IPG Fiber Lasers: What’s New in Applications for ... · What’s New in Applications for...

IPG Photonics – ALAW 2009 – Presentation – For Reference Only

IPG Fiber Lasers: What’s New in Applications for Fabricators

ALAW Laser Applications Workshop13-14 May 2009

Randolph Paura, P.Eng.Regional Manager, CanadaMaterials Processing Consultant

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IPG Photonics – Reference Only2 4/16/2010

Agenda Introduction Company background Fiber laser basics (power supply review) Fiber laser adoption and growth Advantageous characteristics of fiber lasers Why fiber lasers are outpacing market growth Recent market statistics Fiber laser advantages Market drivers for growth, development and applications

Fiber laser power sources (single mode versus multi-mode)Fiber laser cutting exampleFiber laser applications: single mode (SM) and multi-mode (MM)Fiber laser applications: Laser Additive MaterialsFiber laser applications: Welding New process regimes for fiber lasersFuture: Outgrowth of continuous improvementFiber laser summary and conclusionsThank you

Hybrid Laser Welding ImagesCourtesy of SMU: Center for Laser Aided Manufacturing

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Introduction

Randolph Paura, P.Eng., IPG Photonics, Regional Manager Canada---Lifetime Member, Laser Institute of America (LIA)Lifetime Member, SPIEMember FMANetwork Member, Materials & Manufacturing Ontario (O.C.E.)Vice-Chair, ANSI Z136 SSC-9Member ANSI Z136.1 ASC ---ALAW 2008, “Fiber Lasers for Fabricators”ALAW 2007, “Doing more with less (Harnessing Fiber Lasers)”Co-Chair, ICALEO 2003 Laser Solutions CoursesICALEO 2002, “Orthotropic SUV Frame Design (LBW enabled)”ICALEO 2001,

Laser Solutions Course Instructor, Weld Quality MonitoringICALEO 2001,

Laser Solutions Course Instructor, Robotic Laser Cutting and WeldingIPG

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Production of diodes

Laser diode Packaging

Amplifier block

Modules

Fully Integrated Laser

Laser Fiber Preform

Laser Fiber


IPG Photonics

Working Fibers Connectors Fiber Lasers Modules Gain Modules Active and Passive Fibers Diode Lasers

IPG

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he c

ompa

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IPG Fiber LasersIP

G F

iber

Las

ers:

The

tech

nolo

gy

Growth of Yb:HPFL SM(near diffraction limited)

5000

100503520103500 1000

20003000

10kW in2010 !

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IPG Fiber LasersIP

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The

tech

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A single module can supply:• 250, 400, 800, 1000+ W of laser power• Wavelength of 1070nm (NIR)• One 7 or 15 um fiber core• 0.34-0.41mm*mrad beam divergenceT x H x D = 60 x 33 x 4.7 cmEfficiency (DC) > 35%Building blocks (modules) for HPFLs

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IPG Fiber LasersIP

G F

iber

Las

ers:

The

tech

nolo

gy

High power multi-mode fiber lasers

Modular multi-kW fiber laser

High beam quality

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IPG Fiber LasersIP

G F

iber

Las

ers:

The

tech

nolo

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BPP For Industrial Lasers

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Trumpf HLTrumpf TruDiskTrumpf TruFlowRofin Sinar DCRofin Sinar HFRofin Sinar DS-HQIPG YLR-SMIPG YLR-MM


IPG Fiber LasersIP

G F

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Las

ers:

The

tech

nolo

gy

Trend in technology

May - 2009Ref. published information: www.trumpf-laser.com; www.rofin-sinar.com; www.ipgphotonics.com

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Feed Fiber Power Density - MM(1:1 spot size reproduction)

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IPG


IPG Fiber LasersIP

G F

iber

Las

ers:

The

tech

nolo

gy

May - 2009Ref. published information: www.trumpf-laser.com; www.rofin-sinar.com; www.ipgphotonics.com

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IPG Fiber Lasers

IPG Product Line:• CW Single Mode fiber lasers from 5 – 5000 watts

(10,000 watts under final development)• Low order mode CW fiber Lasers available from 100 watts to

above 50kW• Pulsed (Q-switched ) over 20 models with peak powers to 50

kilowatts and pulse energies to 10-milli-joules

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IPG Fiber Lasers

New products for materials processing (2009):• 15 Watt CW Single Mode green operating at

535nanometers, narrow line width• Pulsed Green at 535nm 10 watts 1 ns pulse duration

50-300 kilohertz (scalable to 100 watts, conversion from 1070 to 535 nm @ greater than 84%)

• 2 new pulsed MOPA models operating at 1070nm , peak power >50kW variable pulse duration 1ns-100ns frequency to 500kHz

• 3 & 4 kW fiber laser designed exclusively for cladding, annealing and brazing applications

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Fiber Laser Adoption and Growth

• Long diode life > 100,000 hrs• High electrical efficiency

30%• Compact size• Mobile • Highest beam quality at all

power levels• Large dynamic power range• Rapid installation

(hours not days)

