welding tool of choice, replacing TIG, brazing, or torch welding,” said Todd Deslauriers, senior applications engineer for LaserStar Technologies (Riverside, RI). “LaserStar Technologies specializes in providing many industries with a wide range of microwelding platforms.” He notes that lasers pro- vide excellent weld consistency, laser pulse stability, low HAZ, and cleanliness. Another part of the growing popularity of lasers is the acceptance among a more educated user base. “Lasers [used to be] a scary word among people. Often, people would picture lasers as seen in mov- ies, usually about to cause imminent pain or death to someone,” he said. Prices of lasers have become much more affordable because of technological improvements in cooling and power supply effi - ciency over the last fi ve–seven years. They are more compact, reliable, and portable, making their use more commonplace. While manufacturers still need to understand lasers and their language for beam quality and delivery, they are becoming more com- fortable with them as they understand the benefi ts. Companies like LaserStar help in that transition with an education department along with demonstrations and three national application laboratories. LaserStar can deliver custom turnkey systems tuned for the special needs of their customers.
said. He believes it is more about reducing time than cost, as repairing molds in-house eliminates trans- portation time and queuing time within the shop. “It’s a natural progression in technology acceptance, as the specialized knowledge within the job shop is no longer so specialized and goes mainstream,” said Deslauriers. He reports that highly effi cient fl ashlamp pumped Nd:YAG lasers provide the source in many of these injection mold repair applications requiring high-wattage energy.
LaserStar also offers a full range of fi ber-engine- based laser welding systems. The FiberStar product line is ideal for high precision welding applications which require pulse stability of <1% and excellent beam quality. These FiberStar welding systems are used in high-dollar-value assemblies that require spot sizes as small as 50 μm and 24/7 performance in an air-cooled package, according to the company. “Maintenance is minimal and these laser systems have an operating life of 50,000–80,000 hours before the core laser source needs servicing,” he said. Uri Resnik, vice president of sales and marketing
One example of how Deslauriers is seeing a
change is in laser welding for repairing injection molds. “These are quite popular today,” he stated. It is more cost-effective to laser repair a damaged injection mold cavity versus traditional TIG welding methods of years past. “There was a time when most companies sent their molds to job shops for repair on laser welders, but now those manufacturers are getting more knowledgeable about how to use a laser themselves. They are performing mold repair in-house with their own laser welding systems,” he
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for O. R. Lasertechnology (Elk Grove, IL) agrees that for the tool and moldmaking industries, laser welding systems are becoming indispensable. “Repairs are done very close to the outline of the workpieces and postprocessing is barely necessary,” he said. Other manufacturing applications where laser welding is growing is in sensors and batteries. “Because of the accuracy and its material compatibility, laser welding is becoming indispensable for these branches,” he said. “Generally the big advantage of laser weld- ing is the low-heat input avoiding deformations and discoloration of the workpieces. Laser welding can be done near sensitive electronic parts without any damage,” he said. “[We] consult with our clients in product design to ensure a laser-compliant manufacturing,” he said. Design engineers need to know that, because of the high precision of lasers, there are higher require- ments in component preparation compared to other methods. He believes a simple rule can be applied— the gap between two objects must not exceed 20% of the laser focus pulse diameter. “By the use of addi- tional materials like wire or powder for example, the tolerances can be further reduced and workpieces can be refi ned with an armoring or a wear-resistive protection,” he said.
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