SSOM2009 Material Processing in the Industrial Environment ... · A COMPANY OF THE I N D U S T R I...

A COMPANY OF THE

I N D U S T R I A L - L A S E R S

13th SSOM Engelberg Lectures on Optics 2009 #1

16-19 March 2009, Hotel Regina Titlis, Engelberg, Swi tzerland

13th SSOM Engelberg Lectures on Optics 2009

Industrial Photonics

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Material Processing in the Industrial Environment



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LASAG Company Presentation

LASAG Core MarketsWeldingCuttingDrilling

Laser Material ProcessingThe SystemStrategies

Laser DrillingLasers, Strategies, Productivity, QualitySingle Pulse DrillingPercussion DrillingHelical Drilling



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How everything started(1969):Drilling of watch stones (Ruby)


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� World largest manufacturer of finished watches as Blancpain, Glashütte, Omega, Rado, Longines

� Manufacturer of high-tech components to� electronics and telecommunications� medical device industry � automotive industry

� More than 40 companies and 50 production centerswith over 440 reporting units and >20’000 employees

LASAG – a company of


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LASAG is a leading manufacturer of industrial Nd:YAG lasers for material processing.

Our lasers are primarily used for cutting, welding, drilling, engraving and ablating of metals and other materials.

We are a world-wide operating company with production in Switzerland and offices in USA, Germany, Italy and Japan.

Thun and Alps


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Company Profile

� Committed to solutions for our customers

� 30 years of experience in laser-drilling,fine-cutting and microwelding

� strong material processing laboratory fora wide range of applications

� development of complete solutions fromlaser to laser focus on workpiece

� Efficient customer support and training

� ISO 9001:1991 / 2000 certificationHeadquarters Thun, Switzerland

Goalsuccessful global supplier of industrial solid-state laser

solutions for micro - material processing in dedicated markets

Profile


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Who we are

Headquarters (80) Thun, established March 04, 1974Product developmentProcess developmentAssemblySales and service

Subsidiaries (20) Arlington Heights, IL,USA since 1984

Tokyo,Japan, since 1996

Pforzheim, Germany, since 1999

Sesto Calende, Italy, since 2007

Mother Company The SWATCH Group Ltd., Biel, Switzerland100 % owned by The SWATCH Group Ltd.

ISO 9001 Certification Since 1990


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LASAG Core Markets





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Lasers and Systems for Material Processing

CO2 laser systems

Excimer laser systems

CO2 laser sources

Pulsed Nd:YAG laser sources

cw Nd:YAG laser sources

Excimer laser sources

Nd:YAG laser systems

LASAG business: serve the customers directly or via (exlu sive) Integrators

Systems

Sources

Dedicated Micro-Processing Systems

LASAG Core Markets

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Applications and Technologies

Applications

� Fine Cutting� Drilling & Trepanning� Precision Spot & Seam Welding� Marking� Scribing & Ablating� Surface Treatment

LASAG Core Technologies

Solid State Laser sourcesBeam guiding technologiesBeam distribution technologiesBeam forming (temporal , spatial)Processing toolsControl techniquesApplication Laboratory for customer

samples

LASAG Core Markets

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Applications and Markets

Applications

� Fine Cutting� Drilling & Trepanning� Precision Spot & Seam Welding� Marking� Scribing & Ablating� Surface Treatment

LASAG Core Markets

� Medical Device Industry � Electronics � Automotive Industry� Aerospace� (Thermal) Solar Industry� Watch Industry

LASAG Core Markets

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Flexible Laser Sources for Dedicated Applications

LASAG Core Markets

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LASAG Laser for Precision Cutting

Med.: Cutting Stents , Hypotubes , Cannulas

Med.: Endoscopes

Watch: Mechanical Parts

Elec.: Stencils

LASAG Core Markets: Cutting

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LASAG Lasers for Drilling/Perforating

Aero: Cooling Holes Turbines

Food: Coffee Filter

Auto: Fuel Filter

Food: Mincer Component

Textile: Spinnerets

Medical:Needle

LASAG Core Markets: Drilling

Food: Sugar Sieves Auto: Connecting Rod

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Drilling in Automotive (Powertrain) Industry

Throttle Valve(Welding)Cramshaft(drilling)Cylinder Gasket(welding)Fuel Filter(Drilling)Control Valve(cutting)Injection Nozzle(Drilling)Throttle valve(Drilling)Nozzle Screw(drilling)Rocker Arm(drilling)Piston Ring(Structuring)Water Pump(welding)Conrods(scribing)Crankshaft(drilling)

LASAG Core Markets: Drilling

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Spotwelding of Flat Solar Absorbers: thermal solar systems (combinationwith oil)

LASAG Core Markets: Welding

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LASAG Laser in Electronic Industry

