THE PUBLICATION FOR INTEGRATORS LASER AND USERS OF LASER SYSTEMS SYSTEMS INSIDE Surface EUROPE treatment ISSUE 50 SPRING 2021 Additive manufacturing Polymer welding
Powering down Underwater cutting for nuclear decommissioning
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LASER Powering through SYSTEMS the pandemic EUROPE Matthew Dale, editor
News 4 Analysis: Additive manufacturing 25 l Coherent bidding war underway Siemens Tim Lantzsch and his colleagues investigate the l Energy upgrades gas turbine blades Laser feasibility of diode lasers for the laser powder l cutter add-on ‘prints’ electronics EU initiative bed fusion of stainless steel l Despite the many challenges posed seeking laser-based solutions Diode lasers l Application focus: 28 by the pandemic, laser technology has developed for metal 3D printing US Navy tests Surface treatment laser cleaning found multiple opportunities. Between Feature: Fibre lasers 10 Handika Sandra Dewi explores the effects Keely Portway’s medical devices feature of circular, square and triangular oscillation on page 12 and Dave MacLellan’s article Greg Blackman asks experts to recap what strategies when treating microalloyed steel on page 34, we learn about the role that 2010-2020 held for the dominant technology in Application focus: Cutting 31 lasers have played in increasing the laser materials processing manufacture of life-saving ventilators, Jan Leschke and his colleagues have Feature: Medical devices 12 as well as exercise equipment, which developed a new process for dismantling Keely Portway explores the use of lasers in nuclear equipment both saw a dramatic spike in demand medical device manufacturing, including how AILU news 34 last year throughout lockdown. they have played their part since the start of the For the manufacture of certain pandemic Dave MacLellan looks at the opportunities medical devices, transparent polymers Ultra-thin glass processing 16 that have arisen for laser technology during the need to be welded, which laser pandemic technology is now starting to be Ultra-thin glass offers exciting opportunities but Products 35 used for. However, the process still poses exceptional manufacturing challenges, lacks stability and productivity, which The latest equipment for industrial laser Matthew Dale finds researchers have therefore been processing Analysis: Polymer welding 20 working to address, as described on Suppliers’ directory 38 Frederik Maiwald and Stefan Hierl determine page 20. the optimal parameters for welding transparent Find the suppliers you need While Greg Blackman’s article on page polymers used in optical and medical devices 10 highlights the continued dominance Analysis: Additive manufacturing 22 of fibre lasers in materials processing, a recurring element in this, our 50th, issue Manyalibo Matthews shares how a deeper is the application of diode lasers to understanding of LPBF will lead to material metal additive manufacturing. innovations and new applications in additive In our news section you can read manufacturing about the development of photonic crystal surface emitting laser diodes that researchers claim could lead to an entirely new class of next-generation, 3D printers. Meanwhile, on page 22 laser diodes Supported by the LIA have been used to influence the microstructure and materials properties of 3D printed parts, while the article on page 25 considers how challenges associated with low beam quality can
Editorial and administrative team Subscriptions: Free registrations available to qualifying individuals. Subscriptions be overcome when using diode lasers in £120 per year for four issues to readers outside registration requirements. Managing editor: Greg Blackman Enquiries to Europa Science, 4 Signet Court, Cambridge CB5 8LA, UK. additive manufacturing. [email protected] Tel: +44 (0)1223 221042 Tel: +44 (0)1223 221030. Fax: +44 (0)1223 213385. Editor: Matthew Dale ©2021 Europa Science Ltd. [email protected] Tel: +44 (0)1223 221047 While every care has been taken in the compilation of this magazine, errors or omissions are not the responsibility of the publishers or of the editorial staff. Advertising team Opinions expressed are not necessarily those of the publishers or editorial staff. Advertising manager: Jon Hunt All rights reserved. Unless specifically stated, goods or services mentioned are not [email protected] Tel: +44 (0)1223 221049 formally endorsed by Europa Science Ltd, which does not guarantee or endorse or accept any liability for any goods and/or services featured in this publication. US Production manager: David Houghton copies: Laser Systems Europe is published by Europa Science Ltd and distributed [email protected] Tel: +44 (0)1223 221034 in the US by DSW, 75 Aberdeen Road, Emigsville PA 17318-0437. Periodicals postage paid at Emigsville PA. Corporate team Managing director: Warren Clark Postmaster: Send US address changes to Laser Systems Europe, PO Box 437, Emigsville PA 17318-0437. [email protected] Cover: Shutterstock Laser Systems Europe is published by Europa Science Ltd, 4 Signet Court, Cambridge, CB5 8LA, UK. Subscribe online for FREE at Tel: +44 (0)1223 221030 Fax: +44 (0)1223 213385 l www.lasersystemseurope.com/subscribe Web: www.europascience.com ISSN: 1759-0752
WWW.LASERSYSTEMSEUROPE.COM | @LASERSYSTEMSMAG SPRING 2021 LASER SYSTEMS EUROPE 3 We are Novanta Novanta develops cutting-edge components and sub-systems for laser-based diagnostic, analytical, micromachining and fine material processing.
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Pho_LSE-PrintAD_Novanta_Feb_2021 1 09/02/2021 11:28:28 VIEW FOR Free webcasts FREE* Now available online
Since Covid-19 has made it temporarily impossible for us to take part in face-to-face meetings or to visit industry events, Laser Systems Europe and LASYS have joined forces to bring you our series of ‘Lasers in Action’ Webinars.
Here you will find topics concentrating on the application of lasers within various industries. You would have usually have seen these presentations at LASYS, but now you can enjoy them at your leisure.
Lasers in action Lasers in action Lasers in action Webinar #1 Webinar #2 Webinar #3
High-Power High-Brightness Blue Lasers Nano-Structured Anti-Reflective Surfaces Laser welding: High-speed laser beam for Energy Storage & E-Mobility for Laser Optics Applications measurement optimizes development process Nuburu will present on the advantages of its Anti-reflective coatings are essential for optical During the development of a new laser shorter wavelength Blue lasers in comparison applications where back reflection can cause process, documenting the process conditions with IR of Green for variety of applications and issues like glare or damage to other parts of the is often time consuming but always essential. materials being welded in the Battery and setup. Traditional anti-reflective coatings are This presentation shows how non-contact e-mobility sectors. sensitive to the wavelength, angle of incidence measurement technology for high-power laser Richard Gleeson, and can get easily damaged under high power beams was used to speed-up and improve the Director European Operations, NUBURU INC. applications. Here, we show how our Nebular development of a multi-focal laser welding Technology overcomes these limitations by using process in the automotive industry. Fully Automated Monitoring of Laser Welding reactive ion etching to create nano-strutured Nicolas Meunier Processes in E-Mobility Applications windows. The results show that Edmund Optics Business Development Manager High Power With thousands of welds per day, most laser Nebular windows present high transmission & Automotive Products Ophir welding applications in e-mobility demand for over a broad wavelength range, are angle of automated process monitoring. 4D explains their incidence insensitive and have a LIDT close to Processing smallest structures in electronics online monitoring principle and how their system that of the bulk material. and probe card manufacturing is integrated into your application. Explore Dr. Sara Castillo, Relentless miniaturization in both consumer the different real world examples with 4D’s Laser Optics Sales Specialist – Europe, electronics and mechanical engineering has monitoring expert Christoph Franz. Edmund Optics brought plenty changes to the fabrication of Christoph Franz, such electronic components as PCBs, control CEO, 4D Diffractive and Metasurfaces: elements, and sensors. This development also from Function to Structure Simulation influences demands placed on laser processing Trust in your laser process with real-time Seamlessly in VirtualLab Fusion machines used in micromachining. Difficult-to- temperature monitoring We present a seamless workflow in the physical- handle materials such as polymers and ceramics Finding and especially keeping the right recipe optics software VirtualLab Fusion for the design present a special challenge. Today’s processing for your Thermal Laser Process is all about a and analysis of diffractive and metasurfaces. limits can be newly defined by employing a strong trust in constant process parameters. An example will be shown on the design of a precession bore system with a green laser. Unfortunately, minor variations of the resources metagrating for large-angle beam splitting Dr. Holger Schlueter can force a major impact on the final results. application. That includes the rigorous analysis Business Development SCANLAB GmbH In order to detect and compensate deviations, of the metasurface unit cells, the spatial the real-time temperature monitoring system arrangement of them, and a full analysis/ Laser welding solutions for e-mobility of SPOLD and LD-Heater helps you to not only optimization of the whole structure. applications by PRECITEC improve quality, but also save running costs and Dr. Site Zhang, Precitec stands for laser cutting, laser welding time. In addition to other thermal applications, CTO (Chief Technology Officer), LightTrans and optical measurement. This presentation we want to show the key feature of the laser demonstrates how our products forward system for Laser Plastic Welding and Laser Laser technology for the automotive industry e-mobility and how our sensors enable
Sintering. How CO2 lasers are used by automotive innovative production processes based on Alexander Goerk, manufacturers and their sub-suppliers to artificial intelligence. Senior Sales Engineer Industrial Components, increase productivity Dr.-Ing. Jens Reiser Hamamatsu Photonics Deutschland GmbH Thorsten Föcking, Team Leader Sales & Support Regional General Manager, Luxinar GmbH Precitec GmbH & Co. KG Blue Diode Laser constantly pushes the limits in applications Latest Cladding Applications with Diode Lasers Since the invention of a blue LED which was The presentation goes through recent diode even honored by the Nobel prize, blue laser laser applications in particular EHLA (Fraunhofer radiation became an interesting opportunity ILT cladding) processes for very thin coating to the industrial production of high reflective applications at high speed and also covers novel material, especially copper. The blue light of the applications on brake disks for reduction of fine latest lasers from Laserline has a high absorption dust. and thus, allows spatter free welds in either heat Andre Eltze, conduction or key hole welding mode. We want Dr.-Ing, Senior Sales Manager, Laserline to review the approach to blue in technology and application using such blue laser and have an outlook for the future as well. Markus Rütering, Dipl.-Ing. Sales Director, Laserline *Registration required
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LASERS IN ACTION
Lumentum acquisition offer ignites Coherent bidding war IN BRIEF
Blue diode laser Laser manufacturer Coherent Now, however, II-VI states its Coherent’s existing merger manufacturer Nuburu has received two more proposal represents a premium agreement with Lumentum and has been awarded eight acquisition proposals after its of 24 per cent to the implied the recent acquisition proposal new patents across 3D value of Coherent’s merger printing and materials acceptance of a $5.7bn offer from MKS Instruments, as it is processing. from Lumentum in January. agreement with Lumentum a more compelling strategic fit On 8 February Coherent and a premium of 9.8 per and would provide Coherent’s The Photonics West confirmed receipt of a cent to the implied value of shareholders with meaningful conference has been proposal around $6bn MKS Instruments’ acquisition upside opportunity. switched to an online from MKS Instruments, the proposal. ‘We are confident our format, to take place global metrology systems ‘The combination of II-VI transaction would have greater from 9 to 11 March. provider. Then on 12 February, and Coherent would create certainty of closing. We have Fraunhofer ILT has semiconductor specialist II-VI not identified any competitive demonstrated that its announced it had proposed a overlaps between Coherent’s extreme high-speed deal worth around $6.4bn. “Our proposal and II-VI’s respective laser cladding process At the time of writing, is far superior businesses in China. We believe can be used to coat Coherent’s board of we would have significant and industrial rollers at to Coherent’s directors still recommends diversified opportunities to speeds up to 200m/min. existing merger the Lumentum offer to agreement with accelerate our growth through Porsche has used SLM its stockholders. It has complementary technology Solution’s new 12-laser announced, however, that it is Lumentum and the platforms, to increase our metal 3D printer to in discussions with both MKS recent acquisition competitiveness by using print the complete and II-VI after its financial and proposal from MKS scale across the value chain, housing for an electric legal advisors determined to demonstrate deeper market drive for the first time. Instruments” that one of the two new intelligence and expertise, and The Photonics Systems proposals could lead to a further diversify our businesses Group announced the superior transaction than the and revenue streams.’ merger of two of its Lumentum offer. a uniquely strategic global II-VI’s proposal follows companies: LS Laser Prior to the II-VI proposal, leader capable of delivering news that it will jointly develop Systems and EPP Alan Lowe, president and CEO to our customers the most optimised, integrated welding Electronic Production attractive combination of Partners. at Lumentum, responded subsystems with Coherent. to the competitive MKS bid: photonic solutions, compound The collaboration – a supply The Laser World of ‘We believe our transaction semiconductors, as well as agreement – will combine Photonics exhibition is superior. In contrast to the laser technology and systems,’ II-VI’s RLSK and HIGHmotion has been postponed proposal by MKS Instruments, said Vincent Mattera, CEO at 2D remote laser processing until Spring 2022 due the Lumentum-Coherent II-VI. ‘We believe now is the heads with Coherent’s to the uncertainty transaction has a clear path right time to embark on this Adjustable Ring Mode (ARM) surrounding Covid-19 travel restrictions. to regulatory approval and combination given significant fibre laser technology. The completion, and Lumentum megatrends, with burgeoning resultant subsystems will remains committed to closing applications in both industrial deliver power adjustment and the transaction in the second and semiconductor capital beam positioning on the fly, to half of the year.’ equipment segments, including produce optimal, high-quality Lumentum also claimed those that enable consumer welds at a very high speed and that MKS’ proposal letter electronics and displays. over large working areas. l to Coherent contained ‘We firmly believe our Follow this story at ‘misleading statements’. proposal is far superior to www.lasersystemseurope.com
4 LASER SYSTEMS EUROPE SPRING 2021 @LASERSYSTEMSMAG | WWW.LASERSYSTEMSEUROPE.COM NEWS
EU initiative to augment laser-based solutions with advanced digital tools
The EU initiative Pulsate least two SMEs and/or slightly the technology providers will to its specific operational has launched an open call bigger companies, one acting have a product capable of environment. for technology transfer as a technology provider and addressing the needs of the Pulsate will select 10 TTEs experiments (TTEs) featuring the other (a manufacturing manufacturing sector, while the overall to participate in the innovative laser-based company) acting as an end user. end user will have a validated programme. Submissions can solutions. By the end of the programme, prototype system applied be made until 22 April. The initiative seeks to promote a pan-European network designed to boost the adoption of laser-based advanced and additive manufacturing technologies through the uptake of advanced digital tools. Selected TTEs will become part of a 13-month support programme, during which Pulsate partners will offer a full set of technical and business mentoring services to scale up the experiments. Each TTE will also be funded with a grant of up to €150,000. The result will be the development of innovative laser-based equipment, processes, ancillary equipment
and software adapted to flexible production environments. TURNKEY LASER The solutions will target SMEs and will be equipped with MACHINES digital tools that improve their productivity, flexibility and Welding, cutting, marking—solve your traceability, lowering their manufacturing and fabricating challenges barrier to entry. by utilizing a broad range of laser-based Applicants of the materials processing solutions from open call should address Coherent. the development and implementation of technology From medical devices to electronics, and systems applicable to laser- automotive to packaging, consumer based equipment for advanced goods to jewelry—our turnkey laser and additive manufacturing. machines enable you to achieve greater This should be in the following efficiency, higher speed, and reduced cost of operation. areas of experimentation: Laser equipment integration, interoperability and robust automation; technology for cost effective laser-based manufacturing; first part right and zero-defect laser-based Learn more at production; and flexible coherent.com/systems technology for small to large +1 800 367 7890 batches. The TTEs must be proposed by a consortium including at
WWW.LASERSYSTEMSEUROPE.COM | @LASERSYSTEMSMAG SPRING 2021 LASER SYSTEMS EUROPE 5 NEWS
Laser cutter add-on enables electronic devices to be ‘printed’ MIT Researchers have created an add-on for laser cutting systems that enables them to ‘print’ functional, custom-made devices and robots, without human intervention. According to the scientists, from MIT’s Computer Science and Artificial Intelligence Laboratory, the technology could be beneficial for product developers, makers, researchers and educators looking to rapidly prototype devices such as wearables, robots or printed electronics. The solution, LaserFactory, comprises two elements: a software toolkit that allows users to design custom devices, and the laser cutter add-on hardware that assembles them, which attaches to the head of a commercial laser cutter. Researchers demonstrated LaserFactory. ‘By leveraging to increase the quality and LaserFactory automatically the system by fabricating a widely available manufacturing resolution of the circuit traces, cuts device geometries, drone, which once completed platforms like 3D printers and which would allow for denser dispenses silver for circuit was fully functional. laser cutters, LaserFactory is and more complex electronics. traces, picks and places ‘Making fabrication the first system that integrates They also want to build on this electronic components, and inexpensive, fast and accessible these capabilities and technology by exploring how cures the silver to make the to a layman remains a automates the full pipeline for to create a fuller range of 3D traces conductive, securing challenge,’ said PhD student making functional devices in geometries, potentially through the components in place to Martin Nisser, lead author on one system.’ integrating traditional 3D complete fabrication. an upcoming paper about The researchers hope printing into the process.
