Tech Briefs Magazine - May 2021 - PIT-11
TECHNOLOGY LEADERS Test & Measurement Systems
Making Laser Processes More Sustainable
L
asers are used in diverse manufacturing processes, and in
recent years the spectrum has
become increasingly wider.
Whether VCSELs in sensor technology,
blue and green lasers for welding battery cells, powerful fiber lasers in additive manufacturing, or quantum cascade lasers in medical technology, laser
technology is currently revolutionizing
numerous industries. But one thing
stands out-even in modern production plants, the opportunity to make
laser-based processes more sustainable
by measuring the laser system itself is
often neglected.
There are many new technologies and
instruments that contribute to increased
production quality in laser-based processes while simplifying documentation and
conserving resources. Today, it is even
possible to characterize the entire beam
caustics with cycle-time-neutral, fully
automated measurements during the
very short loading of a robot cell or in a
sealed construction chamber in additive
manufacturing.
A Paradox With Risks
For many years there was a persistent
belief that a laser beam, per se, is " maintenance-free, " since it never " dulls " as a
tool. Even now, there are still companies
that invest in state-of-the-art production
facilities but measure the laser far too
rarely and using outdated measurement
technology. The reality is that laser
processes change over time. People in
industry are starting to realize how
important it is to check the focused laser
beam. In addition to increasing
demands on component quality and the
economic pressures faced by many
firms, sustainability is becoming a crucial decision factor. But here, laser technology and environmental awareness
should go hand-in-hand. The objectives
are straightforward:
* No scrap;
* Reduced material consumption;
* Lower energy consumption;
* Minimization of rework.
When designing processes, one thing
must be kept in mind: a laser only works
as well as its beam delivery. And its built-
in components do wear out and get dirty
over time. This often causes either the
focus diameter to grow larger overall or
the focus position to shift, which also
results in a larger beam diameter. In
either case, this reduces the power density at the processing level. If these
changes go unnoticed, additional costs
will arise - material wasted in defective
parts and/or time and labor wasted in
troubleshooting the problem. To compensate for the change in the process
without actually fixing the source, users
resort to reducing processing speed
and/or increasing laser power. Both
lead to higher consumption of energy
and process gases. In other words...not
something anyone wants or can afford
these days!
Focus Quality and Unit Cost
To increase the sustainability of the
laser process, one can start at a couple of
Laser Source
different entry points. First, it is paramount to know how the beam focus
behaves overall and how any changes in
laser power and focus position will affect
the process. These investigations are
usually conducted during development.
Once the laser process is put into
operation, however, a measurement can
tell whether the laser still works in the
production environment as it did in
development. As the operation continues, essential maintenance tasks include
checking the optical lenses and protective windows - and replacing them as
necessary. If errors and rejects are occurring, it is recommended to have a clear
measurement strategy that defines how
to quickly get the laser system back up
and operating again.
The following procedure usually produces good results:
1. Check the beam adjustment at the
cutting nozzle (if relevant).
Laser Delivery
Laser
Processing
Head
Figure 1. Changes in the laser beam on its way from the laser source to the laser head in industrial processes.
Relation between Focus Quality and Cost per Part
in Industrial Laser Processes
cost for
energy and
process gases
€
actual savings
per part
€
low beam quality
high beam quality
Figure 2. The relationship between focus quality and unit cost in industrial manufacturing processes.
Photonics & Imaging Technology, May 2021
11
Cov
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Tech Briefs Magazine - May 2021
Table of Contents for the Digital Edition of Tech Briefs Magazine - May 2021
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