Oscillating Laser Beam Opens Up Applications for Aerospace Parts

Considerable process benefits are gained by welding and cutting with high frequency beam oscillation, particularly in macro material processing of large components where thick metal sheets and fiber-reinforced plastics can be cut more quickly and cleanly. Diverse materials of poor weldability can also be robustly bonded. Now, SCANLAB America, Inc. (St. Charles, IL) offers the welDYNA scan head, a scan system for oscillating-laser beam cutting and welding that unites the advantages of higher laser powers and maximum dynamics. This scan head is designed for multi-kW lasers of high beam quality and features digital servo control, an integrated sensor system for real-time monitoring, and water and air cooling in a robust, industrially-suitable housing. It can be easily integrated or installed with collimation and focusing modules of commercial fixed optics. This system opens up countless interesting new application possibilities in aerospace processing, where thick metal parts and composite materials must be cut.

Also, for numerous automotive electro-mobility applications, a substance-to-substance bond between different materials (such as between copper and aluminum) is of interest as an alternative to mechanical joining. Advantages include improved electrical conductivity, more homogenous heat transfer and higher mechanical strength. Also, fabrication of devices and fittings often calls for pressure-tight bonding of the same or dissimilar material types, such as in heat exchangers or cooling units. This is precisely where the welDYNA 2D scan system shines: Overlapping laser beam motions relative to the seam geometry enable tear-resistant welds of diverse materials, even for joining partners with poor weldability. High-dynamics beam oscillation allows much faster cutting speeds and improved cutting quality. Key factors are the high ‘wobble motion’ frequencies of several kHz and the availability of freely definable scan patterns. Together, they deliver far superior process parameters compared to other laser methods. Applications show considerably reduced splatter formation, making weld seams and cut edges clearly smoother while also slowing down optics wear.

SCANLAB America, Inc., 100 Illinois Street, St. Charles, IL 60174, 630-797-2044, www.scanlab.de/en.