UK-Japan project developing diode lasers for metal 3D printing
A £1.5m project is developing route to market for the chips – PCSEL-based chips for 3D although the chips produced metal laser printing. will be suitable for any printer Vector Photonics Vector PCSELs (photonic crystal manufacturer. In addition, the surface emitting laser diodes) UK’s Compound Semiconductor are able to offer high power, Applications (CSA) catapult will high reliability and high undertake reliability testing of manufacturing efficiency to rival the chips. the laser technology currently Currently, 3D printers use used in 3D printing. CO2 or fibre lasers directed by Led by UK firm Vector mirrors to scan over the surface Photonics and funded by of metal powder, melting it Innovate UK, the Bloodline layer-by-layer to form structures Vector Photonics: ‘PCSELs and greater manufacturing project also comprises – a process known as selective offer a unique combination efficiency – the result of higher semiconductor epitaxy laser melting (SLM). of increased laser power, by resolution printing with less and industrial equipment Vector Photonics’ PCSEL scaling up the PCSEL arrays; finishing overheads and faster manufacturers from Japan. technology has the potential to improved reliability, by removing printing speeds. PCSELs will The latter will provide product further optimise SLM, according the mirrors and offering an enable an entirely new class of assessment and, ultimately, a to Dr Richard Taylor, CTO at entirely solid-state solution; next-generation, metal printers.’
6 LASER SYSTEMS EUROPE SPRING 2021 @LASERSYSTEMSMAG | WWW.LASERSYSTEMSEUROPE.COM Laser safety Enclosures for Optical Tables
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Siemens Energy upgrades gas turbine blades using powder bed fusion
Siemens Energy has developed Gas turbine blades become a digital repair chain using damaged over time due to hybrid laser powder bed the high temperatures and gas velocities produced fusion (LPBF) that can add new during their operation features to gas turbine blades. With it, cooling structures that prevent blade tip failure can be implemented in critical areas, meaning turbine blades can be upgraded while being repaired. Due to the coupling of high temperatures with high gas velocities during gas turbine operation, burn-off at the blade tip can occur, ultimately leading to gap formation and a measurable drop in the performance of the entire turbine. This process leads to a vicious circle. With greater gap formation, the temperature of Siemens Energy the blade material increases due to the overflowing hot gas, thus preventing material loss. Energy team, a digital repair the customer to create a real which, in turn, leads to even However, blades that have chain was established that win-win situation,’ said Heiko faster material loss and further been in operation at high can morph the geometry Lammers, an AM advisory increases the gap between the temperatures have individual parametrically. The team expert at Siemens Energy. blade tip and ring segment. shapes, making the LPBF repair also had to develop the LPBF The first blade sets have Using LPBF, structures with more challenging. Therefore, a process for an extremely been manufactured and a inner channels can be produced CAD-CAM chain was developed oxidation-resistant material for conversion of the standard in high resolution on an existing by Siemens Energy that the blade tip. repair procedure to the process component. This high resolution automatically adapts the shape ‘This add-on slows down the is underway, states Siemens is important to incorporate the of the LPBF tip to perfectly tip degradation and ensures Energy. The technology will be new cooling geometries with a match each blade. constant power output for applied to other components, very limited cross-section. With By combining 3D blue laser customers. We can therefore with it being possible to this design, the critical areas scanning with an algorithm raise the value of the repaired upgrade component designs can be cooled more effectively, developed by the Siemens component for both us and using this digital repair chain.
US Navy tests laser cleaning technology on aircraft components
The US Navy has tested laser amount of consumables, can benefits of laser cleaning. The ATI team will now develop a cleaning technology on aircraft be dangerous to operate, and Laser Adapt support components to remove require extensive PPE. The cost-benefit analysis that could corrosion and other hazardous FRCE Advanced Technology lead to the handheld laser coatings safely. and Innovation (ATI) team and system’s procurement. The technology was tested materials engineering division Despite such units costing by Fleet Readiness Center East have therefore been looking to between $400,000 and (FRCE), a division of the US Navy adopt laser ablation technology $500,000, the FRCE engineers that provides maintenance, at the facility to address these said they expect the system repair and overhaul support to issues. would pay for itself in the long the weapons platforms of the Laser solutions provider with various coatings. The run – with reduced costs for Marine Corps. Adapt Laser recently demonstration was attended by purchase and disposal of Typically, aircraft support demonstrated a hand-held several groups of maintenance hazardous materials, as well components are cleaned laser ablation solution at FRCE artisans, engineers, marines, as the benefits of quicker using plastic blasting and by stripping paint from a large and coast guardsmen. turnaround time, improved mechanical removal methods, aircraft engine can, aircraft FRCE team members and worker safety and decreased both of which use a significant components and test-panels viewers were surprised by the environmental hazards.
8 LASER SYSTEMS EUROPE SPRING 2021 @LASERSYSTEMSMAG | WWW.LASERSYSTEMSEUROPE.COM More Productivity for Micro Machining and 3D Printing
A little ray of light Discover Laser Systems Europe Online
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www.scanlab.de www.lasersystemseurope.com FEATURE: FIBRE LASERS DEVELOPING THE DOMINANT TOOL
Greg Blackman asks processing, however, having come a long way over the past decade. Lasers experts to recap what Systems Europe approached fibre laser 2010 to 2020 held for manufacturers to ask how the technology developed between 2010 to 2020, and what additive manufacturing. Fibre lasers are now the advancement of further advancements the future may hold: the dominant technology for laser-based fibre laser technology industrial materials processing, and many Michael Hepp, product line manager at tools employ lasers with a power of more nLight: In 2010, the market for kilowatt- than 10kW. class industrial lasers was less than $1bn, The trends towards higher laser power Fibre lasers are regarded by many as the with metal cutting being by far the largest will continue. At least as important, laser source of choice for ablation, cutting, application (80 per cent market share). CO₂ however, will be the significant increase in welding, marking, engraving, drilling, lasers were the dominant technology, and tool performance and versatility enabled cleaning and additive manufacturing, across most fibre lasers had 4kW or less power. by lasers with more useful and even a wide range of industries. The growth in fibre lasers over the last tunable beam shapes and sizes. Such This success can be attributed to 10 years has been driven by a number programmable lasers were introduced two their excellent beam quality, stable of factors: their performance, reliability, years ago, and they immediately provided output, extended power range, high and cost-per-part advantages over other dramatic improvements in metal cutting and wall-plug efficiency and low maintenance laser and non-laser technologies; their welding, the largest industrial applications. requirements, all offered in a small footprint, decreasing cost and increasing power level; Other existing and emerging applications with fast turn-key operation. their adoption in non-cutting applications, will be improved by the ability to tailor the The technology has not always been especially welding; and their enabling heat input to the workpiece, allowing real- the dominant player in laser materials of new applications to emerge, such as time process optimisation and providing Coherent
Coherent’s Adjustable Ring Mode fibre lasers feature two independently controllable, co-axial beams from a single fibre
10 LASER SYSTEMS EUROPE SPRING 2021 @LASERSYSTEMSMAG @researchinfo | WWW.LASERSYSTEMSEUROPE.COM | www.researchinformation.info FEATURE: FIBRE LASERS
fibre lasers for tasks that were formerly market. Ultra short pulsed fibre lasers had impossible for them, such as welding an average power of a few watts in 2010. copper or dissimilar materials. And the Now picosecond and femtosecond lasers, demand for these processes will increase with average powers exceeding 100W, are tremendously with the growth of e-mobility commercially available. Such higher average and energy storage applications. We’ll also and peak powers became available with the see new ARM products introduced which development of new fibre technology. are more specialised in function. These will The development of fibre lasers with meet the demands of other tasks that are shorter wavelengths with today’s green or not currently well serviced by other laser UV lasers have also reached power levels of types, or even non-laser technologies. several hundred watts.
Andreas Siewert, European sales Mark Greenwood, CEO of Trumpf Laser manager at IPG Laser: The extraordinary UK: In 2010 nanosecond pulsed fibre development of fibre lasers at IPG over the lasers were only in the tens of watts of past 10 years has contributed to increasing output power, while CW laser sources their market share in the overall laser had just reached kilowatt capability and market. During this period, the R&D focus represented a disruptive new-kid-on-the- was less on improving the beam quality or block technology. Both have progressed in increasing the laser power for ytterbium power capability by an order of magnitude, high-power CW fibre lasers, as today’s laser power was already available 10 years ago. Rather, the development focus was on “Fibre laser increasing the wall-plug efficiency to more than 50 per cent for ytterbium fibre lasers. technology, previously unattainable productivity and The reduction and optimisation of although maturing processing quality. In addition, market the individual components was key to demands, such as electrification of the developing fibre lasers that are now much nicely, is not yet out automotive industry, will demand even more compact and cost effective to of steam” higher laser reliability, stability and uptime. produce. Ten years ago a 1kW IPG fibre laser Meeting these needs will allow laser-based was available in a 4U 19-inch rack. Today tools to capture a growing portion of the we supply 4kW lasers in the same housing. nearly $100bn worldwide laser tool market. Therefore, the power-per-volume increased with nanosecond pulsed fibre lasers now by a factor of four. in the hundreds of watts and CW in the Jarno Kangastupa, managing director This development will continue and tens of kilowatts, becoming the dominant of Coherent’s business unit in Tampere, will lead to more compact fibre lasers. technology for materials processing. Finland: In 2010 fibre lasers were firmly IPG’s new YLR-U series incorporates the Although fibre lasers were by nature hugely established for cutting thin materials, latest advances in industrial pump diode efficient compared to other solid state but CO2 lasers dominated thick material packaging, in combination with the high and CO2 laser sources, some incremental cutting. Fibre laser welding was yet to performance of its fibre design. The 2kW efficiencies have been achieved here too. take off. Since then fibre laser costs have IPG fibre laser is now available in a 2U 19- The size of lasers has also reduced dropped tremendously, as efficiency and inch rack. The company is currently working substantially over the period: a 400W CW output powers have increased significantly. on scaling this laser class to higher powers. laser of 2010 is now the same size as a Innovations such as Coherent’s Adjustable In the future 6kW average power will be 2kW laser. The cost of these lasers has also Ring Mode (ARM) technology have extended available in a 4U 19-inch rack housing. reduced dramatically, as the technology has fibre laser capabilities and broadened their The average power for IPG nanosecond matured and industry uptake has increased, adoption in many applications, like welding, pulsed fibre lasers increased from with volumes going from hand-crafted usually at the expense of technologies such 200W to 3kW in the decade. The current low-volume production to lean, single-piece as CO2 lasers. development will lead to 5kW and more, to manufacturing lines. ARM technology enables the use of increase market share in the laser cleaning This move to volume manufacturing has resulted in significant improvements
nLight in quality and reliability. With minimal maintenance requirements fibre lasers truly IPG Photonics IPG represent fit-and-forget technology. Another key development has been the ability to change beam characteristics within the laser, which is providing some advantages in certain applications. Fibre laser technology, although maturing nicely, is not yet out of steam and there is still plenty of scope for innovation. Further increases in power and functionality, combined with further miniaturisation and The average power of IPG’s nanosecond pulsed nLight’s latest programmable AFX-1000 laser price erosion will come, helping fuel the next fibre lasers has increased from 200W to up to is suited to metal additive manufacturing l 3kW over the past decade applications generation of applications.
WWW.LASERSYSTEMSEUROPE.COM | @LASERSYSTEMSMAG SPRING 2021 LASER SYSTEMS EUROPE 11 FEATURE: MEDICAL DEVICES CREATING MEDICAL MARVELS
How lasers have sectors, came together to produce medical member of the consortium and has been ventilators for the UK’s National Health mass-producing critical components played their part in the Service (NHS), under the collective name for medical ventilators. The company pandemic, including VentilatorChallengeUK. has dedicated a significant part of its UK The consortium has spent the past manufacturing sites in Gloucestershire making medical devices. year working together to deliver the and South Wales to producing precision- Keely Portway reports Penlon ESO 2 and Smiths Parapac plus machined components for the two different ventilators to the NHS. Ventilators consist ventilators, with both sites running seven of numerous components that require days a week. either laser welding, laser marking, or a Marc Saunders, director of group combination of both to manufacture. Such strategic development at Renishaw, components include: power supplies; explained: ‘Ventilators are sophisticated air compressors, pumps and bellows; medical devices and we felt that our pressure regulators; valves; electric motors capabilities would be best applied to helping Lasers have been used in manufacturing and motor controllers; pressure, oxygen scale up the production of designs with across industries for decades. In more and flow sensors; heat and moisture existing technologies. We soon realised recent years, the flexibility and precision exchanging filters; and air and Hepa filters. that many other industrial companies of the technology has led to them being Each consists of sub-components, and were thinking the same way and that we increasingly used to make medical devices. are typically manufactured separately, then would need our combined capacity and Many of these devices contain electronics combined before being shipped out to capabilities to achieve this endeavour.’ and are generally made of different metals medical settings. Many companies involved Renishaw was one of a network of with different characteristics that have been in the VentilatorChallengeUK stepped up welded together. Fibre lasers are often used production of such parts and components for this task, thanks to their ability to create over and above – and in some cases, “Every ventilator a strong enough weld seam so that medical instead of – their core business. device manufacturers can be assured their Engineering firm Renishaw was a founding produced is a life product will be safe for long-term use. saved” Laser-based additive manufacturing has also come to be more widely used in the medical sector. It can produce almost any shape, even very complex and intricate structures. The benefit here, in terms of safety and longevity, is that it reduces the need to manufacture a product in multiple parts.
