Theme : Performance & Process Improvement - · PDF fileLASER WELDING : A New Assembling...
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LASER WELDING : A New Assembling Method for a Production Benefit Theme : Performance & Process Improvement
Transcript of Theme : Performance & Process Improvement - · PDF fileLASER WELDING : A New Assembling...
LASER WELDING :A New Assembling Method for a Production Benefit
Theme : Performance & Process Improvement
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Adhesion
LASER
Over-Mold
Snap-fitUltrasonic
Spin Vibration Linear/Orbital
Bolt
WeightReduction
Module
Integration
Total Cost Reduction
Technology
DSIDRI
Positions of the LASER Welding Assembly
EmbrioEmbrio MatureMature
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LASER Welding Summary
380nm 780nm
UV IR
Visible
CO2Nd:YAGDiode Laser800～950nm 1.06μm 10μm
Near IR Mid IR Far IR 約０．７～１．５μｍ 約１．５～５．６μｍ 約５．６～１０００μｍ
Part’s move Scanning
Simultaneousmulti-head Rapid multi-scanning
mirrorSpecial optic
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LASER Welding Principle
TransmissiveTransmissiveScattering Energy
AbsorbAbsorbAbsorbed Energy
Surface ReflectionSurface ReflectionReflecting Energy
Clamping PressureClamping Pressure
LASER
Power / SpeedFocus DiameterMaterial Part Design
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Benefits of LASER Welding Assembly
• Clean：no flash/no barrs
• Fast：no holding cycle time
• Strong：cross link of GF at joint surface
• Inexpensive：Facility/total cycle
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Comparison 3 methods：Welding Time・ Burst Strength
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
Bur
st S
tren
gth(
MPa
)
0
5
10
15
20
25
30
35W
elding Time(sec)
Burst Strength(Mpa)
Welding Time(sec)
PA6 30%GR
PA66 30%GR
UR PA66
HTN 35%GR
PET GR (exp.)
・no flash ・less facility cost
ＰＡ6ＧＲ３０
Break at typical area Not a joint
Orb
ital
Orb
ital
Lin
ear
Lin
ear
LA
SER
LA
SER
Orb
ital
Orb
ital
Lin
ear
Lin
ear
LA
SER
LA
SER
Orb
ital
Orb
ital
Lin
ear
Lin
ear
LA
SER
LA
SER
Orb
ital
Orb
ital
Lin
ear
Lin
ear
LA
SER
LA
SER
Orb
ital
Orb
ital
Lin
ear
Lin
ear
LA
SER
LA
SER
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Comparative Look ; cross sectional observation
Orbital vib. welding
Laser WeldingLinear Vibration Welding
Adhesion・Seal joint
Ultrasonicwelding
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Comparison with the other assy. mehods
Bolting Adhesion LASER Hot Plate Linear welding
Reliability △ - ○
Effect to inner ○
Aesthetic
Design freedom
Productivity △（Curing）
△ - ○（color change）
○（Warpage）
◎
◎
◎
◎
○（Warpage）
△(Flash）
△（Flsdh）
△（weld time）
△（separation）
△（Separation）
△（Thermal）
◎ ◎
◎
×（Vibration）
◎
○
△
△
△
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Du Pont Development Approach
Confirm Laser welding technology as a production method
MaterialsMaterialsMaterials
MoldingMoldingMolding
TestingTestingTesting
DesignDesignDesign
SystemsSystemsSystems Welding ProcessWelding ProcessWelding Process
麗 速強 安
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•• MaterialsMaterials– Transmittance：Polymer・Pigment・Additives
– Absorbent：Polymer・heat gen./melt・Pigment
• Design– Wall thickness・Basic part geom・Joint design
• Molding– Warpage/Sink mark
• Welding process– Power・Speed・Cycle time・Focus spot
Considerations for polymer laser welding optimization
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Transmittance & Absorbent relation between the polymer & Laser light
0
20
40
60
80
100400 800 1200 1600 2000 2400
Wave length (nm)
trans
mitta
nce
trans
mitta
nce
(%)
PA 6
POMPBTPC
LDLD(800(800～～950nm)950nm)
YAG Laser(1064nm)
typ. BK
PA 66
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Material / Wall Thickness & Transmittance
0
20
40
60
80
100
0 1 2 3 4 5
Wall Thickness (mm)
(%)
(@ 940nm)(@ 940nm)
trans
mitta
nce
trans
mitta
nce
Zytel® ＰＡ６６ UR
Zytel® ＰＡ６ GR
Crastin® GRPBT
Delrin® POM
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Polymer Laser Welding Optimization -Laser Power & Irradiation Time
Las
er Ir
radi
atio
n T
ime
Laser Power
No melt
