Direct-Diode Industrial Systems

Direct-Diode
Industrial Systems
Laser Systems for High-Power Materials Processing Applications
Superior Reliability & Performance
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Focus on High-Power Direct-Diode Laser Technology
Products
HighLight series of high power direct
systems extremely flexible and capable of
free space beam delivery system. The spot
diode laser (HPDDL) systems are sim-
solving your production challenges. The
formed by the laser can be tailored to the
ple to use and have a proven track
HighLight is a solid-state laser system
application and is ideal for processing
record in industrial environments.
based on laser diode bars with beam
large surface area parts with localized and
These systems consist of a light
shaping optics and either a fiber optics or
minimal heat input.
weight, rugged laser head, a user
friendly control unit with a Graphical
Applications
Materials
Examples
The compact size of the laser enables
Cladding
Stainless steel alloys
316L, 420
mounting the head on a robot or a
Heat Treating
Carbon steels
Cast iron
Stainless steel alloys
Gray cast iron
4140, 1045
420SS, 440SS
Metal Welding
Mild steels, Stainless steel alloys
Titanium
1010, 1020
304SS, 316SS
Plastics Welding
Thermoplastics
Thermosets
Polypropylene
Acrylic
HDPE
Nylon
Polycarbonate
Soldering and Brazing
Lead based
Silver based
Copper based
PbSn, SnAg, CuSi
User Interface (GUI) and a chiller.
gantry type system. The lightweight
and rugged design is employed in production sites worldwide processing
everything from small hand tools to
massive steel shafts and heavy truck
axles. The types of industrial production processes include surface cladding
for remanufacturing of engine components, heat treating of drive train components and hermetic welding of large
pressure canisters. The compact size
and ease of installation makes these
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Cross-section of HPDDL vs. Induction Hardened (inset) Crankshaft
High-power diode lasers for localized, high-speed
hardening with minimal distortion, pre-processing
or post-processing required.
Focus on Heat Treating
Advantages
Heat treating a surface with a laser is
• High processing speed — 3X over induction hardening
as simple as point the laser, heat the
• Low or negligible distortion
surface, and let it cool. HPDDL’s are
• No pre-processing or post-processing required
ideal for performing laser-transforma-
• Precision heating control
tion hardening in a manufacturing
• Flexibility — easily handles any work piece shape/geometry
environment because of the superior
• Higher hardness capability — over Rockwell C 60 without cracking or spalling
heat treat characteristics, the flexibility
• Fatigue life improvement on powder metal parts and drive train components
of the process, the compatibility with a
lean manufacturing environment, and
Industry Applications
fast cycle time for processing the parts.
• Bearing Surfaces
When comparing yields, operating
• Hand Tools, Needles, and Pins
expenses, and environmental impact,
• Cutting Surfaces and Forming Tools
this method is the most cost-effective
• Pumps and Stamping Dies
laser heat-treating process. With their
• Valve Seat and Seal Surfaces
high edge definition and 805 or 940
• Turbine Blades
nm wavelength, HPDDL are highly
• Drive Train Components
absorptive and require no pre-coating
• Powder Metal Parts
of the work piece to achieve absorp-
• Gears and Cams
tion. They feature greater wear resistance and, under certain conditions,
increase the fatigue strength.
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7
6
Efficiency lb/kW*hr
Heat Input/Distortion
5
4
3
2
1
0
HPDDL
CO2
Plasma
GTAW
The optimum cladding solution when weld metallurgy,
consumables cost, distortion, and thickness control are important.
Focus on Cladding
Advantages
Cladding is the deposition of material
of laser systems. The HighLight system
on a base part for the purpose of
uses a unique beam profile to paint the
• Large-area cladding with minimal
scanning
rebuilding the part or improving
surface in a continuous line as the
• Excellent cladding metallurgy
the material properties of the base
cladding material is deposited on the
material. The HighLight series based
surface. This large area cladding provides
• High efficiency process — lower thermal
input and lower powder consumption
HPDDL cladding process is the most
the lowest dilution and smoothest
• Minimal pre-processing and
post-processing
cost effective process available today
cladding surfaces compared to all other
• Precision control
for the production environment. This
processes. This process is significantly
• Significantly lower consumable cost
laser process has the highest material
more efficient than the processes that can
capture efficiency in the industry with
be performed with a Nd:YAG, CO2 or fiber
• High-resolution process — ability to
deposit thinner clad layers
>95% of the powder material being
laser because of the unique beam shape.
• Lower residual stress and distortion
deposited on the surface of the work
When comparing to the initial capital cost,
piece. The lesser the wasted material,
the low cost of ownership and the high
the lower the costs. The HighLight
performance of the process, the HighLight
• Super Alloys for CFB Components
series is an all solid state system
laser system delivers the best price per-
• Water Walls and Water Tanks
delivering outstanding reliability and
formance of any of the laser based
• Hard-Facing of Valve Seats
efficiency compared to all other types
cladding processes.
• Bearing Shafts
Industry Applications
• Bearing Seats, Cylinder Liners, and Pins
• Hydraulic Shafts
• Earth Moving Equipment
• Agricultural Equipment
• Remanufacturing
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More flexibility in
terms of gap tolerance
than other “keyhole”
welding processes
such as CO2 lasers,
disk lasers, fiber
lasers and E-beam
processing.