Ramping up ventilator production The use of lasers to manufacture medical devices has accelerated even further in the past year, due in no small part to the pandemic. In the UK, for example, a consortium of UK industrial, technology and engineering businesses from across Tech) Amada Weld the aerospace, automotive and medical Amada Weld Tech uses fibre lasers and femtosecond lasers in the manufacture of stents
12 LASER SYSTEMS EUROPE SPRING 2021 @LASERSYSTEMSMAG @researchinfo | WWW.LASERSYSTEMSEUROPE.COM | www.researchinformation.info FEATURE: MEDICAL DEVICES Renishaw Amada Weld Tech) Amada Weld
Welding technology has been vital for the production of battery packs for life support systems throughout the pandemic
regimes were enhanced to minimise the potential risk of the spread of infection. “Laser cutting Our staff responded magnificently to this Renishaw has demonstrated how additive challenging situation.’ manufacturing can be used in the of stents has The VentilatorChallengeUK project production of spinal implants developed rapidly in concluded in July, after more than doubling the stock available to the NHS. During that suppliers co-ordinated by the consortium. line with demands time, ventilator peak production exceeded Other members included: Accenture, from the medical 400 devices a day, with the shortest time Airbus, AMRC Cymru, Arrow, DHL, Ford, taken to achieve 1,000 ventilators being GKN Aerospace, Haas F1, HVM Catapult, device industry” three days. Despite global competition for Inspiration Healthcare, McLaren, Mercedes- parts combined with lockdown challenges, AMG F1, Meggitt, Microsoft, Newton, the consortium sourced parts from more Penlon, PTC, Racing Point, Renault Sport than 22 countries, with the furthest distance Racing, Rolls-Royce, Siemens UK & Siemens as medical devices, software and surgical travelled by a single part being 5,226 miles. Healthineers, Smiths Medical, STFC Harwell, robotic systems for procedures such as The consortium achieved full MHRA STI, Thales, Unilever, Williams Advanced deep brain stimulation for Parkinson’s approval for the Penlon ESO 2 device in just Engineering and Williams F1. disease, and stereoelectroencephalography three weeks, becoming the first newly- Many of the participants, like Renishaw, for the treatment of epilepsy. adapted ventilator design to be given were using their capabilities to make Renishaw has previously demonstrated regulatory authorisation as part of the UK ventilator components for the first time. how additive manufacturing can be used Government’s fight against the virus. It went However, it is not the first time for the firm in the production of spinal implants, in on to secure a CE mark. when it comes to manufacturing for medical collaboration with Irish Manufacturing ‘It was an extraordinary few weeks, applications, being a renowned supplier of Research (IMR) and manufacturing software with so many companies from different in-lab dental CAD/CAM systems, and also company nTopology. For the project, IMR fields aligning on a single goal and pulling leveraging its expertise in metal 3D printing designed a representative titanium spinal together so effectively and so quickly,’ said for the manufacture of dental frameworks. implant, aimed at the cervical spine, using Saunders. ‘The consortium’s key message The company additionally has experience nTopology’s generative design software. is that “every ventilator produced is a life in producing neurological products such IMR then manufactured the implants using saved” and Renishaw is proud to be playing Renishaw’s RenAM 500M metal additive its part in this vital endeavour.’ manufacturing system. The technique was
GE Additive beneficial in producing spinal implants with Battery backups lattice structures, which could otherwise Amada Weld Tech has also turned its prove difficult to achieve. This infrastructure welding expertise – using both lasers and is lightweight, and can be optimised to other welding technologies – to aiding meet the required loading conditions, plus, the fight against the pandemic. As a key it has a greater surface area, which can aid supplier to both the medical and battery integration of the prosthetic device into the industries, the firm has been listed with body. the UK government as a supporting To prepare for the work on the manufacturer for the production of ventilators, the firm temporarily shut its ventilators and medical systems, which it UK manufacturing facilities to introduce helped increase the production of. additional measures to protect the welfare According to David Van de Wall, laser of its employees. ‘We reorganised our sales manager for the company, one of factories to increase spacing, as well as the biggest challenges for hospitals is zoning areas to restrict movement around electrical power failure. This is because GE Additive’s direct metal laser welding technology was used to create the Giglio the sites,’ explained Gareth Hankins, backup generators offer the first line of Interspinal Fusion System director of group manufacturing. ‘Hygiene defence, so, in the case of total or extended g
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to adapt their existing technology to new expertise to create 14,000 face masks for applications. hospital ships and Navy personnel. GE Healthcare ‘Adaptation to facilitate rapid ventilator In its Madison, Wisconsin, facility the firm production is a critical component of also leveraged 3D printing to ease supply response to the pandemic,’ remarked Van chain bottlenecks and speed up ventilator de Wall. ‘Superior welding technology, in production. particular, will be an important piece of this ‘GE Additive has offered their capacity puzzle, now and moving forward.’ to help print ventilator parts,’ said Jimmie Beacham, executive chief engineer for Superior stent manufacture advanced manufacturing at GE Healthcare. Like Renishaw, Amada Weld Tech was not ‘Many of their customers have also offered new to the medical devices field, having up their excess capacity to us. Everyone previously worked with many medical is very willing to help us with the capacity, device experts to supply laser welding, laser once we design the additive parts.’ marking and laser cutting technologies. Initially, the firm focused on the more One area of expertise is making stents, immediate tasks, such as training new the elastic structures made from metal or workers, strengthening supply chains and polymers that are implanted into the human bringing in new equipment. But longer term, body to give support to blood vessels, food it aims to use technologies such as 3D pipes and other organs. printing to further speed up production. These structures are manufactured from Once again, GE is not a newcomer to raw materials in the form of sheets, ribbon, medical applications, having used its wire or tubing, with the latter two most technology for several different products in widely used. Laser cutting is commonly this area. GE Healthcare in Wisconsin is using 3D-printing used to remove any excess material and Most recently GE Additive collaborated to speed up ventilator production create the desired flexibility. Lasers can also with Tsunami Medical on the Giglio be used to automate wire cutting for wire Interspinal Fusion System, which was g power failure, battery technology is critically stents, with such wires often joined using designed for lumbar diseases with an important to life-sustaining care. Therefore laser welding. Amada Weld Tech supplies indicated segmental requirement. The in May, Amada Weld Tech increased its laser systems for all of these tasks. system focuses on developing implants strategic partnerships with manufacturers ‘Laser cutting of stents has developed of battery modules, used in vital life support rapidly in line with demands from the systems such as ventilators. In addition to medical device industry,’ said Van de Wall. ‘It such systems needing a reliable battery is possible to laser cut extremely complex “Everyone is very backup in the event of a total power failure, shapes in 1 to 25mm outer diameter tubes, willing to help us battery power ensures essential support with walls as thin as 0.2mm. Together with and monitoring can be maintained safely as the trend to further reduce strut dimensions with the capacity, patients are moved between wards. from about 110µm down to merely 60 to once we design the Amada Weld Tech provided technology, 85µm, these requirements demand an including its high duty DC resistance accurate laser cutting system.’ additive parts” welding power supply and parallel gap Amada Weld Tech works with fibre weld heads, to battery pack manufacturers lasers and femtosecond lasers for this rushing to increase production as the purpose. ‘We found these to be the most pandemic took effect. capable types of lasers for our customers’ that are almost ready for use, straight from Van de Wall said that the demand for demands,’ said Van de Wall. a metal additive manufacturing machine. ventilators exceeds the production capacity ‘The average power required for small- Giglio consists of an interspinal spacer of typical ventilator manufacturers, and scale tube-cutting applications is, in most device and the necessary tools for its acknowledged that manufacturers who cases, relatively low. Most stainless steel positioning and fixing in a minimally invasive usually produce other products have found stents are typically cut with 200 to 500W operation. themselves switching production over to fibre lasers, with higher power levels needed Five mobile, articulated pieces enable meet the increase in ventilator demand. only for nitinol. the extraction of fins for anchorage to the ‘Manufacturers already using advanced Femtosecond lasers typically range vertebrae. A surgical operation makes an welding technologies are typically well between 10 to 50W average power. incision for the passage of the device. This poised to switch their production over to Power levels alone do not indicate much, is correctly positioned using a guide wire ventilators, because there is extensive however, as the cut quality, the speed of the stretched from the insertion point. Once welding demand in all of the aforementioned movement system and the heat load on the the device is positioned, it is tightened by a ventilator components,’ he said. stent typically dictate that the maximum special tool, together with the guide wire. Laser marking, laser welding, resistance power that can be used is significantly lower It is here that Tsunami was able to take welding, hot bar bonding and micro arc than the maximum power of the laser.’ advantage of GE Additive’s direct metal welding are all used in some way during the laser welding (DMLM) technology in a manufacture of these components. A helping hand number of ways. In light of this, the company committed Across the Atlantic, GE Healthcare For instance, it offers the ability to create to providing manufacturers with additional helped lead the charge in aiding the precise geometries, including gears and welding technology, as well as support pandemic effort. The company’s additive mechanical moving parts, on a very small l to existing customers looking for ways manufacturing division initially used its scale, with no assembly needed.
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Case study: Hypotube manufacturer makes full Cambus Medical use of laser processing
Cambus Medical, in Galway, was certainly the catalyst for Ireland, has become a global starting our business, but market leader in medical device from the very beginning laser Some of the diverse microcomponents manufactured by Cambus, manufacturing through targeting processing was one of the main thanks to the flexibility and versatility of laser processing and achieving excellence in a enablers,’ Comerford explained. very specific area: hypotubes ‘Lasers were just appearing on. In addition to catheter shafts, really depend on the super- and related components in PTCA work and our first Cambus Medical also produces high reliability and prompt (such as catheter shafts) for customer wanted a “cutting many high-precision micro quality service we get from manufacturers of percutaneous edge laser-made” product. So component solutions, speciality partnering with Coherent. And transluminal coronary we made a bold decision to needles and wire assemblies lastly, these machines are very angioplasty (PTCA) catheters. spend a substantial part of our utilising the impressive range of versatile and user-friendly, In addition to its unique PTFE start-up cash on two Rofin (now laser and non-laser technologies enabling Cambus to provide a LG (Teflon) coating capabilities, Coherent) machines: a StarCut employed in the business. quite diverse product offering, Cambus is expert in using a Tube laser cutting machine and a in terms of size and shape, as broad range of manufacturing StarWeld (now the Select series) Strong market growth well as a huge range of batch technologies, including laser laser welding system.’ Both In addition to welding, drilling sizes.’ cutting, laser welding and machines are still running today. and cutting, many Cambus The StarCut Tube machines laser marking, together with ‘Not only did laser technology products require marking, for are self-contained CNC-style traditional technologies such as give us our first customer, it functional and/or identification automated systems featuring electrical discharge machining also gave our fledgling business purposes. Since all its products up to four cutting axes and a (EDM), passivation and injection a credibility for cutting- are for single-use applications, user-friendly GUI. Today these molding. edge products, which older they don’t need black marking are available with a choice According to Barry technologies such as EDM could based on ultrashort pulse (USP) of a microsecond fibre laser Comerford, Cambus co-founder not,’ Comerford continued. lasers. Instead they rely on for high throughput, or a and CEO, lasers play a key role in ‘Soon we were picking up conventional marking with a everything the firm makes. business in areas ranging fibre laser that provides a cost- “Laser technology from PTCA devices to related effective solution for directly gave our fledgling Why lasers? components, such as pressure marking the metal or for coating The development and sensing guidewires. And today removal. business credibility refinement of PTCA in the 1980s we also have a growing business Thanks to continuous strong for cutting-edge brought about a revolution in structural heart products, growth across each of the products” in the treatment of coronary such as TAVR and TAVI.’ above applications, Cambus artery disease (CAD). The The company has always now operates seven Coherent founders of Cambus had several worked closely with its StarCut Tube series laser cutting femtosecond ultrashort pulse years’ experience supplying customers in developing custom machines, six Coherent Select (USP) laser for the ultimate components for this purpose, and standard products based on series welding machines, and surface quality, or even both before deciding to start their delivering the highest levels of five laser marking systems. lasers in a hybrid machine. own company in 2006. performance, in terms of torque, Cambus has stayed very The use of a granite cutting ‘Our PTFE coating system trackability, flexibility, lubricity, loyal to Coherent for three platform is a key feature that inflate and deflate times and so primary reasons, according to ensures high precision, so Comerford: ‘First, we benefit users can cut struts as thin as from having uniform equipment: a human hair, while processing
Coherent the same hardware, the same tubes up to 30mm diameter, software, and most importantly as well as cutting flat stock. the same results. We handle The Select series of welding contracts from single units up systems are multi-axis (linear to full volume manufacturing, and rotary) manual welders therefore we need consistent that support semi-automated quality and tolerances, as well and automated operation: as high yields. Machine reliability either joystick control or is just as important; we typically fully-CNC programmed. All operate with two four-day 40 parameters can easily be hour shifts plus a weekend shift. adjusted without any special And we still operate our original know-how via a multi- 2006 machines! We work these functional joystick and large l Cutting slots on a tubular component to enable flexible delivery machines hard and so we colour touchscreen.