• No resonator alignment• Maintenance free• Single mode - pure Gaussian• Multi-mode - near top hat• Consistent spot size over

complete dynamic range• Air cooled to 300 watts• No warm up, on demand

power• Modules can be added for

future power upgrades

Advantages over previous technologies:

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Fiber Laser Adoption and Growth

Laser LaserLaser

Chiller Chiller Chiller

8kW CO2<12% efficientUses laser & process gas84KW consumption1665 x 1524 x 11003241 lbs$450-500K USD

4kW Fiber Laser~25% efficient100,000 hrs diode life16KW consumption860 x 810 x 1500500 lbs$350-$450K USD

4kW Nd:YAG<4% efficient<2000 hrs lamp life92KW consumption3200 x 1700 x 12503000 lbs$600-700K USD

250mm per grid

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Market Driver for FL Utilization

Key market drivers for fiber laser utilization:• Utilization of high strength steels in automotive production

(hot stamped steels requiring laser trimming)• Increased utilization of remote welding applications• Electron beam quality welds possible with fiber Lasers• Energy related automotive applications- fuel cells, batteries• Extensive use of pulsed lasers in the manufacture of silicon

based and photo-voltaic solar cells• Enabling of new manufacturing processes that improve quality

and reduce the total cost of manufacturing• Reduced cost to manufacture is always the driver

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Additional Driver for Development

Military applications & objectives:• Efficiency, effectiveness and mobility of defense services

rendered• Tactical High Energy Laser (THEL) program• Advanced Tactical Laser (ATL) program• Airborne Laser (ABL) program

• Joint High Power Solid State Laser (JHPSSL) program• Seeking 10kW SM laser as a module for 100kW + units• “Lasers will challenge the primacy of projectile weapons”

Lasers for Security, Northrop Grumman, Case #07-0573http://www.osa.org/News/policyprograms/specialevents/Northrop%20OSA%20RD%20Caucus%20Lasers%20for%20Security%20090607rev.pdf

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Additional Driver for Development

Military applications & objectives:• Feb 25, 2009• IPG Photonics wields high-power laser weapon

• Laser Avenger

• The fiber-laser maker's diodes are shooting down both the competition and, thanks to a Boeing demonstration, unmanned aircraft.

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Fiber Laser Power SourcesIP

G F

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Las

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New

app

licat

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for f

abric

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Single Mode versus Multi-Mode• Single Mode

– Near “Gaussian” Power Density Profile– ~7 - 20 um feed fiber optic cable dia.– mW to 5 kW

• Multi-Mode– Lower mode order (quasi-Gaussian)– 50 – 100 um feed fiber optic cable dia.– 100 W to +20 kW (and greater)

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Cutting with Fiber LasersR

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010002000300040005000600070008000

Power Requirments

(Watts)

2 4 6

Cutting Speed (m/min)

CRS (1mm) Cutting Speed Versus Power Requirements

FL Cut PowerFL Power DrawDC Cut PowerDC Power Draw

:

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New process regime…

Thick section cutting with NIR lasers

High power and beam quality are making this possible

30ºØ1.8 @ 0.4mm-12.5N2

(20bar)0.5580016mmStainless Steel

30ºØ1.8 @ 0.4mm-12.5N2

(20bar)0.5580016mmStainless Steel

30ºØ1.0 @ 0.5mm+3.0O2 (2.5bar)0.5400016mmMild Steel

AngleTip Dia. & Offset

Focal Position

Gas (type) & pressure

Speed(m/min)

Power(Watts)ThicknessMaterial

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Fiber Laser Applications - SM

Single Mode (SM) fiber laser applications:• Stent cutting• Cutting surgical blades • Cutting solder-masks• Welding of razor blades• Silicon cutting ( solar panels )• Adjustment of disc drive flexures ( bending )• Laser engraving ( rolls and flat plate )• Welding of medical devices• Laser sintering• Soldering• Laser marking• Remote cutting

CdTe IsolationYLP-RA-1/50/30/30

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YLR-200-SMf= 100 mm (~25 µm spot size)

Overlap welding E-Cu58 0.3 + 0.3 mm

top view

bottom view

Scanner welding of copper contacts

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Micro welding of fuel cell components

v= 80 m/min v= 40 m/min

Laser: YLR-500-SM

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There is now the power and beam quality to achieve “excessively” high power density and/or a wide spectrum of caustic beam profiles to examine the boundaries of existing processes and explore new process regimes.

Consider the advent of remote cutting…

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Fiber Laser Applications - SMIP

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Fiber Laser Applications - MM

High power, low-mode order fiber laser applications:• Cutting of hydro-formed automotive frames• Blank welding for automotive industry• Titanium welding of aircraft skins and structures• Laser cladding for Aerospace and Oil industries• Battery welding for automotive and medical device industry• Pacemaker welding for medical device industry• Transmission welding for Automotive Industry• Sheet metal cutting and welding

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Fiber Laser Applications - LAM

Laser Additive Manufacturing:• Low volume manufacturing

• Medical devices• Defense components• Space components• Functional prototypes

• Surface modification and repair• Gas turbine engines• Tools and dies• Heavy equipment

• Shafts• Bearings• Other wear surfaces

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Laser Additive Manufacturing:• Advantages over existing technologies

• Metallurgical bond versus mechanical bond• Very low and controllable heat input with minimum dilution and heat affected zones• Minimal stress and distortion created by deposits• Rapid cooling rates• Cost effective for repairs and manufacturing• Ability to add a high abrasion resistant wear surface(s)

• Ref. LAM Workshop March 3-4, 2009, San Antonio, Texas • RPM & Associates Inc., Rapid City, SD • Optomec, Albuquerque, NM

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Fiber Laser Applications - LAMIP

G F

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G F

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3 & 4 kW Power Supplies (Others available upon request)

• Beam switchable for multi-cell production.

