The laser welding method has certain clearcut advantages over other methods for welding plastics. Laser welding does not require that the part being welded be electrically conductive as is required for competing technologies including resistance welding, arc welding, and electron beam welding. During the transmitting welding the laser beam is transmitted by the first join partner and absorbed by the second join partner. Sonotek ultrasonic nozzles are used to spray clearweld 100, 200, and 900 series coating materials in plastic laser welding applications requiring precision thin deposition.
The first part of this practical book introduces the structure and physical properties of. Laser beam welding is a welding process that uses a laser beam to melt and vaporize material. In 1985 the first transmission laser welding process was demonstrated and patented by toyota in japan toyota, 1985 using carbon black additive to modify the absorption properties of the lower plastic. The process is frequently used in high volume applications using automation, as in the automotive industry. Plastic welding seminar report, ppt, pdf for mechanical. Laserinfrared welding typically has weld times from three to five seconds and dukanes laser welding equipment can handle parts from approximately tenthousandths inches thick to onequarter inches thick. Laser welding is currently used by industries for its quality, its high speed and. Plastic welding laser welding of plastics is an established process that is increasingly used in different markets and is displacing the traditional welding methods.
Laser laser laser pressure different process versions of laser welding for different plastic designs. Sonoteks picomist nozzle is perfectly suited for spraying fine lines of clearweld material in repeatable, controllable spray processes. Hence, laser welding is particularly well established in this market. In order to mark plastics with lasers, one needs as a general rule, depending on the use case, to develop the correct plastic compound for the end product, which will be subjected to the laser marking procedure in the course of constant development tests. Being such a concentrated heat source, in thin materials laser welding can be carried out at high welding speeds of metres per minute, and in thicker materials can produce narrow, deep welds between squareedged parts. Providing consultancy and advice for laser welding of plastics, textiles and composites.
Lasers offer a wide range of welding or brazing laser welding with filler material methods. Cw lasers are typically used for keyholepenetration welding applications. Moreover, the process is totally free of debris, unlike other welding processes. Quality control laser plastic welding, impossibly consistent. Laser welding is one of the welding methods which are applied in the production of automotive bodies. Speed and efficiency cleanliness, no debris as with vibration or ultrasonic welding no consumables, such as adhesives. A distinction is typically made between four versions of laser welding for plastics. Laser systems from leister are used in a wide range of industries.
The concept involves passing a focused laser beam through an upper, laser transmissive part to the interface of the two parts to be joined. The laser transparent material should have a laser transmittance of at least 15% to 20%, apart from the admixed additives like color, fiber content, etc. Process overview laser transmission welding pdf newsletter. The different absorption characteristics of the joining partners form the basis for laser welding. The processes that are discussed are friction welding section 3, hot plate welding section 4, ultrasonic welding section 5, laserir welding section 6, rf welding section 7 and hot gasextrusion weld ing section 8. Either fiber, disk, co 2 or diode laser can be used for cw mode welding. Laser plastic welding, a roughly decadeold assembly method, boasts its own resume of breakthrough applications. Also explore the seminar topics paper on plastic welding with abstract or synopsis, documentation on advantages and disadvantages, base paper presentation slides for ieee final year mechanical engineering me or production automobile students for the year 2019 2020. Hot plate welding is very simple welding process as compared to other plastic welding process and most commonly used. Laser welding guide amodel ppa laser welding has become a popular method of joining plastics in a wide variety of applications. When laser energy is not transmitted, either through choice of radiation wavelength or because of the materials selected, melting starts at the upper surface of the plastic. Laser light penetrates the upper layer and is absorbed by the lower material a.
Weld quality because the process is nonintrusive, the parts typically exhibit excellent. When two component plastic parts need to be joined, laser welding employs four basic steps to accomplish the task. Polymer processing xxii 2007 1 carl hanser verlag, munich 43 fig. The distinction between direct and transmission laser welding of plastics is described in more detail below. Plastic laser welding is noted for its very readily controlled local and noncontact introduction of heat, minimal heat influence zone and low mechanical stress on the adherends. The first part of this practical book introduces the structure and physical properties of plastics, before discussing the interaction of material and radiation in the nir and ir spectral range. After transmission processing, the light is focused on the workpiece to achieve continuous welding. As such, it provides comprehensive information on material and process characteristics as. This innovative technique is based on the sttir simultaneous through transmission infrared principle, where laser energy passes through one plastic component and is absorbed by the second component. Laser beam welding lbw is a welding technique used to join pieces of metal or thermoplastics through the use of a laser. Many thermoplasts are sufficiently transparent for use with lasers and can even be colored as required. Integrated laser source pneumatic sliding door available for seated or standing work position cnc controller beckhoff clamping device standard accuracy clamping fixed base plate with glass plate or welding mask movable carrier plate for mounting the work piece fixture guides for stabilization at pneumatic cylinder.