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ULTRASHORT-PULSE LASERS UNLOCK FREEFORM PROCESSING FOR FUTURISTIC DISPLAYS
‘The thermal, optical, chemical and For fragile ultra-thin glass, however, such mechanical properties of ultra-thin glass mechanical techniques do not suffice. Not make it a much more suitable cover material only do these methods require the application Ultra-thin glass offers for flexible displays than polymers or glass- of force and produce particles – both of which polymer stacks,’ said Liebers. ‘It also grants are detrimental to ultra-thin glass – but they exciting opportunities enjoyable haptics, which is, of course, relevant are also limited in their ability to create curved for touch-screen devices.’ edges. This means they could only be used but poses exceptional In addition to folding smartphone to produce traditional square or rectangular manufacturing technology, flexible ultra-thin glass could be displays, rather than futuristic flowing used to form displays that blend seamlessly displays for vehicle interiors. In addition, edge challenges, Matthew with vehicle interiors, following the curves of a polishing or grinding is not feasible for ultra- Dale finds car dashboard, for example. thin glass, due to its low mechanical stability. However, despite being a suitable cover Other processing techniques glass material for flexible displays, ultra-thin glass manufacturers use include those using is still very fragile and has limited flexibility, laser technology, which of course removes which makes it challenging to manufacture the possibility of mechanical tool wear. and handle. Crack-based thermal laser separation using CO2 lasers is a well-established technique. Foldable smartphones such as the Samsung Available manufacturing methods However, similar to the mechanical methods Galaxy Fold and Huawei Mate X began hitting There are a number of techniques it is also limited in its curvature processing, the market in 2019. The devices offer the manufacturers currently use to process according to Liebers. Another alternative is screen size of a small tablet, while being able standard smartphone glass, the high rigidity ablative laser cutting using UV lasers, which, to fold down to the form-factor of a standard of which makes it easy to handle and cut. while being able to provide good curvature smartphone. Classical scoring and breaking processes and edge quality, has a very low throughput, in This functionality, however, was achieved using diamond tips or wheels work well, addition to producing particles. at the expense of screen durability, as the as do typical grinding and polishing post- The fragility of ultra-thin glass, in standard smartphone cover glass had to be processing steps used to provide the combination with the limited freeform replaced with a polymer that, while flexible, necessary finish. capability of the above processing methods, proved more susceptible to damage such as scratching. Last year saw the release of Samsung’s Galaxy Z Fold2, which the firm claims has a 3D-Micromac foldable screen made from flexible ultra- thin glass. While this is factually correct, the screen still requires a polymer cover – pre- installed on the device – to protect the glass from damage. This means the user is still required to interact with a polymer surface that scratches easily. According to René Liebers, product manager for display and glass systems at laser micromachining integrator 3D-Micromac, the demand is therefore rising for durable ultra-thin cover glass of around 30μm in thickness (smartphone cover glass is typically 450 to 550μm thick) that can function independently and substitute this glass-polymer sandwich. While this cover glass is available, due to its high cost it is not yet suited for mass production or widespread The laser cutting system microSHAPE, by 3D-Micromac, is perfectly use. suited to cutting ultra-thin glass using a USP laser source
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“Fully integrated nearly invisible displays made from ultra-thin glass are the future”
There is exceptionally high potential for USP laser processing in industry, with numerous laser sources and beam delivery optics already available on the market. However, as Liebers made clear, the investment cost still needs to come down for the technology to experience broader adoption. In addition, there is still a lack of well-educated engineers that can use the Ultra-thin glass is now being used in the flexible displays of foldable smartphones technology effectively in new applications. ‘The necessary knowhow is very will therefore prevent them from being used to The mechanics of ultra-thin glass specific,’ said Liebers. ‘Integrators, such as manufacture futuristic displays. processing using USP lasers are detailed in 3D-Micromac, currently have to put large ‘Fully-integrated, nearly invisible displays the white paper recently authored by Liebers, amounts of effort into process development made from ultra-thin glass are the future,’ featured at the end of this article. Meanwhile, for increasingly complex tasks during said Liebers. ‘The display unit itself can stay he shared with Laser Systems Europe how the customer evaluation period for this rectangular, but the touch unit and cover has established the technology is for display technology.’ to be more flexible in its shape, so freeform manufacturing, as well as the developments When 3D-Micromac provides a USP laser cutouts become increasingly important for that could potentially drive its success further system to display manufacturers (the firm the cover material.’ in these applications. has supplied some of the biggest names in ‘Currently USP lasers are already well display manufacturing), it sells its expertise in A new era for freeform glass processing established at display manufacturers, both in addition to the equipment. Thankfully, in recent years ultrashort-pulse 24/7 production as well as R&D,’ said Liebers. ‘We have the knowhow to process ultra-thin (USP) lasers and their associative beam ‘Yet there is still room for more uptake. The glass, as well as the tools required,’ Liebers delivery technologies have emerged and main issues are the cost of the technology and confirmed. ‘The customer doesn’t just buy matured. the necessary process knowledge required, a laser machine, but a complete solution, These technologies are defined, as their when using it to develop new products.’ including the ideal settings for processing g name suggests, by their extremely short pulse duration in the range of picoseconds (10-12s) all the way down to hundreds of femtoseconds (10-15s). At such short durations, the energy delivered to the workpiece with each pulse is huge. Despite this, a very small heat-affected zone is achieved due to almost no heat being generated in the surrounding material. This capability makes USP lasers the perfect solution for processing ultra-thin glass, via a process known as filamentation. Here, the ultrashort pulses do not ablate the glass, but rather modify it to create a filament inside the glass that serves as a weak point to make a clean break. ‘In general, it is very hard to find a comparable technology to filamentation, especially in terms of heat input and thermal side effects,’ remarked Liebers. ‘The process has numerous advantages, including the ability to create freeform shapes and cutouts. A high-end edge quality is achieved at cutting speeds of up to 1,500mm/s, without the introduction of tension, particles or the need for additional post-processing.’ Scanning electron microscope image of ultra-thin cover glass cut using a USP laser
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g their materials. In addition to performing them it’s necessary that the machine is very the integration, we give the customer basic intuitive and easy to use.’ training that tells them how to use the 3D-Micromac A potential solution could be embedding machine and how to optimise it for further the specific processing knowhow in the projects or products.’ machine software, in order to make it This training can only go so far, however, easier to use by employees who aren’t as and never equates to the many years required knowledgeable in USP laser processing. This for 3D-Micromac to teach its employees the is far easier said than done. required knowhow for USP laser processing. ‘They would want to be able to select This makes matters challenging for the options for ultra-thin glass or thick glass customer, when looking to reconfigure their from a database, and then have the machine systems for future applications. For display automatically configure to be able to process manufacturers in particular, this is almost those materials,’ said Liebers. ‘This could certainly inevitable, as the lifecycle of their be a good solution to establish USP laser products is typically one to two years. processing in industry to a further degree – in ‘As initially they are buying a specialised addition to the initial investment cost coming tool with specific process knowhow, if they down – but, it is very challenging to put this then need to optimise the tool for a different knowhow into software form. This has been application in the future, they need to bring done for other laser processes, but further the knowledge in-house by educating their Ultra-thin glass with thickness below 30µm cut work is required before this can be done for workforce,’ said Liebers. ‘In addition to using a USP laser USP laser processing.’ teaching them about the laser, they’ll need It is certainly clear that USP lasers will to teach them the fundamentals of laser- this high investment in both equipment be the go-to processing tool for ultra-thin material interaction and the many variations of and education that deters customers glass once the material reaches the required dedicated optics that can be used to influence from adopting USP lasers as part of their cost level for use in the mass production of the process. Companies will therefore have production process. consumer displays. However, the barriers of to invest a lot of money and time into growing ‘It is often an issue that a laser machine is high investment cost and required process their employees from a starting point up to not going to a glass manufacturer because knowhow must be overcome to encourage being a specialist.’ they don’t have the money to invest in an further adoption of USP laser processing, l Unfortunately, it is a combination of engineer to run it,’ confirmed Liebers. ‘For while ensuring its longevity.
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Figure 1: (a) transparent-absorbent welding of a 70 x 85 x 130mm³ Absorber-free laser surge tank and (b) absorber-free transparent-transparent welding transmission welding of of a 50 x 50 x 2mm³ exemplary fluidic component transparent polymers
Frederik Maiwald and Stefan Hierl determine the optimal parameters for welding transparent polymers used in Figure 2: schematic sketch (top) and images of microtome optical and medical devices sections (bottom) demonstrating the weld seam formation in
dependence on the Rayleigh length zR: bulged surface because of poor focusing (a) and desired weld seam without surface Transparent-absorbent welding, defect (b) material: polyamide 6, laser power = 60W (cw), feed in which the lower joining partner rate = 200mm/s is coloured, has been commonly Optical and medical devices made established for many years. It is of polymers are gaining popularity frequently used in the automotive due to their cost advantage industry, for example in the compared to glass. However, manufacture of sensor housings the typical usage of coloured and surge tanks. In contrast, no absorbent additives – used to absorbers are required for new improve the absorption of laser transparent-transparent welding radiation in polymers – is not processes, which are enabling sought after when welding such components such as fluidic devices. This is because most devices or optical sensors made optical and medical applications of identical, clear material to be instead require purely transparent joined without colouring or other materials. additives – while still benefiting Laser transmission welding of from the above advantages. polymers has previously been Due to the laser-absorbing demonstrated without absorbers. blackening of the lower joining However, the process is still known partner in transparent-absorbent to lack stability and productivity. welding, the zone of laser radiation Together with our colleagues, we absorption and fusing is located set out to determine the optimal exactly at the interface between parameters for achieving fast and the two partners. reliable transmission welding in When welding transparent transparent polymers. polymers without absorbers however, two challenges emerge: partner, including its upper surface laser power caused by absorption, Process principle the deposition of laser energy in (figure 2a). maximising the radiation intensity Laser transmission welding is a general; and achieving the required On the contrary, if the beam is in the joining zone (figure 2b). well-known joining technology selective energy deposition in the focused within the workpiece with for thermoplastics. It can provide joining zone. To attain absorption a high numerical aperture (NA), Equipment setup precise, reliable and hermetic without additives, lasers emitting in the joining zone can be selectively Figure 3 shows our experimental sealing without particle formation the polymers’ intrinsic absorption melted. The Rayleigh length setup for absorber-free laser
or the requirement of adhesives. spectrum – between 1.6 and 2µm zR – the distance from the laser transmission welding. A thulium These advantages are essential for – are used. beam waist to the point where fibre laser with a wavelength of medical and optical applications. However, welding with standard the area of the cross-section is 1,940nm is used. The fixed-focus The welding process is used in two optics leads to poor focusing and doubled – must also be short. In setup consists of a breadboard, variants: transparent-absorbent insufficient energy concentration doing this, the decrease of the where a rail carrying the optical welding and transparent- in the joining zone, resulting laser beam’s cross-sectional area elements is mounted on slides. transparent welding, as in figure 1. in melting of the upper joining overcompensates the loss of The beam is guided through an
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Figure 3: sketch of the processing setup with a high NA focusing Figure 4: (a) photographs of microtome sections of typical weld optic and off-axis pyrometer for process monitoring seam states and (b) distance between specimen’s surface and upper (U) and lower (L) end of the weld seam in dependence on
laser focus position zf,rel. (c) Pyrometer signal averaged along 20mm seam length. Material: Topas 8007-04, laser power = 60W, feed rate = 200mm/s, Rayleigh length = 0.3mm
adjustable beam expander and a focus shift measured in air. Due Galilean telescope with a high NA to refraction, the shift in air is less (0.6) focusing lens. A fine threaded than inside the material. Figure 4a spindle moves the rail, enabling the shows photographs of microtome variation of the distance between sections of typical weld seams for the optics and the specimen. A different laser focus positions. The clamping device with a conical sections were photographed in slit hole fixes the two specimens polarised light using a transmission (50 x 50 x 1mm³ each) in an light microscope. Figure 4b overlap. A two-axis linear system schematically shows the weld moves the specimens at up to seam and the measured distance 300mm/s. between the specimen’s surface Regarding the weld seam quality, and the upper (U) and lower (L) end surface (U = 0). The specimens using a pyrometer, for example. vertical expansion of the seam of the seam in dependence on the have to be checked and a focus Since the signals are recorded is especially crucial. Whereas an laser focus position zf,rel . Figure adjustment downwards is advised. with a frequency of more than excessively large seam leads to 4c shows the corresponding, The pyrometer signal is 2.6mV. 50kHz, closed-loop control of a molten surface with visible and averaged pyrometer signals, Class III: Although both joining focal position or other parameters palpable irregularities, a seam of detected along a 20mm section in partners are connected tightly, is possible. This will form part insufficient length causes leakage the middle of the specimen. the welds of class III (zf,rel = 0.8mm) of our future work, as will the and inadequate strength. The resultant seams can be are inadequate, since the surface investigation of adapted intensity To fulfil the high demands divided into four classes: is damaged by a palpable bulge distributions for the process on weld seam quality in the Class 0: The welds of class 0 caused by the weld seam. The stabilisation and transformation of medical industry, online process (zf,rel = 1.2mm) are inadequate as pyrometer signal is 4.2mV. weld seam geometry. monitoring is necessary. A no firm connection of the joining The experiment showed that customised pyrometer based on partners is achieved. The joining proper and faulty parts can be Acknowledgements Micro-Epsilon’s CTM-3CF1-22, partners are loose after welding, differentiated using a pyrometer. This work is supported by the with an optical filter blocking the even if the visible heat-affected Both a molten surface and a faulty European Union and the Free laser wavelength, is therefore zone covers both partners. The joint can be distinguished from State of Bavaria as part of integrated off-axis into the temperature leading to a visible proper results. Operating the TheCoS, 3D-LasPyrInt-Scanner experimental setup. Due to the heat-affected zone is less than the process between 1.3 and 1.5mV and GipoWeld projects. We filter, the sensitivity is reduced melt temperature (Tmelt) needed for signal ensures the desired result would like to thank the sponsors to the range of 2 to 2.5µm. The bonding. The pyrometer’s signal of tight seams without surface and project partners Arges, analogue output is processed with is below the threshold and only defects (marked blue in figure 4b Bayerisches Laserzentrum, over 50kHz using a cRIO-9035 noise with a mean value of 0.8mV and c). Gerresheimer Regensburg, controller. is detected. Additionally, weld seams LPKF WeldingQuipment, Micro-
Class IA,B: Class I (zf,rel = 1.1mm and processed with up to 2.6mV Epsilon Messtechnik, Nexlase Welding tests 1.0mm) represents the desired signal can be acceptable, since and the universities in Erlangen- In our welding tests using result. Since line energy and focal the surface may or may not show Nuremberg and Pilsen for the good l the crystal clear cyclic olefin position are well-matched, both noticeable defects. co-operation. copolymer Topas 8007-04, at joining partners are connected least seven welds per setting firmly and a sufficient distance U Conclusion and future work Frederik Maiwald and Professor were processed at 60W using a (0.1mm < U < 0.2mm) between the Our experiments determined that Stefan Hierl work at the East Bavarian Technical University 200mm/s feed rate and at five seam and the surface is achieved. by focusing the beam of a thulium of Regensburg’s Laser Material different laser focus positions (zf,rel) The pyrometer signals are 1.3 and fibre laser with a high NA, precise Processing Laboratory between 0.8 and 1.2mm. 1.5mV respectively. weld seams can be achieved in This work can be read in full in Procedia CIRP, At zf,rel = 1.05mm, the laser focus Class II: In this marginal case (zf,rel transparent polymers without Volume 94, 2020, Pages 686-690 position is in the joining zone and = 0.9mm), a firm connection is additional absorbers. To fulfil the (https://doi.org/10.1016/j.procir.2020.09.117) and in the Journal of Laser Micro/ with increasing zf,rel , the laser focus achieved but the surface may or high demands on quality in the Nanoengineering, Volume 16, Number 1, 2021 (https://doi.org/10.2961/ position shifts down the material. may not show noticeable defects, medical industry, the weld seam jlmn.2021.01.2002) The values of zf,rel represent the as the weld seam just reaches the position needs to be monitored
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Tailoring microstructures in metal additive manufacturing
Manyalibo Matthews shares how a deeper understanding of laser powder bed fusion will lead to material innovations and new applications in additive manufacturing
that meet performance-driven Figure 1: (a) schematic of the diode laser annealing LPBF system, criteria for qualification and (b) images of the printing and annealing steps certification in an as-fabricated This article was co-authored by state. Joseph McKeown, Saad Khairallah, There are many reasons: and Tae Heo of the Lawrence a lack of control of local Livermore National Laboratory thermal histories that drive microstructure control; a Additive manufacturing (AM) deficiency in predictive technologies have advanced to capabilities due to a lack of a critical juncture. Components in situ process monitoring to with geometries that cannot be provide data for validation; obtained through conventional and material feedstocks that processing can now be are not suited to AM. As AM designed and built, however evolves from rapid prototyping their performance is still severely technology to a serial limited. This is due to a lack of manufacturing tool, a profound understanding and control of the knowledge of the AM process parameters that influence their itself and the resultant structure microstructure and materials across relevant length scales properties. (macro- to microstructure) are Until recently, the arguments required to design an essential, favouring AM for metals and scientifically-based uncertainty alloys have largely been: the quantification (UQ). ability to build complex parts that cannot be achieved with A new design strategy conventional casting and To meet emerging challenges moulding processes; reduction in metal AM, a team at the of the number of parts in a Lawrence Livermore National complex assembly, to avoid Laboratory (LLNL) have issues associated with welding developed a design strategy and joining; and a reduction in based on carefully tailored and cost and material waste. simulation-driven light sources part designs were realised. able to demonstrate: a thermal- In this context, alloys that have to control thermal history. Full realisation of the tailored microstructure-property been considered for metal AM The work provides a path heat source approach has toolkit; unique, architected AM have almost exclusively been towards the fabrication of high- delivered deeper understanding microstructures; managed those developed for standard performance components. and control of the effects that residual stress states; and manufacturing processes, Our approach integrated new currently limit the fidelity of LPBF optimised alloys for metal AM. such as conventional steels experimental approaches with AM: microstructure, residual This new paradigm has (for example 316L stainless real-time process monitoring to stress, micro-roughness and extended metal AM design steel), aluminium alloys (such as inform and validate predictive porosity. capabilities from macroscale Al-Cu-Mg-Sc-Si), Ni-Cr-based modeling efforts, fundamentally Specifically, guided by geometries to local, site-specific superalloys (Inconel 718/625), transforming metal laser powder modeling and using highly control of microstructure and titanium alloys (largely Ti- bed fusion (LPBF) AM through flexible, optically-tuned AM and properties in new alloys 6Al-4V). However, AM of these the development of a framework platforms that were custom designed specifically to take alloys does not result in parts by which new materials and built at LLNL, we have been advantage of AM.