Surface degradation･Void･Carbonized
AdequateAdequate
WeldingWeldingZoneZone
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Polymer Laser Welding Optimization -Productivity；Speed & Power
0
50
100
150
200
250
0 0.1 0.2 0.3 0.4
Energy Density(J/mm2)(k
gf)
0
50
100
150
200
250
0 100 200
Laser PowerLaser Power (W)
Stre
ngth
Stre
ngth
(kgf
)
1m/min
2 m/min
3 m/min 5 m/min
6 m/min4 m/min
(Zytel(Zytel®®HTN51G35HSL)HTN51G35HSL)
Stre
ngth
Stre
ngth
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Polymer Laser Welding Optimization - Mn
HTN51G35HSL NC + BK (2mm ovlp TP)
0
50
100
150
200
250
0.0 0.2 0.4 0.6
(J/mm2)
(kgf
)
0
50
100
150
200
250
0.0 0.2 0.4 0.6
(J/mm2)
(kgf
)0
2,500
5,000
7,500
10,000
12,500
Weld strengthWeld strength
MnStre
ngth
Stre
ngth
Stre
ngth
Stre
ngth
Energy DensityEnergy DensityEnergy DensityEnergy Density
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•Process Window
0
50
100
150
0 10 20
Scan speedScan speed (m / min)
Weld
stre
ngth
Weld
stre
ngth
(kgf
)
Power (W)：constant
Polymer Laser Welding Optimization - Absorbent material
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Ret
entio
n of
tran
smitt
ance
(%)
100
80
40
20
0
60
H.U.T (min)15 30Std.
Laser Transmittant BKDev’t grade
Typ. grade
Polymer Laser Welding Optimization - Moldability
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Wel
d st
reng
th
Scanning speed
Polymer Laser Welding Optimization - Process Easiness
After After optimizationoptimization
Before Before optimizationoptimization
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Door Lock actuator
Customer: Hella
Zytel® 73G15 NCMinlon®FE260001BK
Leakage Test Sensor
Customer: Bosch
Crastin® SK603 NCCrastin® SK603 BK
LASER Welding Assembly - Case Study
Camshaft position sensor
Customer: Delphi
Zytel® LT 74G33HSL BKZytel® 74G33 HSL BK
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Door locking housingCost reduction on production (faster production cycle), More design freedom, precise positioning, no flash
Trap Canister
ASIAN Kogyo
Zytel® 103FHS NCZytel® FE110003 BK
Gearshift housing
Daimler Chrysler
Zytel® 70G30 NCZytel® 70G30 BK
LASER Welding Assembly - Case Study
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• DESIGN/CAE support for proposed basic geometry– minimize mold deformation & sink mark
• Propose adequate material selection– Including optimized pigment and heat stabilized
• Collaborate with system supplier & pigment supplier• Development support for production facilities• Development support by utilizing various TP and
co-relate to the real applications• Total development coordination for on-line monitoring
& quality assurance
Development Support As a Total Solution
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• LASER Weldable
•NC Possible to use as Transmittance side
•BK Possible to use as Absorbent side
PA POM
•LASER Weldable but, difficult than PA/POM
•NC Possible to use as Transmittance side
•BK Possible to use as Absorbent side
PET/PBT/PCT
• No transmittance, cannot use T side• NC/WT
Possible to use as Transmittance side• BK Possible to use as Absorbent side
LCP
•No transmittance（some exceptions）
FR
• No transmittance, cannot use T side
• BK Possible to use as Absorbent side
MR
• LASER Weldable
• but,PBT/PET is rather difficult than
PA/POM
GF/Impact resistance
EP Material & LASER welding
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Du Pont various test pieces
Box: warp/cornerBurst/tensile
Sphere: Burst T-joint Tensile
overlapShear
“Koma”Burst
Pure tensile
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Global Technical Link & technical support
JPN UTC US. ATCEU ETC
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Contacts: DuPont & System Suppliers :
• Hakuto (Fine Device Co., Ltd.) : KANG, Myeon-Koo-TEL +82-2-529-8910
• (Parker Corporation) ; -TEL
• Branson Korea Co., Ltd. : YOO, Jae Du-TEL +82-31-422-9572
• Miyachi Korea Corporation : PARK, Seung-Kwo-TEL +82-31-707-5855
• DuPont Korea : Byung-Gul HamEngineering Polymers -TEL +82-2-2222-5377http://plastics.dupont.com
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