• Plug and play fiber sizes and geometries

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Fiber Laser Applications – Welding

• Autogenous laser welding– Remote (thin sheet)– Close coupled (thin & thick)

• Cold wire (filler wire)• Hybrid (Laser +MIG)• Hybrid (Laser +TIG)• Hybrid (Laser + TIG + Wire)• Hybrid (Laser + Plasma)• Hybrid (Laser + Plasma + Wire)

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IPG Photonics Reference Only39 4/16/2010

Fiber Laser Applications – Remote Welding

Scanner Remote Processing

Working Distances~ 500 mm

Scannerfree Remote Processing

Working Distances 1000-1500 mm

Source IWS

Source Highyag

Source Kuka

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Fiber Laser Applications – Remote Welding

Ref

.: H

ighY

AG

, FA

NU

C, N

uTec

h

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Fiber Laser Applications - Welding

- Ship building- Pipeline welding- Tube welding-Off-Shore-Industry-Railcars

Que

lle: B

IAS

Laser-HybridX70t = 12 mmPL = 10.5 kWvS = 2.2 m/min

Hybrid Laser Welding – Examples & Candidates

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Fiber Laser Applications - Welding

Hybrid Laser Welding – Examples & Candidates

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Fiber Laser Applications Welding

Monfalcone, Italy

The first outfitting of a welding gantry with a 10 kW fibre laser source for hybrid welding in production at Fincantieri Shipyard in Monfalcone in 2007

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Fiber Laser ApplicationsIP

G F

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New Process Regimes for Fiber LasersIP

G F

iber

Las

ers:

New

pro

cess

regi

mes

for f

abric

ator

s

The limitation is no longer the power source, but how it is applied and the physics of the process application itself:• Extreme narrow gap welding• Hybrid thick section welding • Remote welding

•Fixed optic•Scanner optic•Flying scanner optic

• Remote cutting• Thick section cutting • Fixed cutting head (no capacitive height sensing)

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New Process Regimes for Fiber Lasers

electronbeam

0,37 mmvs = 8 m/min

fiberlaser

0,18 mmvs = 10 m/min

1,6

mm

Saw Blade Welding

1 m

m

vs = 30 m/min

fiberlaser

laser power 1.0 kW

Fraunhofer InstitutWerkstoff- undStrahltechnik

IWS

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Welding copper

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New Process Regimes for Fiber LasersIP

G F

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New

pro

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regi

mes

for f

abric

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Orthotropic bridge construction:New core and sandwich solutions for structural panels enabled by laser welding, thick section blind welds of 3/8” –1” thick deck plate to ribs and webs beneath

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pdf

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New Process Regimes for Fiber LasersYLR 20000

0

5

10

15

20

25

30

0 5 10 15 20

Welding Speed m/min

Pene

trat

ion

mm

20 kW15 kW12 kW10 kW

Stainless Steel(1.4301/SUS 304)Spot size 420 µm

Overlap joint 2x 15 mmStainless steel 1.4301,

1 m/min.

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FutureIP

G F

iber

Las

ers:

The

futu

re

Outgrowth of continuous improvements at IPG:• Increase in SM power (near future target of 10kW)• Diode coupled fiber delivery (e.g. for brazing

applications)• Increased beam quality and power from single element

diodes• QCW fiber lasers• Increased modulation capability of pulsed fiber lasers

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Fiber Laser SummaryIP

G F

iber

Las

ers:

Sum

mar

y

Conclusions:• Fiber lasers have made a major Impact in the world wide

material processing market

• Fiber lasers have expanded the material processing market

• Reliability has been proven on multiple material processing applications at all power levels in production environments

• The performance of fiber lasers exceeds previous laser technologies while offering substantial cost benefit to users

• Fiber lasers can compete, on a cost basis, with other technologies such as Plasma, EDM and Electron Beam

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Fiber Laser SummaryIP

G F

iber

Las

ers:

Sum

mar

y

IPG is committed to:• Continuing improvement and expansion of product offerings

• Continuing reduction in the cost of ownership

• Expansion of the market through application development

• Our mission is to make Fiber Lasers the preferred choice for manufacturing technology

• Commitment to support of our customers

THANK YOU FOR YOUR ATTENTION

[email protected]

Please consider joining the LIA & FMA

• Great networks of knowledge

• Training seminars, webinars…

• Conferences (ALAW, ICALEO, ILSC, etc.)

IPG Fiber Lasers: What’s New in Applications for ... · What’s New in Applications for...

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