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Figure 2: digital twin workflow for controlling metal AM microstructure “Controlling residual stress could have a tremendous impact on the production of metal AM components”
solidification analyses for are correlated with the the nucleation propensity of mechanical property response equiaxed grains, based on a given a choice of AM process reference solidification map for parameters by employing 316L4. The ALE3D is the core the microelasticity model component of our AM digital implemented in the meso-micro twin (DT) that evolves in a multi- code, as well as the crystal- scale computational ecosystem. mechanics-based constitutive The workflow of the DT is shown model implemented in the in figure 2. A high-quality thermal ALE3D code7. profile is produced that resolves As representative Tailoring laser sources to controlling the laser beam profile the powder layer and accounts demonstrations, the integrated control material properties was developed by our group, for melt pool dynamics. The DT framework has been Although typical commercial namely using non-Gaussian thermal profile feeds into the successfully applied to LPBF systems use circular (elliptical, Bessel) laser beams cellular automata finite element predicting and analysing Gaussian intensity profiles to control the local thermal (Cafe) method to predict the the laser processing- operated in continuous mode, history3. Distinct from the grain size distribution and microstructure-mechanical simple modifications can result large area annealing described orientation. response relationships for AM in significant changes in the above, this technique involves The Finite Element Analysis- 316L stainless steel, Ti-6Al-4V, thermal history, microstructure imposing variable thermal based high-fidelity mesoscopic and Ti-Nb alloys. and morphology of single gradients dictated by the beam model simulates the laser For instance, our DT LPBF tracks1. An example of a shape to shift the solidification energy deposition and effects framework could capture the modified laser source is shown conditions for a given alloy. The on melt-pool dynamics5. The difference in microstructural in figure 1, which displays an in change in microstructures can main output is an accurate features in terms of grain situ annealing method to reduce be characterised and compared thermal history profile that is morphology, size, and texture residual stress in 316L stainless in terms of grain shape, size and coupled to a highly-efficient for different laser beam shapes steel parts during LPBF2. A crystallographic texture. macroscale cellular automata (such as Gaussian versus set of laser diodes were used method for microstructure grain elliptical), which agrees with as the heating source, which Using multi-scale simulations growth and orientation4. our experimental observations illuminates the recently scanned to inform experiments This, in turn, is refined with discussed earlier in this article. and solidified surface layer The conditions most favourable a higher-fidelity microscale The mechanical properties and with homogeneous intensity to grain refinement were microstructure prediction, based responses of the simulated immediately after melting. This identified by experiments with on the adaptive mesh phase AM microstructures were then surface layer heating/cooling support from an in-house evolution phase-field code that examined by assessing several strategy introduced smaller Arbitrary Lagrangian-Eulerian resolves grain morphology down mechanical response metrics, temperature gradients into the three-dimensional (ALE3D) to the dendrite level6. Finally, including effective elastic printing process, resulting in a simulation code, which informed the resolved microstructures modulus, local microelastic g reduction in residual stress up to 90 per cent for samples heated above a critical temperature. Figure 3: (a) overview of experimentally validated multiscale simulation framework to predict tailored Additionally, the variation in microstructure formation, (b) solidification map for TiNb including SEM images of melt pool cross sections annealing strategies, specifically that of annealing in select layers, showed similar stress reductions could be achieved without the need to heat every single layer, cutting down on total processing time. This new approach to controlling residual stress could have a tremendous impact on the production of metal AM components, both through the improvement of materials and the reduction of post processing (annealing) steps. Another innovative use of
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Figure 4: (a) temperature measurements and thermal modeling of laser heated Ti-6Al-4V, (b) dynamic based on validated ALE3D-Cafe transmission electron microscopy (DTEM) images of an Al-Cu alloy during solidification and phase field models were used to derive a physics stability criterion which minimises defects in metal AM, and more accurately capture columnar-to- equiaxed transitions occurring under rapid solidification. Unique, architected AM microstructures were demonstrated through tailored beam profiles, paving the way towards a new voxel- scale paradigm for metal AM; grain-level engineering using formatted laser beams showed an improvement in process stability and final material properties. Managed residual stress, using large area in situ diode laser heating, led to a 90 per cent reduction in residual stress of 316L steel AM g response and elasto-plastic Several findings highlighted this approach can be used in components, as compared with stress/strain response. the importance of the alloy conjunction with a high-speed conventional processing. Finally,
freezing range, ΔTf, as a strategy camera system for in situ optimised alloys for metal AM Alloy design: new materials for optimising spatial control monitoring of the temperature were demonstrated, leading to Along with tailoring energy of microstructure during AM. distribution during LPBF8. new alloys that solidify into an sources to control solidification Simulations of Ti-Nb alloys were A fundamental AM need has isotropic state under metal AM l of existing alloys used in LPBF, performed to optimise alloy been simulation capabilities process conditions.
there is a need to develop alloys composition to increase ΔTf and that capture far from equilibrium better suited to take advantage induce a columnar-to-equiaxed kinetics and microstructure This work was performed of these processes and their transition, thus allowing us evolution under rapid under the auspices of the US parameters. It is anticipated that to integrate alloy design with solidification conditions. This Department of Energy by LLNL growth in AM materials diversity process design and control to has been hindered by a lack under Contract DE-AC52- will soon drive advancement identify optimal material and of experimental validation 07NA27344. IM release number of AM technologies. High process condition combinations. data for modelling. Using LLNL-TM 818384. performance materials such dynamic transmission electron as titanium aluminides are Cross-cutting diagnostics microscopy, we captured Dr Manyalibo Matthews is leader of the Laser Materials Interaction already under investigation. integration time-resolved images of rapid Science Group at Lawrence New alloys for structural (such Accurate process diagnostics solidification fronts with high Livermore National Laboratory as Al-Ce based alloys) and are essential for validation of spatial and temporal resolution References biomedical (orthopedic implants) models and to establish high- (figure 4b), and calibrated a [1] TT Roehling et al., ‘Modulating laser intensity profile ellipticity for microstructural control during applications, high-strength and speed online feedback control phase field model for rapid alloy metal additive manufacturing,’ (in English), Acta Materialia, vol. 128, pp. 197-206, Apr 15 2017. high radiation-resistant alloys for dynamic adjustment of solidification to better predict [2] JD Roehling et al., ‘Reducing residual stress by selective large-area diode surface heating during such as high-entropy alloys, laser parameters, allowing in microstructure evolution in AM9. laser powder bed fusion additive manufacturing,’ Additive Manufacturing, vol. 28, pp. 228-235, and gradient materials, among situ control (on-the-fly process 2019/08/01/ 2019. [3] TT Roehling et al., ‘Controlling grain nucleation others, are also generating modification) of laser parameters Creating bespoke materials and morphology by laser beam shaping in metal additive manufacturing,’ Materials & Design, vol. increased interest. to enhance processing speed systems of the future 195, p. 109071, 2020/10/01/ 2020. [4] R Shi, SA Khairallah, TT Roehling, TW Heo, JT To address these needs, we and obtain desired materials Through ongoing efforts at McKeown, and MJ Matthews, ‘Microstructural control in metal laser powder bed fusion additive created an integrated modeling- microstructures and properties. LLNL and around the world, manufacturing using laser beam shaping strategy,’ Acta Materialia, vol. 184, pp. 284-305, 2020/02/01/ 2020. experimental validation Our work in this area includes the underlying science of LPBF [5] SA Khairallah et al., ‘Controlling interdependent feedback loop for AM alloy the development of non- AM is becoming more deeply meso-nanosecond dynamics and defect generation in metal 3D printing,’ Science, vol. 368, no. 6491, pp. 660-665, 2020. design and optimisation (figure contact temperature monitoring revealed, leading to AM material [6] JD Roehling et al., ‘Rapid Solidification in Bulk 3). A multiscale simulation systems to obtain accurate innovations that are leading to Ti-Nb Alloys by Single-Track Laser Melting,’ (in English), JOM, Article vol. 70, no. 8, pp. 1589- 1597, Aug 2018. framework was developed that temperature profiles during new industrial applications. [7] R Shi, S Khairallah, TW Heo, M Rolchigo, JT couples thermodynamic models, the laser-metal interaction and Guided by modelling and McKeown, and MJ Matthews, ‘Integrated Simulation Framework for Additively microstructure-scale phase field solid-liquid phase transitions using highly flexible, optically Manufactured Ti-6Al-4V: Melt Pool Dynamics, Microstructure, Solid-State Phase simulations, and laser track- (figure 4a). Hyperspectral tuned platforms, we have Transformation, and Microelastic Response,’ JOM, journal article vol. 71, no. 10, pp. 3640- 3655, October 01 2019. scale multiphysics simulations imaging was employed to demonstrated material [8] D-X Qu, J Berry, NP Calta, MF Crumb, G Guss, to quantitatively predict tailored obtain 2D spectral radiance and property control that can and MJ Matthews, ‘Temperature Measurement of Laser-Irradiated Metals Using Hyperspectral form the basis for bespoke Imaging,’ Physical Review Applied, vol. 14, no. 1, microstructure formation. This extract real-time temperature p. 014031, 07/10/ 2020. [9] JT McKeown, AJ Clarke, and JMK Wiezorek, framework was experimentally distribution by fitting measured component designs. Specifically, ‘Imaging transient solidification behavior,’ (in English), Mrs Bulletin, vol. 45, no. 11, pp. 916-926, validated using data from laser- spectra according to Wien’s a comprehensive thermal- Nov 2020. processed Ti-Nb alloys. approximation. Ultimately, microstructure-property toolkit
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Exploring the potential of diode lasers for additive manufacturing
Tim Lantzsch and his colleagues investigate the feasibility of diode lasers for the laser powder bed fusion of stainless steel
Figure 1: a Zemax simulation of spot deformation at different deflection angles of the laser beam resulting from chromatic aberrations (left) and the resulting optical design of the colour-corrected f-theta lens (right)
This article was co-authored by Markus Schauerte, Martin Traub, Thomas Westphalen and Christian Tenbrock of Fraunhofer ILT, and Johannes Schleifenbaum of the RWTH Aachen University Chair for Digital Additive Production
In recent years, laser powder bed fusion (LPBF) has become an established manufacturing technique due to it enabling the manufacture of complex part geometries without additional tools1. State-of-the-art LPBF machines feature a combination of multiple single-mode fibre lasers and galvanometer scanners due to their excellent focusability (BPP < 0.4mm·mrad) and dynamic beam positioning. However, due to the high cost of fibre laser beam sources and galvanometric scanners, LPBF machines still pose significant investment costs. Highly efficient high-power based positioning system2,3,4, galvanometer scanner and diode lasers could present a resulting in less dynamic laser a colour-corrected f-theta “LPBF more-affordable alternative to beam positioning and thus lens, was developed and machines still fibre lasers in LPBF machines. reduced system productivity. integrated into an LPBF machine. However, the lower beam quality To overcome these productivity Furthermore, the optical system pose significant (BPP > 8mm·mrad) and spectral restrictions current approaches was used to process stainless investment width (920 to 1,050nm) of use diode laser arrays to scale steel AISI 316L to demonstrate commercial high-power diode melt pool size2,3,4, which results its feasibility for producing fully- costs” lasers results in chromatic in reduced part quality, namely dense metallic components. aberrations and reduced higher surface roughness and focusability, thus making lower geometrical accuracy. Machine configuration with Trumpf’s QBH-compatible modifications to LPBF machines In this study – conducted For the machine setup, a collimator (f = 100mm) and necessary. as part of the Fraunhofer commercial grade fibre-coupled combined with an IntelliScan Current approaches to lighthouse project FutureAM: TruDiode 301 laser from Trumpf, III 30 galvanometer scanner address these challenges Next Generation Additive emitting a maximum laser from Scanlab. In order to limit rely on a combination of fixed Manufacturing – an optical power of PL = 300W at λ = 920 - chromatic aberrations resulting focusing optics with a gantry- system, featuring a standard 1,050nm, was used. It was paired from the spectral width of the g
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Figure 2: laser power characteristic (left), laser beam caustic measured at PL = 300W (middle) and laser intensity distribution at focal position (right) for the developed DL-LPBF optical system “State-of- the-art LPBF machines feature a combination of multiple single-mode fibre lasers and galvanometer scanners” Figure 3: DL-LPBF laboratory machine setup Processing results The LPBF machine setup described above was used to perform the first trials on the a theoretical build up rate of diode laser based LPBF (DL- 4.5mm³/s. LPBF) of stainless steel AISI To improve the surface 316L. Hatching parameters quality, contour parameters were determined to ensure were introduced. The line energy manufacturing of functional during the contour exposure was parts with a relative density of varied through adjustment of the ρ > 99.9 per cent. Due to the laser power and scan speed. The limitation of the available laser resulting surface roughnesses power and the comparably large of side-skin surfaces in as-built
focus diameter of ds = 240µm, condition and after sandblasting the powder layer thickness and are displayed in figure 5. The laser power were kept constant measured surface of the test
at DS = 30µm and PL = 300W specimens is highlighted. A
respectively. Hatch distance contour line energy of EL,C =
Δys and laser scanning speed 0.43J/mm yielded a minimum g vs were varied accordingly. average surface roughness high-power diode laser, a colour- yielded a focus beam diameter The resulting relative density of SA = 25.6µm in as-built
corrected f-theta lens was of ds = 237µm at a Rayleigh was determined optically via condition, which corresponded
developed and manufactured. length of zR = 1.9mm. The optical microsections and image to a minimum average surface
The result of the Zemax system was mounted onto a processing. roughness of SA = 13.6µm after simulation for the laser spot motorised z-axis, which was The parameter range with the sandblasting. deformation due to chromatic used during the process setup resulting densities and build up Furthermore, geometrical aberrations at different to precisely align the focus rates, as well as an exemplary restrictions during DL-LPBF, deflection angles for different position to the LPBF machine’s microsection, are depicted in such as maximum free overhang wavelengths, as well as the substrate plate, and was then figure 4. angle and minimum detail resulting optical design for the kept at a constant position The chosen parameter set resolution, were investigated by f-theta lens, are demonstrated during processing. (highlighted in red) yields a manufacturing test specimens in figure 1. The beam paths An overview of the LPBF reproducible relative density using the above-mentioned
indicated in blue, green and red machine setup is in figure 3. of ρrel = 99.94 per cent and processing parameters. The represent different deflection angles of the scanner mirrors M1 and M2. Figure 4: identified processing parameter range for the DL-LPBF of stainless steel AISI 316L (left) and corresponding The developed f-theta lens microsection for the chosen process parameter set (right), highlighted in red uses a back focal length of 185mm, which resulted in a focus beam diameter of approximately 235µm. The deflection angle of the laser beam was limited to 6.5° to limit chromatic aberration (figure 1), which resulted in an effective scan field size of ∅ = 90mm. The laser power characteristic and laser beam caustic of the laser optical system are in figure 2. The laser optical system
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Figure 5: resulting average surface roughness SA depending on the contour Figure 6: overview of geometrical restrictions (highlighted red) and line energy EL,C in as-built condition and after sandblasting manufacturable geometrical features (highlighted green) for DL-LPBF processing of stainless steel AISI 316L
results are demonstrated in The findings obtained figure 6. from the process parameter The scanner-based DL- study and the investigation on 0.2mm. However, some of the Conclusion LPBF approach presented geometrical limitations were impeller’s blade tips exhibited In summary, scanner- within this article enables the transferred onto a turbocharger significantly larger deformations. based DL-LPBF enables the manufacturing of free overhang impeller demonstrator, which These only occured on blade manufacturing of fully-dense angles of up to α = 40°. A was chosen to show the tips with overhang areas metallic components with minimum wall thickness of twall capabilities of scanner-based oriented parallel to the recoater similar properties to those = 250µm and a minimum gap DL-LPBF. The impeller had a and facing in the recoating manufactured with state-of-the- with of tgap = 200µm can also be diameter of 85mm and a height direction. Due to the filigree art fibre laser LPBF machines. achieved. Horizontal bores with of 50mm. An image of the blade geometry, the overhangs This demonstrates the feasibility diameters of dbore = 1 - 5mm manufactured and sandblasted deformed and hindered the of diode lasers for additive can be manufactured without impeller, as well as the 3D scan recoating of subsequently manufacturing. However, the internal support structures. of its geometrical accuracy, manufactured layers, resulting spectral width and beam quality Larger bore diameters require using striped light projection, are in geometrical defects. A of high-power diode lasers internal supports for defect- shown in figure 7. possible solution to this result in a complex and costly free manufacturing, whereas The 3D scan of the problem is the use of dedicated optical design and restrictions smaller bore diameters cannot demonstrator geometry down-skin parameters for regarding the achievable be manufactured due to powder indicated an average the manufacturing of filigree maximum scan field size. sintering. geometrical deviation below overhang structures. Nevertheless, DL-LPBF, especially when combined with other emerging technologies Figure 7: turbocharger demonstrator manufactured using DL-LPBF (left) and corresponding 3D-scan after such as direct blue diode sandblasting using striped light projection (right) lasers and dense wavelength combining, will be well suited to l future LPBF applications.
