Technology Spotlight: New laser cutting technology means newfound productivity
Posted on Oct 19, 2022
Combining advanced laser control, new assist gas hardware, and noncontact part mapping now allows fabricators to significantly reduce the cycle time in cutting 3-D parts produced from high-strength, low-alloy (HSLA) plate, according to the laser experts at Prima Power Laserdyne.
By shortening the time for piercing of 5- to 10-mm-thick steel plate in parts containing several hundred holes, slots, and other shapes, the manufacturer has reduced the cycle time more than 30 percent compared to traditional laser processes, said Prima Power Laserdyne President Terry L. VanderWert.
Fiber lasers with average power of 2,000 W have been commercially available for more than 10 years. In fact, automotive component manufacturers have embraced this technology in a large way. The fiber lasers in this power range, a majority of which have continuous wave (CW) output, are well-suited for automotive metal cutting and welding applications. That may be changing, however.
Greater Laser Power
Quasi-continuous wave (QCW) lasers produce peak power 10 times greater in pulsed mode than CW mode, providing new process opportunities in automotive and many other industries, according to Dr. Mohammed Naeem, Prima Power Laserdyne’s senior manager, applications engineering and technology development. (CW lasers are the result of power sources that continuously emit light. QCW lasers have power sources that emit the laser both continuously and at defined intervals.)
“Major QCW laser enhancements in process speed and quality have been made recently in both aerospace and medical device manufacturing. These are now being adopted in other industries, particularly in the automotive sector,” Naeem said.
For Prima Power Laserdyne, innovation in this area has centered around SmartTechniques™, a suite of hardware, software, and control technology that is designed to improve productivity and quality in laser processing and provide unique capabilities for high-power laser cutting, welding, and drilling using both CW and QCW fiber laser systems (see Figure 1). In particular, SmartPierce™ and SmartSense™, along with a patent-pending gas assist nozzle—all developed for aerospace applications—hold great promise for the automotive industry, VanderWert said.