Laser processing has replaced various traditional material processing applications, such as cutting in welding, in both manufacturing and R&D environments.
Some of the key advantages of laser processing include.
1.The ability to process metals and non-metals (such as ceramics and polymers).
This can be achieved by adjusting laser characteristics such as peak power, wavelength and pulse duration.
It is a non-contact technology that prevents contamination of the workpiece or wear and tear of the “processing tool”, just as with conventional machining.
An automated process is easily achieved due to high speed, high precision and repeatability.
2.Ability to machine very small features down to the micron level
Machining of flat parts or complex three-dimensional parts can be easily achieved by using the right workstation, which can be machined at various angles to the workpiece surface.
Laser cutting
Laser cutting is more accurate and faster than other cutting solutions such as plasma, oxy-fuel or waterjet. Electrical discharge machining (EDM) can also be used for high-precision cutting, but only for conductive materials and is usually a very slow process.
The available laser power continues to increase, allowing for cutting ever-increasing thicknesses. For example, a 4 kW fiber can be used to cut metals such as mild steel, stainless steel, brass, copper and aluminum to a thickness of 6 mm at speeds in excess of 1 m/min. With increasing power, thicknesses of 25 mm and more can be achieved with more than 10 kW. Waterjets can be used to cut very thick materials over 50 mm thick, but operating costs are usually high and cutting speeds can become slow, depending on the geometry of the part.
Laser Welding
Lasers can be used to weld a variety of materials such as carbon steel, high strength steel, stainless steel, aluminum, copper and titanium. Unlike traditional arc welding processes, which require an electric current, lasers rely on the absorption of light to generate heat and can also be used to weld non-conductive materials, such as polymers to themselves or metals. Compared to plasma arc welding techniques such as TIG and MIG, the beam can be tightly focused, resulting in high precision and a small heat affected zone. Deep, narrow, high aspect ratio welds can be produced, allowing both small, thin parts and thick, large parts to be welded. For example, 40 kW can be used for deep penetration welding of metals of about 40 mm. Laser welding is usually performed in the open air, using a covering gas, which is often easier to achieve than electron beam welding, which requires a vacuum.
Lasers can be used both macroscopically and microscopically, with feature sizes down to the micron level. There is a growing interest in laser micromachining of variable shapes and dimensional features in a variety of materials. The requirements for quality and yield are increasing, as are the tighter tolerances required for dimensional and positional accuracy. Improved laser sources and manufacturing technologies, along with advanced system integration and process control, are available to meet the increasingly demanding industry requirements.
The optimal choice of pulse duration, wavelength and processing technology for high-precision micromachining applications depends on material properties as well as application specifications such as quality, feature size, tolerances and throughput. Typically, pulsed lasers in the nanosecond and shorter picosecond and femtosecond pulse durations are used for micromachining, driving ablative processing techniques that remove a well-defined amount of material per pulse with minimal impact on surrounding material, allowing micron-level dimensional accuracy.
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