Tim Lantzsch is team leader of LPBF machine technology at Fraunhofer ILT
References [1] Terry Wohlers, Robert I Campbell, and Olaf Diegel. Wohlers report 2020. ‘3D printing and additive manufacturing state of the industry’ 2020. 978- 0-9913332-6-4. [2] Florian Eibl. ‘Laser powder bed fusion of stainless steel with high power multi-diode-laser-array’. Dissertation. 1. Auflage. Edition Wissenschaft Apprimus. 978-3-86359-587-6. [3] Florian Eibl, Christian Tenbrock, Tobias Pichler, Tobias Schmithüsen, Daniel Heussen, and Johannes H. Schleifenbaum. ‘Alternative beam sources and machine concepts for laser powder bed fusion’. Piscataway, NJ: IEEE, 2017. Proceedings of the 2017 High Power Diode Lasers and Systems Conference (HDP). 9781538632642. [4] Miguel Zavala-Arredondo, Nicholas Boone, Jon Willmott, David TD Childs, Pavlo Ivanov, Kristian M. Groom, and Kamran Mumtaz. ‘Laser diode area melting for high speed additive manufacturing of metallic components’. Materials & Design. 2017, 117, 305-315. Available from: 10.1016/j. matdes.2016.12.095.
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UNDERWATER LASER CUTTING FOR NUCLEAR DECOMMISSIONING Jan Leschke and his colleagues have developed a new process for the safe dismantlement of nuclear equipment
This article was co-authored Figure 1: the test stand used includes a gantry system for Figure 2: cutting process in by Benjamin Emde, Jörg the cutting motion and a hydraulic platform to position laboratory conditions using Hermsdorf, Stefan Kaierle and the setup in and above the water the 45° head Ludger Overmeyer of the Laser Zentrum Hannover
As an ever-growing number of nuclear power plants reach the end of their lifetime, their decommissioning is increasingly being brought into focus. Additionally, political programmes, such as the nuclear phase-out in Germany that will be completed by the end of 2022, are increasing the number of nuclear power plants that require dismantling. Germany’s phase-out programme affects 23 nuclear power plants, with the decommissioning of 17 of them already underway1. Worldwide there are 442 active nuclear power plants, while an additional 54 are under construction and 119 more are planned2. Taking into account these numbers, the dismantling of nuclear power plants will clearly continue to be a topic of concern for the foreseeable future. Therefore, with the increasing number of facilities requiring dismantlement, takes place in the remaining of these existing methods, is added, which must also be the need for optimised cooling water of the reactor. especially saw and water jet stored. deconstruction technologies Several tools and processes cutting, is the generation of To overcome this drawback, arises. such as saw cutting, water jet secondary waste that then a project has been carried out In nuclear decommissioning, cutting or plasma cutting are needs to be filtered out of the at the Laser Zentrum Hannover dismantlement often takes currently used in this field, with water. (LZH) to study the feasibility of place as soon as a plant shuts each of them having their own In addition, in the case of using laser cutting under water down to reduce any risk of advantages and disadvantages. water jet cutting, a considerable to minimise secondary waste contamination. Separation work The main disadvantage amount of abrasive material production.
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Figure 3: different dross types formed due to parameter 3D-MICROMAC FEATURED PRODUCT variations: a) ball type, b) line type, c) inhomogeneous/none
microSHAPE – Laser Cutting cost-effective and high-quality of Glass Substrates cutting of wafers and large glass substrates – including Laser processing of glass ultrathin glass. enables rapid, highly precise The modular platform and highly reproducible is designed for all ablative processing of brittle glass and non ablative cutting or substrates. Compared to structuring processes. This conventional processing includes filamentation, thermal methods, laser processing laser separation, half cut or Figure 4: optics that were developed to enable optimised cutting scores with: full cut. The highly versatile of nuclear power plant components under water. • Free-form geometries system enables the combining • Internal contours of different laser processes, as • Best surfaces and edge well as processing with multiple quality laser process heads. The • Minimal chipping availability of several handling • Possibility for processing and inspection options enables coated substrates the system to be a highly • No masks, wear parts and efficient production platform. other expedients necessary All processes meet the In addition, the laser is ideally requirements of industrial suited for removing coatings customers and guarantee thanks to its high selectivity. clean and gentle processing, With the microSHAPE as well as excellent processing laser systems, 3D-Micromac quality. offers unique processing https://3d-micromac.com technologies and innovative https://youtu.be/ process management for the BTjctX375BU
required a lower amount of loss: minimising the width of the energy per unit length to make cutting kerf and maximising the Cutting experiments Within the cutting tests, each cut, meaning a wider formation of dross. and results 1.4301 samples with 3, 6 and range of parameters could more The investigations showed The laboratory studies were 15mm thickness, as well as easily be tested compared to that varying the cutting gas carried out in a 1m³ water tank, zircaloy samples with 3mm the other thicknesses/material. pressure and the laser power, as as shown in figures 1 and 2. A thickness, were processed. In Since the goal of the project well as the interaction between disc laser was deployed for the order to gain a fundamental was to minimise the generation these parameters3, had a tests, with air used as the cutting understanding of the process of secondary waste, the weight significant effect on weight loss. gas. As would be the case with and the influence of its loss of each sample (in g/m) due Both parameters were tested at nuclear power plant components, parameters, comprehensive to cutting was determined for predefined low and high levels. the samples to be cut consisted testing was first carried out each test. In theory, as well as Besides the influence on of stainless steel (1.4301) or a on the 3mm 1.4301 samples. in the field, two aspects of laser weight loss, the kerf properties zirconium alloy (zircaloy). This was because the material cutting could reduce the weight changed as expected when g
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Figure 5: successful validation of the process and the developed optics at a 4m depth under water waterproof axis system, which was positioned on the ground of the tank (see figure 5). To prevent the laser fibre from getting wet, the parts exposed to the water were covered by a hose. The tests included the cutting of 1.4301 sheets of 3 and 15mm thicknesses. Both sample types were successfully cut, verifying the laboratory results. Following studies at the LZH will focus on using the developed laser process to cut 1.4301 with thickness > 15mm, as well as the cutting of multiple l layers of material.
The investigations were carried out in the project AZULa (Automatisierte Zerlegung von Reaktordruckbehältereinbauten mit Hilfe von Unterwasser- g cutting 3mm 1.4301 (see the angles. While the 0° head has a Lasertechnik). The research variations in dross types in “Two aspects higher efficiency when cutting project (FKZ 15S9408) was figure 3). Using a high cutting of laser cutting thick materials, the 45° head supported by the German gas pressure of 3.75 bar and could cut back allows for easier handling, since Federal Ministry of Education a low laser power of 2kW, thin secondary waste: the angle of the optical system and Research (BMBF) through cutting kerfs and a medium minimising the must not be changed for the Gesellschaft für Anlagen- amount of line-shaped dross alternate cutting of horizontally und Reaktorsicherheit (GRS). We were achieved, resulting in a width of the and vertically positioned parts. would like to thank all funding weight loss of about 5-10g/m. cutting kerf and organisations and our project By changing the parameters maximising dross Process validation partner, Orano. to a low cutting gas pressure formation” and future plans of 0.25 bar and a high laser The project concluded with Supported by power of 4kW, large dross balls the transferring of the laser were formed on the back of the process from laboratory samples, while the kerfs gained conditions to those reflecting in width. This dross formation thick samples changed in their industry. The developed led to the lowest amount of weight loss behaviour. In their laser optics were validated weight loss in the study at about case, the lowest amount of to Readiness Level 6 (system 1-3g/m, confirming that the goal weight loss (about 36g/m) was prototype demonstration in a Jan Leschke is a research assistant lies in maximising the dross achieved using a comparably relevant environment)4 at 4m at LZH formation. The applied cutting high cutting gas pressure of depth in a water tank at the Benjamin Emde is head of the speed for this parameter was 6 bar. Unterwassertechnikum at the underwater technology group at LZH Jörg Hermsdorf is head of the 0.9m/min. Leibniz University Hannover. materials and processes department Other parameter variations Underwater laser optics The tests were carried out at LZH in the scope of the study The second part of the using a mobile disc laser system Stefan Kaierle is the scientific- resulted in dross reduction and project consisted of the set-up and operated by Laser technical director at LZH therefore increased weight development and construction on Demand. The movement at Ludger Overmeyer is chairman of the scientific directorate and a loss. Compared to conventional of laser optics optimised for the 4m depth was realised by member of the board of directors techniques, such as band saw underwater nuclear power plant integrating the optics with a at LZH cutting, weight loss can be decommissioning applications. reduced by about 95 per cent The optics consisted of References: using laser cutting. stainless steel and due to [1] Deutscher Bundestag - 19. Wahlperiode, ‘Bericht nach §7 des The cutting of the 3mm their cylindrical geometry Transparenzgesetzes - Rückbau von Kernkraftwerken für das Berichtsjahr zircaloy samples showed equal (see figure 4), were able to fit 2019 (Drucksache 19/24770),’ Bundesanzeiger Verlag, Köln, 2020. [2] Nuklearforum Schweiz, ‘Kernkraftwerke der Welt (www.nuclearplanet.ch),’ behaviour and depended through gaps ≥ 120mm, which Olten, 2020. strongly on the applied cutting is sufficient for most nuclear [3] J Leschke, B Emde, J Hermsdorf, S Kaierle, L Overmeyer, ‘Controlling the gas pressure. The 6mm thick power plant components. The kerf properties of underwater laser cutting of stainless steel with 3mm samples of 1.4301 gave similar optics were designed with an thickness, using an Yb:YAG laser source in nuclear decommissioning processes,’ Procedia CIRP, Bd. 94, pp. 493-498, 2020. results when lowering cutting interchangeable head that [4] JC Mankins, ‘Technology Readiness Levels: A White Paper,’ Office of Space speed to adjust the energy per enables switching between 0° Access and Technology, Nasa, 2004. unit length. However, the 15mm (perpendicular) and 45° working
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EXPERIMENTING WITH BEAM OSCILLATION FOR METAL HARDENING EDMUND OPTICS FEATURED PRODUCT
Handika Sandra Dewi explores the effects of circular, square and triangular oscillation strategies when treating microalloyed steel
Laser surface treatment hardening. A doughnut beam can be used to increase profile, which has higher energy the resistance of metals to intensity at the edge compared environmental attack when to the centre of the beam, has sufficient resistance cannot be been reported to produce attained by alloying addition. homogeneous treated areas. A Superpolished Optics For example, hardening the top-hat beam profile, which has Edmund Optics is a world-class Edmund Optics has surface of a metal using a laser homogenous energy intensity manufacturer of high-precision developed a process for optical is one strategy for improving across the beam shape and optical components and surface polishing down to an its fatigue properties. The therefore delivers equal energy an innovator in the optical RMS surface roughness of laser increases local surface input to the specimen, also manufacturing field. Each sub-Angstrom ≤1Å (10-10 m) temperature and induces creates a homogenous treated of Edmund Optics’ global for parts-per-million-level martensitic transformation, area. factories is specialised in scattering, all supported which increases hardness a particular area of optical by a comprehensive in- and induces residual stress manufacturing for both off-the- house metrology suite. This characteristics that hamper “Laser surface shelf and custom parts. superpolishing manufacturing Conventional subtractive process produces ultra-low fatigue crack propagation treatment can optical polishing methods scattering optics ideal for any through the material. increase the leave behind subsurface materials processing application Laser hardening is a precise resistance damage on the optic as a where a short wavelength or and energy-efficient method of metals to natural result of the process, high laser power is required, that offers flexibility when leading to scattering and an such as surface treatment, hardening complex structures, environmental overall decrease in system cutting, welding or marking. such as crankshafts for internal attack” efficiency. Many laser systems Superpolished optics are equally combustion engines. However, and applications demanding ideal as substrates for ion- the commonly used Gaussian an increased throughput and beam-sputtering (IBS) coatings. laser beam profile produces Another developing lower losses require optical www.edmundoptics.eu/ components that minimize this knowledge-center/trending-in- non-homogenous depth in the technique that could be of scattering. optics/superpolished-optics hardened area. interest to laser hardening The depth homogeneity is beam oscillation, in which of laser-treated zones is one special optics use mirrors to factor that can define the oscillate the laser beam at a solidification rate. therefore experimented with quality and efficacy of altered specific frequency and pattern, With efforts to optimise laser surface treatments on mechanical properties in the while moving across a material’s laser hardening still underway, microalloyed steel disks using a material. Since the depth surface. in addition to the continual variety of oscillation strategies. homogeneity depends on the The technique influences advancement of oscillating This was so that we could laser beam profile and shape, the distribution of input laser optics, combining the two observe their effect on the customised laser beam shapes energy, and has been shown fields – using beam oscillation quasi-static laser beam profiles can tackle this problem. to increase efficiency in laser to influence laser hardening – and the geometry of the treated For example, doughnut and welding by increasing weld becomes an interesting topic areas. Microalloyed steels are top-hat beam profiles can be depth and influencing both to study. commonly used in industry as a of particular interest for laser temperature gradient and My colleagues and I have base material for crankshafts. g
