icaleo
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Hong Kong/China Mike Hay
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Israel Dan Aronovic
972-9-899-5813 • aronovic@actcom.co.il INDEX OF ADVERTISERS
Japan Masaki Mori
81-3-3219-3561 • mori-masaki.@ics-inc.co.jp Advertiser ............................................................................................................. Page
Taiwan Diana Wei
886-2-2396-5128 FAX: 886-2-2396-7816 • diana@arco.com.tw Aerotech, Inc.................................................................................................................. 8
CORPORATE OFFICERS Gentec Electro-Optics, Inc. ......................................................................................... 23
Chairman Robert F. Biolchini
Vice Chairman Frank T. Lauinger
II-VI, Inc. ...................................................................................................................... C2
President and Mark C. Wilmoth Laser Mechanisms, Inc................................................................................................C3
Chief Executive Officer
Executive Vice President, Jayne A. Gilsinger Laser Research Optics .................................................................................................10
Corporate Development
and Strategy Ophir-Spiricon, Inc. ....................................................................................................... 7
Senior Vice President, Brian Conway PhotoMachining........................................................................................................... 20
Finance and Chief Financial Officer
TECHNOLOGY GROUP Rowmark, LLC.............................................................................................................. 26
Senior Vice President and Christine A. Shaw
Publishing Director Scanlab AG ...................................................................................................................11
Synrad, Inc................................................................................................................... 15
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F
or those readers that follow my industry itself has become more sharing, and
blogs on www.industrial-lasers. ILS has tapped resources there to publish back-
com, you’ll recall that I have been ground information on this vibrant market.
digging into early published ref- In addition, this month we also offer readers a
erences to establish the first ap- look at proven applications in laser additive manu-
pearance of the term “industrial laser.” In doing facturing, fiber laser cutting and welding, and sur-
so, I couldn’t help but notice among them the fol- face treatment.
lowing titles: Our cover features Airbus, who made their first
steps into additive manufacturing in flying aircraft
• “Will Laser Make Grade as Proven Welding in 2014. Peter Sander (Airbus Operations GmbH)
Process?” – Iron Age (1964) tells how the company uses a multistep approach,
• “Lasers Ready for Production Role” – from first parts to clean sheet design (see page 5).
CURRENT GROWTH
Steel (1964) Benjamin Mehlmann and Josef Sedlmair (F&K
• “Laser Applications Invade Production Field” Delvotec Bondtechnik GmbH) describe combin-
PROSPECTS FOR – Automation (1968) ing a 1kW fiber laser with a heavy-wire bonder to
• “The Great Potential of Laser Beams in connect copper ribbons measuring several milli-
INDUSTRIAL Industry” – The Engineer (1969) meters wide with excellent connection quality and
• “Will Lasers Serve as Heat Treaters Ally” – high speed, specifically for battery pack connec-
Iron Age (1970) tions for e-mobility (see page 12).
LASERS POINT TO
• “Laser Makers Finally Get Practical” – Christian Dornscheidt and Caesar Sasse (SMS
Purchasing Week (1971) group) describe the production of hard-to-weld
THE CHINA MARKET • The Laser May Be Ready For the Big Time – strip materials using patented inductive heat treat-
Business Week (1971) ment, including information about fiber lasers
and weld-seam heat treatment on recent installa-
I especially liked the last one because it actually tions for pickling lines in Finland and in Arkansas
took 29 years before industrial laser system reve- (see page 16).
nues cracked the billion-dollar mark in 1990, which I’m happy to welcome back Bob Kolcz
I consider the big time. Sales passed $5 billion in (Prima Power), who writes about P & A Metal
2006 and $10 billion in 2011, and revenues are pro- Fab (Clackamas, OR), a contract fab shop that
jected for more than $13 billion this year. installed a laser/punch combination machine that
A major contributor to this growth in the last provides them with outstanding flexibility, speed,
few years has been the China market, which today accuracy, and productivity (see page 21).
makes up about a third of all industrial laser sys- David Gillen (Blueacre Technology) says that in
tem revenues. In my article describing this vibrant the past, laser cleaning applications have been
market, I point out that estimated laser process- limited. However, he says now it is advancing, as
ing equipment sales in China are expected to top companies are implementing similar principles
$4.5 billion, or 35% of the total market (see page used in medical device and semiconductor pro-
9). No wonder all eyes are on China when consid- cessing to increase yield and reduce overall pro-
ering the growth prospects for industrial lasers. duction costs (see page 24).
It’s a difficult market for analysts to understand
as verifiable in the form of available official gov-
ernment historical statistics—which are not avail- David A. Belforte
able, at least to Westerners. Fortunately, the laser belforte@pennwell.com