Plugs

Flat Cables

Lead Frames


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Laser Processing of Watch Components


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Laser Material Processing





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Workpiece

Holder/Protection(Workpiece)

Laser-pulsed/cw

-beam product/brilliance-temporal/spatial

-etc

Process support-Gases-Powder-Wires

Optics-Geometry/Profile/

Intensity-Distribution-Positioning

-Temporal Form

Positioning/movement

(Roboter/CNC)-Material Carrier

Protect.-Operator-Machine-Optics

Control-Position-Process

Laser Material Processing: The System

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workpiece

Optics-Geometry/Profile/

Intensity-distribution-Positioning

-temporal form

holder/Sprotection (workpiece)

Optics


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Optics: Integration of Laser Tool into 3-D Manufact uring

workpiece

deflector

mirror mirror

Opticalfiber

Proc. head


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Optics: Flexible Delivery of Free Beam or Fiber Bea m

Cavity

Resonator

Pilotlaser

Fiber OpticProcessing Head

Workpiece

FiberMultiplexer

Fiber


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System Strategies to Increase Productivity


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workpieceControl-Position-Process

holder/protection (workpiece)

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ILT04_#041

Closed-loop Feedback Control for Cu spot welds

EPFL Lausanne, Advanced Photonics Laboratory, 2003

Process Control

Process Control


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Laser Welding

Spot Weld Contour Weld

Nd:YAG (p)Nd:YAG(p) Nd:YAG(cw)

One SpotLine of spots One Pulse Series of pulses

High-Speed*SHADOW*

ScannerCNC

Rotat. axis

Beam ShapeOptics

(Axicon, Cylind.OpticsFiberoptics)

Seam Weld

time

power

milliseconds

Laser Material Processing: Strategies

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Drilling Strategies with Pulsed Lasers

single shot percussion trepaning Helical drilling

precisionablation/pulse

© IFSW© IFSW

Laser Material Processing: Strategies

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Laser Drilling





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Laser drilling in industrial use: strategies and applications

Laser is a well established Tool forDrilling holes with diametersBetween 0.01 and 1.2 mm and

Aspect up to 30:1(Laboratory: up to 200:1)

Quality, geometry and productivitydefine the

Drilling strategy and laser type:“low quality“: thermal drilling

„high quality“: shortpulse helicaldrilling

Laser Drilling: Lasers ,

Strategies, Productivity,

Quality

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„Process chart“ laser drilling

10-11 10-10 10-9 10-8 10-7 10-6 10-5 10-4 10-3 10-2

W/cm 2

109

108

107

106

105

Interaction time or pulse duration (s)

Thermal (melt) Drilling

AblativeDrilling

1J/cm 2

106 J/cm 2

Ionisation Vaporization Melting

Short pulse - Laser therm. Laser pulses (N d:YAG) cw-Nd:YAG,CO 2

Laser Drilling: Lasers , Strategies, Productivity, Quality

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Microdrilling : Industrial Laser Types

0 1 10 100lateral dimension (µm)

depth/pulse (µm)

100

10

1

0.1

0.01

ms−µs-PNd:YAG

DiskFiber

ns-fs-PSolidS.Fiber

CVL2/3/4f

SolidS.Excimer

Hint:smaller lateral structuresare possible by using opticalphenomena and processthreshold

Laser Drilling: Lasers , Strategies, Productivity, Quality

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Drilling Strategies with Pulsed Laserssingle shot percussion trepaning Helical drilling

precisionablation/pulse

© IFSW© IFSW

Laser Drilling: Lasers, Strategies , Productivity, Quality

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Typical Drilling performance of pulsed Nd:YAG Laser s

Strategy: Single Pulse Percussion Trepan Helical Depth(mm) mm few cm cm mmAspect(D/T) < 15:1 >50:1 <20:1 <30:1Diameter(D) 0.02/1 0.015 /1.5 0.08 /open 0.05-0.4 (mm)

Tolerances(%) 10-15 10 5-10 <2Holes/s <1000 <5 <0.1 <<0.1

© IFSW© IFSW

Laser Drilling: Lasers, Strategies , Productivity, Quality

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LASAG Lasers for Drilling/Perforating

Aero: Cooling Holes TurbinesPercussion

Auto: Connecting RodSingle Pulse

Auto: Fuel FilterSingle Pulse

Food: Mincer Component

Textile: SpinneretsPercussion

Medical:Needle

Single Pulse

Laser Drilling: Lasers, Strategies, Productivity, Q uality

Food: Sugar SievesSingle Pulse

Food: Coffee FilterSingle Pulse

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Drilling with pulsed Lasers

Geometry Quality

Shape-axial -lateral

Tolerances-roundness-conicity -roughness

„Side effects“-Metallurgy/HAZ

-Recast

Influence

Laser parameterMaterial Quality

GasStrategy, Handling

Laser parameterOptics / Nozzle

Material

Laser ParametersMaterial Properties

DesignGas


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Number of holes per workpiece