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Figure 1: (a) illustration of the experimental setup for (b) circular, (c) square and (d) triangular oscillation strategies including top view (e), (f), (g) and cross-sectional (h), (i), (j) images of the resulting tracks and quasi- static laser beam profiles at different interval times (k) – (s) g Experimental setup +/- 10mm, can oscillate at up square track, while three vivid used to stack semi-transparent In this work we used oscillating to 500Hz for 1mm amplitude lines were found on the edge drawings of the oscillation optics recently developed by and can support laser power up and centre of the triangular strategies along the robot’s Permanova Laser System. to 8kW for wavelengths from track. Respective cross- path. The amount of assembled The optics have two main 1,030 to 1,070nm. sectional images (figures 1h, drawings represents the components: the optical Figure 1a illustrates our i and j) show that the circular number of oscillations at a unit and the control system. experimental setup. The oscillation strategy produces specific interval time. The optical unit consists of oscillation optics were homogenous depth, while the As a result, figures 1q, r and s a collimation and focusing mounted to a moving robot melted regions and vivid lines have similar features to the top lens, water cooling, cover and integrated with Trumpf’s of the square and triangular view of the track in figures 1e, slides, temperature and safety 1,030nm TruDisk laser. The strategies result in a locally f and g. sensors, and two additional robot moved along the X-axis, deeper treated area. The most important feature oscillating mirrors. The mirrors producing single, straight, laser- Quasi-static laser beam through figures 1k to s is perform very fast rotations treated tracks. Circular, square, profiles of the oscillation the contrast. The brightness around a central axis, resulting and triangular oscillation strategies were visualised corresponds to how often the in a movement of the focus spot strategies (illustrated in figures by reconstructing the laser laser beam passes through in two directions relative to the 1b, c and d) were performed beam pathway at 0.5s, 1s and the area. The brighter the area, laser head. using constant laser parameters 2s (shown in figures 1k to s). the more often the laser beam The control system features and a 1mm beam spot. A vector graphic editor was passes through. Therefore, software where adjustments brighter features on the image can be made to laser power, Results can be associated with higher oscillation speed and oscillation Top views of the tracks (see local energy input due to pattern. The software provides figures 1e, f and g) show the “Oscillated laser multiple passes of the laser predefined settings that can characteristic shapes achieved beams influence beam. It is now clear why the be modified as desired. The with each oscillation strategy. both spatial and beginning and end sections of laser power and scan speed While the beginning and end temporal energy the tracks were not fully treated. can also be set to change sections of the tracks were not input distribution The laser beam only passes during the oscillation to achieve fully treated, the middle section through this area once, and variable energy density over the of each track was fully treated during laser thus the energy input was not scanning area. for each oscillation strategy. surface treatment” sufficient to induce martensitic These optics have a 1:1.76 Small regions of melted material transformation in the material. optical ratio, a scanning area of were found at the edge of the The microstructure of the
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melted regions at the edge of experiences over time ranges oscillation patterns. While the square oscillation strategy from X0 to X1 on figures 1q, r and “Beam oscillation triangular and square oscillation resulted in increased softness s. The centre of the triangular shows potential strategies produce quasi-static compared to the non-melted oscillation track received for surface laser beam profiles with equal regions. This means that the energy input from 0s, while treatment, distribution and an abrupt drop hardness is not homogeneous the neighbouring edges did although further in the energy intensity from across the treated area. not. Accordingly, the temporal the edge peak of the profile, For the triangular accumulation of energy input is efficiency is a circular oscillation strategy oscillation strategy, while a higher at the centre of the track required” produces one with higher homogenous microstructure compared to the neighbouring energy input at the edges and was achieved across the edges. gradual intensity decrement treated area, due to the vivid However, the speed of beam oscillation consumes towards the centre. The latter lines it demonstrated non- the oscillating laser beam more energy than the above results in homogeneous homogeneous depth, which decelerates at the vertices of beam shaping techniques. microstructure and depth over hampers the improvement of square and triangular oscillation However, we will conduct the treated area, making it the fatigue properties. Therefore, strategies due to mechanical further experiments using a best oscillation strategy of the the circular oscillation strategy, limitation, thus causing larger beam spot diameter and three for laser hardening. which demonstrated both additional local energy input different oscillation strategies Beam oscillation therefore homogenous depth and at these points. This additional that may be able to improve the shows application potential in hardness, was considered the energy input contributes to efficiency of beam oscillation. surface treatment, although best choice for performing laser the melting of the edges of the Despite its lower efficiency, further improvement of the hardening via beam oscillation. square oscillation track and the beam oscillation has shown efficiency and resultant treated production of the vivid lines on flexibility in tailoring energy depth is required. Temporal Mechanical limitations cause the triangular oscillation track. input, and thus the geometry aspect and mechanical additional energy input of the treated area without the limitation of the oscillating Temporal aspects and Observations need for changing any optics. optics also need to be mechanical limitations of In general, the beam oscillation Therefore, beam oscillation considered for choosing an the oscillating optics could strategies produced shallower should indeed be considered oscillation strategy for surface explain the melted regions and treated areas compared to for laser hardening and other treatment. Experimenting with vivid lines on the square and a common Gaussian beam surface treatment applications. a larger beam spot and other triangular tracks respectively. or other beam profiles such oscillation strategies to improve Imagine the oscillating laser as top-hat or doughnut, Conclusion process efficiency is on our l beam passing through a as well as those produced Oscillated laser beams future research agenda. standing point at the cross- using diffractive optical influence both spatial and sectional position of the tracks elements. In terms of the temporal energy input Handika Sandra Dewi is a PhD student at during the process. The energy energy needed over the distribution during laser surface Luleå University of input that standing point volume of the treated track, treatment through overlapping Technology
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Finding the silver lining Dave MacLellan, executive director of AILU, on opportunities that emerged for laser technology during the pandemic STA AV Macsa ID Pro Plates Pro
‘The only thing constant is change’ is a quote by the Greek philosopher Heraclitus. During the past 12 months, there has been a huge amount of change all over the world which has resulted in some winners, as well Left: home gym equipment made with laser cutting; middle: laser-marked ID matrix an on antigen as many losers. Businesses with a test device for Covid-19; right: laser-cut stainless steel bike frame good online store have generally fared well, and organisations that • Renewable wind and solar to launch a range of laser cut UK market growing by around 27 have adapted their offering to energy weighted plates. The established per cent from April to September home delivery have very often • Green transport (bicycles) ‘Pro Plates’ division, has seen compared with the previous year. experienced huge growth. • Electric aircraft (drones and such extreme growth that Electric bikes saw a near In among the doom and battery-operated planes) turnover has quadrupled over the doubling in volume for the same gloom stories of closing high- This topic is finding traction with past 12 months, with no signs period. What applications are street stores and struggling government funding all around of a slow-down. The demand in interesting for lasers in this entertainment and hospitality the world. Europe is likely to fuel the laser market? Laser-cut tubes and sectors, there are opportunities Underlying all of the above cutting machines for years to forks form the frames of many for laser manufacturing. Most are is low carbon generation and come. modern bicycles (made from due to shifting habits imposed the storage of power, as well stainless steel, titanium and by lockdown on our daily lives. as the application of power to Diagnostics and healthcare aluminium) as well as laser- In this article we look at a few drive transport systems. Lasers With the rush to develop etched stainless steel parts and success stories and the markets are used in the cutting and Covid-19 vaccines bearing novel designs using laser additive where lasers are powering strong welding of battery components, fruit, and Europe being well manufacturing. growth and creating a positive the 3D printing of low-mass represented in this industry, there Even carbon fibre bike frames impact on our world. structures, ablation and drilling are plenty of other areas that are are often made using laser in photovoltaic substrates and booming where laser applications cut polymer preforms. The Green economy films, and the manufacturing of abound. Rapid testing for the European market is 20 million During the first lockdown there structural components. virus and antibodies, as well as cycles per year (compared to was a marked reduction in genome sequencing to detect cars, with 12 million) so there is travel and airborne pollution in Home health and fitness variants, have created a step a large potential for lasers, even many places. It led people to With gyms shut down in the change in the market for funding if the unit cost and number of l re-evaluate international travel’s first lockdown, there was a and research in these sectors. components is small. necessity, and even commutes to rush to buy exercise equipment Applications in this field include the office. With a new president in (treadmills, rowing machines and laser marking for permanent DATES FOR YOUR DIARY the US, and COP26 later this year weight benches all sold out within identification, tracking and anti- in Scotland, there is an added weeks). During the first months counterfeiting, as well as the ILAS 2021 Online Symposium 24 to 25 March emphasis on decarbonisation of lockdown, UK sales of gym laser welding of plastics (often www.ilas2021.co.uk and protecting the planet from equipment increased by around white or transparent) which are overheating. This is driving 5,800 per cent. Gyms lost up to a used in pharmaceutical and Webinar on Laser Applications in several initiatives that present third of their members, as many diagnostic products. the Low-Carbon Economy great opportunities for laser people decided they wouldn’t 17 June, 2021 www.ailu.org.uk/events manufacturing: return for the foreseeable future. Bicycle boom [email protected] • Electric vehicles (battery and One UK job shop, Proform Group Bicycles experienced a huge +44 1235 539595 hybrid) in north-west England, decided surge in orders last year, with the
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LASER SYSTEMS
PRODUCT JUPITER SERIES
Amada Weld Tech’s new Jupiter series of UPDATE modular systems can be used for laser welding, laser marking, resistance welding, micro arc welding and hot bar bonding applications. The systems can be equipped with all the joining process modules available from the company. The modular system platform comes SAFETY in four sizes, so it is adaptable to specific production requirements. The stable LAS 800 platform enables connections of very high quality and accuracy. Jupiter models ULT has introduced the LAS 800 fume feature an ergonomic system design with extractor for the removal of large amounts of high quality components, designed for the finest dusts and gases that occur during 24/7 continuous production. All models are laser materials processing. equipped with a human-machine interface According to ULT, the device is one of with touchscreen for easy programming quietest systems in its class, which also and standard safety features. scores with its compact, robust and flexible Control systems, based on a design. The standard equipment is a cartridge programmable logic controller or industrial filter system with a 30 litre dust container. The PC, collect all available process parameters four filter cartridges of class M are compliant and process data into one control system. with DIN EN ISO 16890 and guarantee long life, The data can be stored in local and remote as well as simple assembly and maintenance storage areas, all engineered to seamlessly options. integrate with an Industry 4.0 factory The LAS 800 can be flexibly configured concept. for changing processes and materials. There Optional features for the Jupiter are several post-filter options, including the systems include: a combustion addition of fine dust filters (H-14) or safety suppression unit for battery pack welding; filters which can be installed if necessary. a transport system with two individual belts There is also the option of using sorption that can be configured for a wide range filters (activated carbon and/or chemisorption) of product carriers, including transfer to bind any odours or gases. Extensive systems; an automatic cleaning station for safety options also guarantee safe use with level in the dust collector, or for monitoring electrodes and thermodes; a ‘not ok’ bin combustible dusts. These include a spark the compressed air, as well as options for to separate products outside the control pre-separator, spark stop with automatic connection to modern and promising bus limits from those within control limits; and a suction stop and shut-off damper, safety communication platforms or the use of a range of water cooling options. shutdown when the H-14 filter is occupied, recirculating air silencer. In addition a metering www.amadaweldtech.eu or a temperature sensor built into the raw gas unit can be connected with a filter aid to space. optimise the filtration of fine and sticky dusts. Also included are sensors for the fill www.ult.de
LASER CASTLE LITE
Lasermet has launched the Laser Castle Lite, a modular, low-cost, self-assembly laser safety cabin ideal for smaller laser operations, such as those using small laser robots for cutting, cladding or welding. The enclosure is fully certified, interlocked and made from the same laser blocking material as the original Laser Castle to protect users from high-energy laser radiation. It has an open roof void for low- cost ventilation. The cabin arrives as a flat-pack in a shipping crate and is easily assembled by the customer out of the box. Its manually operated door, safety interlock switch, dual- message LED warning sign, emergency stop break glass, internal emergency stop button and entry door maglock – are all linked to the ICS-Solo interlock control system. www.lasermet.com
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LASER SYSTEMS
Coil-fed fibre laser Enhanced Procudo Laser cutting system Peening System Danobat has introduced LSP Technologies has enhanced its a flexible fibre laser Procudo Laser Peening System, enabling it cutting system to be integrated more easily and effectively that is coil into factory workflow and operations. fed, rather The upgrades include: secure remote than sheet monitoring worldwide for customers; fed. This highly productive AI-based alerts for system conditions, machine takes full advantage of maintenance and supplies; a more user- all the benefits offered by fibre laser friendly human machine interface with cutting technology (efficiency, speed, a clearer graphic workflow; and optional versatility, minimal maintenance), as well offline programming with 3D models to as the benefits from the use of metal coils speed development of laser peening metal (up to 15 per cent savings in materials treatment patterns for complex geometric cost and improved sheet utilisation). shapes. The system consists of a sheet feeding line It is designed for rapid integration into a and an integrated laser cutting module that sheet to obtain the desired geometries. The process and can be integrated with a wide work together for continuous operation. exit of the cut pieces can be automated using variety of automated part-handling robots The feeding line is equipped with an different systems, such as robots or stackers. and CNC machines. Included are self- uncoiler which unrolls the coil, a straightener Due to its modular design, multiple diagnostic and self-adjusting technologies which removes the sheet’s contours heads can be integrated into the solution to monitor power levels, assure laser beam and internal stresses, and a looping pit to exponentially increase the cutting quality and deliver accurate spot size, as which stores the straightened material for process’s productivity. The workload will be well as monitoring for chillers, water flow, processing. consequently distributed among the heads. hydraulics and air flow intrinsic to laser The laser consists of a fibre laser generator https://sheetmetal-america. peening. and a cutting head that moves in sync with the danobatgroup.com These systems also feed data to AI software to monitor supplies and all component functions by learning how Glass processing machine they match up against typical operation patterns. AdValue Photonics has introduced a laser https://lsptechnologies.com glass processing machine to drill, cut, mark and mill glass materials, including soda lime, borosilicate, optical glasses, fused quartz, and coated glasses. This laser machine provides superior flexibility, quality and throughput for glass fabrication. It can drill glass substrates with thickness from 50µm to 10mm with hole size 50µm to 90mm in diameter. The technology’s programmable drilling design offers little-to-zero taper and micro crack holes. The equivalent drilling speed surpasses conventional mechanical drilling methods. For example, it takes only 1.5s to drill a 10mm hole on a 1mm thick glass and The machine is equipped with a fibre 3s on a 2mm thick glass. laser, motion system, camera alignment This technology offers a ‘green’ system and granite surface plate to provide fabrication process. No cooling water is low-maintenance cost, high precision and needed, as is the case with conventional boosted productivity. mechanical processing or water-jet cutting. www.advaluephotonics.com