Ttlr welding process advantages branson contour laser assembly systems use a process called through transmission infrared welding ttir. However, there is also a variety of other additives, including colorings, that are ir absorbent. Laser plastic welding is leaving a noticeable mark in the assembly world. It combines the advantages of contactfree welding without forming fluff or excessive melting with the possibility of welding with a. The consequent joining method is known as direct laser welding.
The mutual melting pool solidifies under external pressure to a highquality weld d. Laser welding is gaining acceptance as a specialized method for joining plastic parts that are sensitive e. This is the first detailed description in english of radiation and polymeric material interaction and the influences of thermal and optical material properties. Infrared welding laser welding laser welding joins materials not easily welded by other thermal assembly methods. The proven process for plastic welding enables very high weld seam strengths and precise weld seams that can be used as a design element. Accordingly plastic laser welding is predestined for applications in which sensitive. Because of different pigment additions today plastics can be welded highly tensile in diverse color combinations. It avoids the two thresholds of thermal strain and posttreatment. Mps compact small footprint integrated laser source pneumatic sliding door available for seated or standing work position cnc controller beckhoff clamping device standard accuracy clamping fixed base plate with glass plate or welding mask movable carrier plate for mounting the work piece fixture guides for stabilization at. You are welcome to try out the following laser applications at the center. Waveguides direct and distribute laser energy simultaneously and homogeneously along the weld line. Used for butt and lap joints, conduction welding maintains a melted pool of metal below and behind the moving laser.
This paper provides an introduction to some important facts and developments in the plastic welding field for assisting the developments in future. From microfluidic devices, created at unparalleled accuracy, to cleanroom class v applications, impossible with other welding methods. As such, it provides comprehensive information on material and process characteristics as well as applications regarding plastic laser welding. Co 2 lasers have good surface absorption for most thermoplastics, hence they are applied for direct laser welding and laser surface heating. Application of laser welding technologies to automotive bodies. Jun 01, 2012 laser welding of plastic parts the two components shown in this video have different transmission properties. Laser welding and laser marking of plastics treffert. Recently, the importance of joining a metal and a plastic has increased by making the best use of these superior properties in various manufacturing fields. Laser joining of metal and plastic industrial laser. Highspeed imaging capabilities by recording realtime welds using. Laser beam welding an overview sciencedirect topics.
Laser welding of polymers flexible method for high strength connections with perfect surfaces. Laser welding is a process used to join together metals or thermoplastics using a laser beam to form a weld. When two transparent parts are held together, the laser transmits its energy through the upper layerlike in transmissive welding. Although there are many methods for joining thermoplastics, laser plastic welding has a few clear advantages. In medical device manufacturing, for instance, cleanliness is absolutely mandatory. Learn more about clearweld plastics laser welding the patented clearweld process. Pdf laser assisted joining of plastic metal hybrids. Laser plastic welding automotive medical technology electronic industry consumer goods industry fields of application. Good quality weld is the prime objective of welding process. Application of laser welding technologies to automotive. Consequently, lasers have been used to weld all types of.
Continuous wave laser welding a laser that can remain continuously on until turned off is known as a continuous wave cw laser. Laser welding for metals and plastics es technology. Guidelines for welding thermoplastic materials hot gas hand and hot gas extrusion welding. As a rule, laser welding results in precise, visually perfect weld seams that can even be used as a design element. All materials that can be welded conventionally can also generally be welded with laser welding processes. Here the lasing material is in the form of a solid ruby. Pigments provide for the absorption of the laser energy in the ir range. Although laser welding has a short history in comparison with resistance spot welding and arc welding, accompanying the spread of high power co2 lasers in the 1990s, laser welding became widely applied to weld ing of tailored blanks1,2. Laser welding in an innovative joining technique for plastics and offer advantages that cannot be achieved with any other process at this time. The co 2 laser was first used for this process, and welding of thin film is possible.