Aspect (depth/diameter)

100

10

1

Quality /geometric tolerance (%)1

5

10

<100 >100 >1000

Cooling holesLubrication holes

Venting holes

nozzles

nozzles

Cooling holesLubrication holes

Ventingholes

Surg.needle

Surg.needle

<100 >100 >1000

Filter/Sieves

FilterSieves

Selected Drilling Markets : Requirements for qualit y/productivity


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Productivity (No. of holes per second )

Aspect (Depth/Diameter)

Selected Drilling Markets : Requirements for qualit y/productivity

100

10

1

Quality(geometric Tolerances(%))1

5

10

0.1 10 1000 0.1 10 1000

FilterSieves

Separatores

Cool.holesLubication

holes

Nozzlesthrottles

Filter/Sieves/Separat

Nozzles

Throttles

Cool.holesLubrication-

holesventingholes

Surg.needle

Surg.needle

Scribing

Scribing

Guid.holes

Flow

Flow

Guidholes

Vias

Vias

IncJet

IncJet


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Strategies with pulsed Lasers: Improvement of Produ ctivity

Strategy: Single Pulse Percussion Trepaning Helical Drilling

© IFSW© IFSW

Machining Strategy: „on the fly“ „stop and go“


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Strategies with Pulsed Lasers: Improvement of Produ ctivity

Strategy: Single Pulse Percussion

Machining Strategy: „on the fly“

time

Comparison production time betweenStationary-“on the fly“ percussion drillingFor holes with small aspect (few pulsesPer hole)


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Percussion Drilling: Comparison of Machine Strategi es

„stop and go“ „on the fly“

8 Pulses

7 Pulses

6 Pulses

5 Pulses

Thermal relaxation time : several ms

10Hz / 6.3J / 7.8kW 10Hz(laser)0.2Hz(drill) / 6.3J / 7.8kW


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Laser- Drilling: Typical Side Effects

Gas

Material

Plasma

LaserBeam


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Basic Researchwith Fraunhofer :

Reduction of thermal Side effectsduringThermal drilling

(see ICALEO 06)


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Trepan-Drilling versus Percussion Drilling


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Influence of Pulse Length in the ns - fs Evaporisati on Regime

Ablation rateµµµµm3/mJ

Micro-machining with ultrashort laser pulses: From basic understanding to technical applicationsFriedrich Dausinger, Helmut Hügel, Vitali Konov, SPIE Proceedings ALT'02

250

750


(Brikas,Nolamp 07)

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Influence of pulse length in the ns - fs regime

HAZ/Pulse(heat conductivity)

Example steel:HAZ(cm)=( 6t p)1/2

HAZ/hole(heat accumulation)

Gedvilas NOLAMP 07

same wavelength and average power


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Strategy: Single Pulse Percussion Trepan Helical D.Depth(mm) mm few cm cm mm

Aspect(D/T) < 15:1 >50:1 <20:1 <30:1

Diameter(D) 0.02/1 0.015 /1.5 0.08 /open 0.05-0.4 (mm)

Tolerances(%) 10-15 10 5-10 <2

Holes/s <1000 <5 <0.1 <<0.1

© IFSW© IFSW


Laser Drilling: Single Pulse Drilling

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1000

100

10

11 10 100 1000 10000

Holes per Second

Hole Diameter(µm)

Aspect <10

Steel


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Single Pulse Drilling: Examples for Through Holes

Flat Filter(coffee machine)FLS0.25-0.4mm

Stainless Steel0.3mm

30 holes/s

Round Filters(fuel filter)KLS0.06mm


700 Holes/s

Lubrication Holes(engine cylinder ring)FLS0.4-0.8mm


30 Holes/s


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Single pulse drilling: blind holes/scribing

Conrod/Bearings

KLS0.05-0.1mm

At. St. C600.5-1mm

>100 holes/s

Surgical needle

NA0.05-0.6mm

Biocompatible St. St.0.5-1mm

6 holes/s

Scribing ceramics/substrates

FLS0.1-0.3mm

AlN1-2 mm

>300 holes/s


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Single shot drilling: surgical needles

Material: Stainless Steel

Function: Crimping thread

Requirements:Entrance: 0.05-0.7 mmshape: circularAspect: 4:1 –8:1Tolerance: 95% within 5%

Productivity: > 6 needles/s


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Strategy: Single P. Percussion Trepan Helical D.Depth(mm): mm few cm cm mm