Focus on Welding
Advantages
HPDDL provide a high quality, conduction-
• More forgiving gap tolerance
style weld in most metals. Typical autonge-
• Increased throughput
nous laser welding requires very tight
• Less weld distortion
fit-up, similar to E-beam processing. The
• Excellent reliability
gap fit-up tolerance required is approxi-
• Low maintenance
mately 3% of thickness, which eliminates
• Flexibility
the use of most low-cost parts because
• Wire feed compatible
they need a machined interface fit-up.
Therefore, the industry defaults to TIG and
Industry Applications
PTA processes in order to achieve a robust
• Automotive Body-in-White
production weld process. HighLight HPDDL
• Metal Housings and Enclosures
achieve process speeds 3X faster than
• Chain Assemblies
Tungsten Inert Gas (TIG) or Plasma Transfer
• Automotive Fluid Assemblies
Arc (PTA) laser welding. Because the
• Tube Mills
HPDDL weld nugget is smaller then TIG or
• Zinc-Coated Steels
PTA, there also is less distortion and, no
post-processing. In addition, the line beam
allows for filler wire to achieve optimum
weld bead geometry. Overall, our HPDDL
make production welding much faster and
improve part quality without changing
upstream stamping or fixturing processes.
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Brazing with Silicon Bronze Feed Wire
Radiator panel wire feed welding
Customized line beam creates smooth bead
geometry and spatter-free process with lower
heat input than other methods.
Focus on Brazing
Advantages
Focus on Plastics Welding
The HPDDL line spot makes feeding
• Lower cost
HPDDL are ideal for transmission welding
wire into the laser beam very easy. No
• Low maintenance
various plastics for industrial applications.
expensive vision systems or precision
• Non-plasma process
Our free-space and fiber-delivered prod-
alignment devices are required. The
• Splatter significantly reduced
ucts provide simultaneous, quasi-simulta-
long beam, which is suitable for con-
• Zinc fuming and sooting reduced
neous or contour welding for a wide range
duction-mode weld, "wets out" the
• No MIG/TIG fouling
of applications. The high brightness and
weld and produces excellent weld
• Lower heat input
custom beam-shaping capabilities of our
bead profiles. For body-in-white braz-
• Faster brazing process
HPDDL provide unmatched reliability and
ing, our HPDDL create excellent braze
joints that require no rework after
brazing.
the highest throughput in the industry.
Industry Applications
• Automotive Body-in White
• Plumbing Assemblies
• Air Conditioner & Cooling Systems
High quality and high throughput
transmission welding of plastics for
automotive, electronics and industrial
applications.
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Si-Bronze wire feed welding
Advantages
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Delivering high-intensity line beams for efficient
removal of thin coatings on a variety of substrates.
Focus on Other Industrial Processes
Advantages
• Non-contact, fast, flexible and no
vibration
HighLight HPDDL provide excellent results
• Improved de-paint quality
in a variety of surface engineering applica-
• Less labor intensive
• Any desired weld-seam contour or
large area
tions, such as large-area paint stripping.
• Easily automated and high process
stability
These lasers feature a line beam, which
• Improved throughput — removal rate
of >40 square meters per hour
enables thermo-mechanical stress-
• No secondary waste
• Low thermal stress and low
mechanical stress
induced dislocations and then physical
• Lower health risk — no hazardous
by-product
• Control of melt geometry
scanning. Unlike abrasive blasting, with its
ablation over a large area with minimal
consumable blast media and disposal
Industry Applications
costs, laser processing requires only gas,
• Electronics Housings
electricity and disposal of the paint dust.
• Automotive Parts
Coatings easily removed by HPDDL include
• Fuel Pumps
paint, adhesives, epoxies, and heavy rust or
scale. Suitable substrates include plastic,
metal, cloth, stone, ceramic, composites,
and wood.
• Low noise and less dust
• Easy to automate
• Lower consumable and disposal costs
• PVDF coating removal application
Industry Applications
• Paint-stripping
• Scale removal
• Rubber mold cleaning
Coherent as your partner.
To compete and succeed in today’s fast-paced research and manufacturing environments, you need
a laser partner who understands your needs. A partner who can provide a wide range of technology
solutions, and the support that goes with them.
Since 1966, Coherent has been helping customers by providing complete laser-based solutions for
a wide range of commercial and scientific applications.
With a heritage of innovation and an uncompromising position on quality, Coherent is the most
forward-thinking and diversified manufacturer of solid-state, gas, excimer and semiconductor lasers
in the industry.
For more information, visit us on the Web at www.Coherent.com. Or call 800-527-3786.
Coherent, Inc.
5100 Patrick Henry Drive
Santa Clara, CA 95054
phone (800) 527-3786
(408) 764-4983
fax
(800) 362-1170
(408) 988-6838
e-mail [email protected]
Benelux +31 (30) 280 6060
China
+86 (10) 6280 0209
France +33 (0)1 6985 5145
Germany +49 (6071) 9680
Italy
+39 (02) 34 530 214
Japan
+81 (3) 5635 8700
Korea
+82 (2) 460 7900
UK
+44 (1353) 658 833
www.Coherent.com
Printed in the U.S.A. MC-043-07-1C0607
Copyright © 2007 Coherent, Inc.
*All product names contained herein are
the trademarks of their respective holders.
Coherent’s scientific and industrial lasers are
certified to comply with the Federal Regulations
(21 CFR Subchapter J) as administered by the Center
for Devices and Radiological Health on all systems
ordered for shipment after August 2, 1976.
ISO 9001:2000 Registered