Laser plastic welding center for laser applications cla. The selection of the process gas is of critical importance in co 2 laser welding, whereas it is less crucial in solidstate laser welding or direct diode laser surface modification. A commonly used additive to make plastic absorbent for ir laser light is carbon black typically 0. Also known as clearonclear plastic welding, this method is ideal when both plastics are mostly transparentor in the infrared wavelength range. Transmission laser welding and the clearweld process are described. Welding of lightcoloured or transparent polymers, which is particularly required in the medical device industry, is successfully achieved with co 2 laser in the case of welding thin films or more general by using the above. Precise and localized application of energy laser plastic welding a business unit with many years of experience in the laser welding of plastics.
Select a technology ultrasonic welding vibration welding laser welding plastic welding ultrasonic food processing. Yag laser welding for films, sheet, thin plastics and moulded components. This is the first detailed description in english of laser radiation and polymeric material interaction and the influences of thermal and optical material properties. Although laser welding has a short history in comparison with resistance spot welding and arc welding, accompanying the spread of high power co2 lasers in the 1990s, laser welding became widely applied to welding of tailored blanks1,2.
The unique capabilities of laser processing has solved some of the problems associated with conventional plastic joining. Laser welding plastic is cleaner, safer, more accurate and more repeatable than other more traditional methods of welding plastic components. Laser welding of plastic parts has established itself as a robust, flexible and precise joining process. Lpkf produces highly reliable systems for the automotive and other industries. Lasermarking 2d and 3d laserwelding lasersintering laserstructuring quality in our testing and analytical laboratories, we can. Laser plastic welding is a method of bonding two or more thermoplastic components together. Morn handheld fiber laser welding machine is a new type highpower, highend continuous welding tool which adopts a highquality fiber laser source to produce a fiber optic beam. When it comes to plastic welding, laser powers of up to approx. The beam provides a concentrated heat source, allowing for narrow, deep welds and high welding rates. With the commonly used overlap welding method, the joint is completely inside the welded part. This process offers a number of attractive features including. Plastic welding we have more than 15 years of experience in developing laser plastic welding processes for welding of both amorphous polymers such as ps, pc, acrylics and semicrystalline polymers such as nylon, pe and pp. Metals are strong and ductile, and plastics are light and easily formable. The usage of closed loop welding temperature controls allows great process safety and control.
Mps laser machine for laser welding of plastic in the quasi simultaneous welding application any welding contours can be realized with the help of scanner heard. Product design and manufacturing requirements determine the ideal welding method contour, scan, curtain or simultaneous. Diode lasers in plastic welding and selective laser soldering. The systems are suitable for a variety of batch and component sizes.
Twi provides a number of services relating to the welding of polymers, including training, equipment and expert advice. Depending on different interactions between laser and thermoplastics, four different laser welding techniques have been developed for plastic joining. Although there are many methods for joining thermoplastics, laser plastic welding has a few clear advantages for the medical. In the following, hot gas air hand welding and hot gas air extrusion welding are. Laser plastic welding with diode lasers supplements traditional welding methods such as ultrasound, vibration or hot plate welding. We have built up an extensive knowledge base covering the more widely used processes for welding plastics, and pioneered the development of innovative techniques that provide improved quality and greater productivity. Beam mode and focal length affect the welds aspect ratio, but in general, conduction welds are wider and shallower than keyhole welds. Laser marking is an innovative procedure for precisely labelling a wide variety of materials such as wood, paper or leather. How laser beam welding works laser beam welding process laser beam welding setup.
Laser plastic welding, also often referred to as throughtransmission welding, is a process of bonding plastic using focused laser radiation. The process is very much different than traditional metal welding. Laser welding of plastic materials has a large field of applications in the packaging industry provided that it can compete, in quality and productivity, with currently used industrial methods. The melting of the latter transfers b the heat to the upperlayer c. In regard to quality, speed, and economy, laser welding systems are superior to conventional processes for industrial projects, making laser welding equipment and services popular offerings for sale. The system satisfies in welding of thermoplastics and automated scanner welding through its efficiency and versatility. Clearweld employs a variety of plastics laser welding methods with the appropriate coating or resin to join two, transparent plastic pieces. Grewell, abe, iowa state university, 100 davidson hall, ames, ia 50011 usa email. Laser provides a solution to a difficult joining process plastic to steel. Aug 10, 2011 laser plastic welding has been around for decades, but with an ever increasing demand for smaller, more intricate and senstive devices, laser plastic welding is growing to become a major player in. All plastics with the same chemical properties can be welded.
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