Optiplex Nexus 3015 Fiber S7 everything in between. Beam Mazak Optonics has released the shaping technology delivers Optiplex Nexus 3015 Fiber S7 optimal thick and thin metal cutting machine. cutting, higher cutting speed, The new 7kW system is superior edge quality and designed with variable beam improved piercing time. parameter product (V-BPP) Active live camera nesting is technology to better control available on the Optiplex Nexus the laser beam for superior cut 3015 Fiber S7, so operators can automated two-pallet design. It is can provide real-time cutting performance. V-BPP enables quickly, easily process additional also equipped with the Mazatrol metrics and maintenance data, selection from a high-intensity, parts on demand, without delay. PreviewG CNC, which helps maximising machine usage and small-spot-size beam to large, The system offers a large simplify set-up and operation. reducing unexpected downtime. doughnut-shaped beams, and side-access door and an Mazatrol PreviewG control www.mazakoptonics.com
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LASER SYSTEMS OPTICS
Economy CO₂ lenses Orbotech Apeiron series A line of low-cost CO2 laser lenses for low- Orbotech has introduced a roll-to-roll power engraving and marking lasers has been manufacturing solution for ultra-thin introduced by Laser Research Optics. flexible printed circuits, enabling the design The Economy CO2 engraving lenses are and mass production of new generations drop-in field replacements offered in plain of electronic devices, including 5G or mounted versions. They are 0.75-inch in smartphones, advanced automotive and diameter with 2-inch focal lengths. Other focal medical devices. lengths will be introduced soon. The system delivers high drilling quality For applications requiring a strong coating and accuracy using two laser beams and to handle dirtier environments, such as four large scan area drilling heads that can acrylic cutting, the lenses are also offered drill in four locations simultaneously and in a premium line with coatings to 10.6μm. optimise laser power usage. It also offers They cost $83 (plain) and $118 (mounted). internal roll-to-roll functionality, resulting in The premium line of lenses with enhanced a small footprint. coatings are $165 (plain) and $195 (mounted). The Apeiron provides built-in beam The lenses are available for use in Epilog, validation tools for size, roundness and Trotec and Universal Laser Systems. energy distribution. Both roll-to-roll and https://laserresearch.net sheet-by-sheet handling of thin flex cores are offered with capacity to drill two panel sheets side-by-side for maximum drilling F-Theta lens for battery production capacity. allow the full www.orbotech.com Jenoptik has developed a compact F-theta performance of lens for 1,064nm applications, such as the lens to be battery foil cutting with high-power lasers. exploited, while It joins Jenoptik’s Silverline lens family for not having any laser applications in the automotive supply back reflections market. in the lens. Thanks to the use of low-absorption Silverline fused silica and a robust optical coating, lenses are used the lens is suitable for applications with across many sectors for applications such ultrashort-pulse lasers and outputs into as ablating, drilling, welding or soldering the kilowatt range. With a focal length of of high-precision structures in plastics 160mm and a minimum spot size of around and metallic compounds. They have a high 23μm, workpieces can be processed in a damage threshold, and guarantee high- scan field of up to 50 x 50mm. The optimised precision and reproducible working results. lens design and innovative lens mounting www.jenoptik.com
TEST & MEASUREMENT
Ophir Helios Plus and Ophir Ariel over 6kW/cm2, a fast 2s response without a diffuser for higher time and a short 10s wait power densities and delivers MKS Instruments has unveiled between pulse measurements. three to five times faster reading two beam power meters, the Ophir Ariel is self-contained, times than competitive products. Ophir Helios Plus and the Ophir ultra-compact and can measure The Ariel features housing that Ariel. industrial lasers up to 8KW in is dust-proof, resistant to water The Helios Plus can be used power. Designed for OEM and splashes and easy to transport. with diode, fibre and Nd:YAG end-user applications in closed Communication options include lasers with powers from 100W – and confined spaces, such as Bluetooth for passing readings 12kW, energies from 10J to 10kJ, additive manufacturing, metal from inside a closed machine to and in wavelengths ranging from cutting and welding, the Ariel a mobile phone or laptop, and a infrared (900-1,100nm) to blue power meter is a robust, battery- USB-C interface. and green (450-550nm) – used for automated measurements can powered device that requires no www.mksinst.com copper welding in the automotive be made. water or fan cooling and is small industry. The system operates by enough to fit on your palm. The Helios Plus is compact, measuring the power, energy and The system measures laser requires no water cooling, exposure time of a short 0.3 to powers from 200mW to 8KW in and provides a high damage several seconds pulse and then a wide range of wavelengths, threshold. Profinet, Ethernet/ calculating power. By keeping the including: green and blue lasers; IP and RS232 communication pulse energy under 10kJ, there is infrared fibre lasers; 10.6µm options make it easy to integrate no need for water or fan cooling. CO2 lasers; and 2.94µm medical into manufacturing networks. This results in a convenient, lasers. The Ariel can be operated Once integrated into the compact, dust-resistant design in continuous or short exposure production control system, fully with a high damage threshold of mode, can be used with or
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COMPLETE LASER SYSTEMS Precitec Powerlase Limited Laser S.O.S www.precitec.com www.powerlase-photonics.com www.lasersos.com 3D-Micromac AG www.3d-micromac.com Trumpf Power Technology PROTECT-Laserschutz GmbH www.trumpf-laser.com www.powertechnology.com ACSYS www.protect-laserschutz.de Quantel www.acsys.de CONTROL & GUIDANCE Purex UK Amada Weld Tech www.quantel.fr www.purex.co.uk www.amadaweldtech.eu Cambridge Technology RGB Lasersysteme GmbH Coherent-Rofin www.camtech.com www.rgb-laser.com SERVICES www.rofin.com Scanlab Synrad Laser on Demand Highyag Lasertechnologie GmbH www.scanlab.de www.synrad.com www.laser-on-demand.de www.highyag.de Toptica Metal Improvement Company Kern Laser Systems LASERS www.toptica.com www.metalimprovement.co.uk www.kernlasers.com Keyence Germany GmbH Coherent OPTICS TEST & MEASUREMENT www.keyence.de www.coherent.com GT Advanced Technologies Laserline GmbH Directed Light Inc. Duma Optronics www.gtat.com www.laserline.de www.directedlight.com www.duma.co.il Gentec Electro-Optics Inc Leister Technologies AG IPG Photonics SAFETY www.leister.com www.ipgphotonics.com www.gentec-eo.com LPKF Laser Quantum Brinell Vision Limited Newson NV www.lpkf-laserwelding.com www.laserquantum.com www.brinellvision.com www.newson.be/rhothor.htm Next Scan Technologies Photon Energy GmbH Lasermet Ophir www.nextscantechnology.com www.photon-energy.de www.lasermet.com www.ophiropt.com
El.En. S.p.A. Aerotech United Kingdom
Via Baldanzese, 17 Industrial Laser Division The Old Brick Kiln, Ramsdell, 50041 Calenzano - Firenze - Italy Tadley, Hampshire RG26 5PR l Tel. +39 055 8826807 Fax +39 055 8832884 Tel: +44 (0)1256 855055 Fax: +44 (0)1256 855649 https://elenlaser.com l [email protected] www.aerotech.co.uk Producing innovation since 1981 El.En. is an italian laser company based in Florence. We produce CO2 Aerotech serves the unique requirements of laser processing and laser laser sources, laser scanning heads and custom laser devices for the machining applications by manufacturing high performance systems and manufacturing industry. With El.En. you can count on reliability, durability components for laser applications. and expert technical assistance because all the core components of our devices are engineered and produced in-house. Our laser sources are Aerotech developments in the areas of mechanics, controls, software geared to achieve speed, precision and ease of integration in a wide range and laser control have provided end users, systems integrators and of applications. This is why since 1981 we’ve been working with more than OEMs with the best possible laser cutting, welding, etching, and marking 2000 companies worldwide, gaining a considerable experience in a wide systems available. range of markets. Start making with El.En!
Fujikura Europe Ltd Edmund Optics
C51 Barwell Business Park, Tel: +44 (0)1904 788600 Leatherhead Road, Chessington, Surrey KT9 2NY, UKK l [email protected] Tel: +44-(0)20 8240 2000 Fax: +44-(0)20 8240 2010 l www.edmundoptics.eu [email protected] [email protected] l www.fujikura.co.uk www.fiberlaser.fujikura.jp/eng Edmund Optics® (EO) is a leading global manufacturer and distributor of precision optics, optical assemblies and imaging Fujikura is a global technology leader providing a wide range of Electrical, components with headquarters in the USA and manufacturing Optical and Fibre Laser products for diverse markets around the world. facilities in the US, Asia and Europe. With a portfolio of more than As an established supplier of Fibre Lasers in Japan we manufacture all 30.200 products, EO has the world’s largest inventory of optical of the key parts such as pump diodes, doped fibres as well as all of the components. internal optical components in-house. Fujikura has been represented in Europe for over 25 years and our European operations are based in the South West of London.
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Here you will find topics concentrating on the application of lasers within various industries. You would have usually have seen these presentations at LASYS, but now you can enjoy them at your leisure.
Lasers in action Lasers in action Lasers in action Webinar #1 Webinar #2 Webinar #3
High-Power High-Brightness Blue Lasers Nano-Structured Anti-Reflective Surfaces Laser welding: High-speed laser beam for Energy Storage & E-Mobility for Laser Optics Applications measurement optimizes development process Nuburu will present on the advantages of its Anti-reflective coatings are essential for optical During the development of a new laser shorter wavelength Blue lasers in comparison applications where back reflection can cause process, documenting the process conditions with IR of Green for variety of applications and issues like glare or damage to other parts of the is often time consuming but always essential. materials being welded in the Battery and setup. Traditional anti-reflective coatings are This presentation shows how non-contact e-mobility sectors. sensitive to the wavelength, angle of incidence measurement technology for high-power laser Richard Gleeson, and can get easily damaged under high power beams was used to speed-up and improve the Director European Operations, NUBURU INC. applications. Here, we show how our Nebular development of a multi-focal laser welding Technology overcomes these limitations by using process in the automotive industry. Fully Automated Monitoring of Laser Welding reactive ion etching to create nano-strutured Nicolas Meunier Processes in E-Mobility Applications windows. The results show that Edmund Optics Business Development Manager High Power With thousands of welds per day, most laser Nebular windows present high transmission & Automotive Products Ophir welding applications in e-mobility demand for over a broad wavelength range, are angle of automated process monitoring. 4D explains their incidence insensitive and have a LIDT close to Processing smallest structures in electronics online monitoring principle and how their system that of the bulk material. and probe card manufacturing is integrated into your application. Explore Dr. Sara Castillo, Relentless miniaturization in both consumer the different real world examples with 4D’s Laser Optics Sales Specialist – Europe, electronics and mechanical engineering has monitoring expert Christoph Franz. Edmund Optics brought plenty changes to the fabrication of Christoph Franz, such electronic components as PCBs, control CEO, 4D Diffractive and Metasurfaces: elements, and sensors. This development also from Function to Structure Simulation influences demands placed on laser processing Trust in your laser process with real-time Seamlessly in VirtualLab Fusion machines used in micromachining. Difficult-to- temperature monitoring We present a seamless workflow in the physical- handle materials such as polymers and ceramics Finding and especially keeping the right recipe optics software VirtualLab Fusion for the design present a special challenge. Today’s processing for your Thermal Laser Process is all about a and analysis of diffractive and metasurfaces. limits can be newly defined by employing a strong trust in constant process parameters. An example will be shown on the design of a precession bore system with a green laser. Unfortunately, minor variations of the resources metagrating for large-angle beam splitting Dr. Holger Schlueter can force a major impact on the final results. application. That includes the rigorous analysis Business Development SCANLAB GmbH In order to detect and compensate deviations, of the metasurface unit cells, the spatial the real-time temperature monitoring system arrangement of them, and a full analysis/ Laser welding solutions for e-mobility of SPOLD and LD-Heater helps you to not only optimization of the whole structure. applications by PRECITEC improve quality, but also save running costs and Dr. Site Zhang, Precitec stands for laser cutting, laser welding time. In addition to other thermal applications, CTO (Chief Technology Officer), LightTrans and optical measurement. This presentation we want to show the key feature of the laser demonstrates how our products forward system for Laser Plastic Welding and Laser Laser technology for the automotive industry e-mobility and how our sensors enable
Sintering. How CO2 lasers are used by automotive innovative production processes based on Alexander Goerk, manufacturers and their sub-suppliers to artificial intelligence. Senior Sales Engineer Industrial Components, increase productivity Dr.-Ing. Jens Reiser Hamamatsu Photonics Deutschland GmbH Thorsten Föcking, Team Leader Sales & Support Regional General Manager, Luxinar GmbH Precitec GmbH & Co. KG Blue Diode Laser constantly pushes the limits in applications Latest Cladding Applications with Diode Lasers Since the invention of a blue LED which was The presentation goes through recent diode even honored by the Nobel prize, blue laser laser applications in particular EHLA (Fraunhofer radiation became an interesting opportunity ILT cladding) processes for very thin coating to the industrial production of high reflective applications at high speed and also covers novel material, especially copper. The blue light of the applications on brake disks for reduction of fine latest lasers from Laserline has a high absorption dust. and thus, allows spatter free welds in either heat Andre Eltze, conduction or key hole welding mode. We want Dr.-Ing, Senior Sales Manager, Laserline to review the approach to blue in technology and application using such blue laser and have an outlook for the future as well. Markus Rütering, Dipl.-Ing. Sales Director, Laserline *Registration required
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