Aspect:(D/T) < 15:1 >50:1 <20:1 <30:1

Diameter(D) 0.02/1 0.015 /1.5 0.08 /open 0.05-0.4 (mm)

Tolerances(%): 10-15 10 5-10 <2

Holes/s <1000 <5 <0.1 <<0.1

© IFSW© IFSW

Laser Drilling: Percussion Drilling

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1000

100

10

1

0.01 0.1 1 10Holes per Second

Hole Diameter(µm)

Aspect <30Aspect <3

Cr/Ni-steel

< 200 holes

10 000 - 40 000 holes

1 hole


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Percussion : Efficiency and Thermal Load

Depth (mm)10 20 30 40 50

500

400

300

200

100

Time(s)TotalEnergy (kJ)

Theory: 16J/mm3

Experiment: 7Hz/72J/1ms

100

10

1


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Percussion Drilling: Side Effects

12

Depending on Alloy , Manufacturingprocess (e.g. single crystal, strengthening)

-Local Recast

-Oxidation

-Risk of cracks / fissures into base material (e.g Ni alloys) or long parallel cracks/Delamination

-HAZ < 0.05mm

Nonregular Shape/ bottle shape

Trumpet entranceDross/Burr without backing


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Optimizing„Sideeffects“

Geometry Influence byEntrance Energy , Pulse duration

Focus positionRamping

Exit short PulsesFocus Positionlow Gas PressureBacking

Quality Influence byRoundness Pulse Modulation

Fiber, eliminating Polarisation Effects

Conicity Focus PositionPulse Modulation

Burr BackingRecast Pulse Modulation , short PulsesHAZ short Pulses: HAZ~(Duration x T-Diffusion)1/2

Steel~ (Duration x 6 cm2/s)1/2


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Percussion Drilling: St.St(1.4301)

Pulse : 2.8ms/ 8.5kW/ 20 pulses/ 0.4mm fiber Thickness of Stainless steel: 6mm


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Strategy: Single P. Percussion Trepan HelicalDepth(mm): mm few cm cm mmAspect:(D/T) < 15:1 >50:1 <20:1 <30:1Diameter(D) 0.02/1 0.015 /1.5 0.08 /open 0.05-0.4(mm)

Tolerances(%): 10-15 10 5-10 <2Holes/s <1000 <5 <0.1 <<0.1

© IFSW© IFSW

Laser Drilling: Helical Drilling

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Drilling Strategies with Pulsed Lasers

Strategy: Single Pulse Percussion Trepanning Helical Drilling

© IFSW© IFSW

Drilling by Melting Drilling by Ablating

Process Energy Fe: 7J/mm 3 55J/mm 3


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„Process Chart“ FM Short Pulse Metal Processing

10-12 10-11 10-10 10-9 10-8 10-7 10-6 10-5 10-4 10-3

W/cm 2

1013

1012

1011

1010

109

(local) interaction time or pulse length (s)

103 J/cm 2

Ionisation evapor isation

Short Pulse ns Laser Pulse (Nd:YAG/FL) cw -Nd:YAG,CO 2

0.1J/cm2ns

ps-fs


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Helical Microdrilling System

50-400µm

ILT


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Helical drilling with microsecond pulses


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50 µµµµm

971 µµµµm

Exit

Quality of nsAblating-drilled holes(St.St.,depth 1mm)

Laser Drilling:Helical Drilling

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Entrance

LaserDrilling:HelicalDrilling

Quality ofns Ablating

-drilledholes(St.St.,

depth 1mm)

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LASAG Company Presentation:Company of Swatch Group, Nd:YAG Laser for Cutting, Drilling, Welding

LASAG Core MarketsWelding: Solar , Electronic, Medical, WatchCutting: Medical, Electronic, WatchDrilling: Power, Medical, Auto, Food

Laser Material ProcessingThe System: Laser, Beam Guiding, Optics, Process Su pport, Protection, Process ControlStrategies: One Pulse, Several Pulses, „on the fly“, Time – and Energy Sharing

Laser DrillingLasers, Strategies, Productivity, Quality:

Solid State (Fiber) Laser, Single/Perc./Helicl,Productivity Aspects, Influence Geometry and Qualit y, Side Effects

Single Pulse: High Productivity, Large Tolerances, H igh Pulse Energy, Through/Blind HolePercussion: High Aspect, Medium Precision, Various H ole Shapes, Reducing Side EffectsHelical: Efficiency, Optics, Quality with Different Pulse Durations, Highest Quality

Summary

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Lake of Thun

I thank You for your attentionand Dr. Ulrich Dürr for a lot of interesting inputs

Please visit us at Thun

SSOM2009 Material Processing in the Industrial Environment ... · A COMPANY OF THE I N D U S T R I...

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