This precision decreases machining and rework time because there is less weld to remove. Another limitation of lasers early on was that they were a stationary pieces of equipment with relatively limited physical reach. That made laser welding impractical in many cases, particularly with large molds. This may not be visible from the top of the finished weld, but it will be revealed once the area is machined. Molds repaired with laser and TIG welding may look the same to the naked eye. However, once you put those molds to the test of a repetitive injection molding process at 20,000 psi, the results will be very different over time.
High laser energy density, small thermal effect area, not easy deformation, less or no subsequent processing. For molds going to the welding repair shop, the quality of the welds and the welding process has everything to do with answering those questions. In the U.S., the most common practice to rebuild worn cavity and core surfaces is with TIG welding.
Moreover, high heat can cause physical distortion of the metal, which may adversely affect delicate features in a precision cavity. When power is supplied by the PFN (pulse-forming network), an intense pulse of light will be released through one end of the crystal rod. The light being released is of single wavelength, thus allowing for minimum divergence. In Laser Welding, the solid-state laser utilizes a single crystal rod with parallel, flat ends, with each end having reflective surfaces. EBTEC has the capacity to address our customers’ precision Laser Welding needs, from prototype through full-scale production.
The importance of the higher M2 values becomes more apparent with welding. The single mode Laser still has a place particularly for deep welds on micro components where the small cross-sectional area can be an advantage. This means that more of the energy from a 1µm source is absorbed into these metals than with a 10.6µm source. Edge preparation involves removing material from a cutting tool in order to extend its life. That may sound counterintuitive, but a maker of glass molds says edge prep has dramatically reduced the amount it spends on tools.
Tungsten inert gas welding has been the traditional method for building-up worn or damaged mold and die surfaces prior to subsequent hand finishing or CNC machining to complete a repair. However, pulsed laser welding technology, which has been popular in Germany for decades, is gaining acceptance here in the United States as an option for mold repair . Using pulsed laser welding, repairs to injection molds can be completed with the mold still installed in the press. This saves time compared to TIG welding, which requires the mold to be removed from the press, heated, welded and then hand-finished before being re-installed.
After all, these classic welding techniques are still the most commonly practiced and are likely the entities that laser welding will be put up against. Quick, reliable solutions for welding bumpers, tail light assemblies, dashboards and many more applications. The GLX is Branson’s premier, global laser welder offering high speed, high volume welding of medium and large parts. The GLX allows designers to incorporate barely visible, particulate -free weld lines into large designs. Laser Welding is a joining solution that creates a particulate-free, clean joint. Laser welding is capable of joining together a wide range of materials.
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In order to manufacture metallic objects by means of 3D printing technology, the only option left until a few years ago was to use these materials for the production of casting cores. However, metal-powder laser welding now makes it possible to manufacture products of any shape by means of 3D printing. This discovery is currently providing laser welding with another boost.
Leister’s innovative laser systems open up new possibilities in the automotive, medical, sensors, electronics and micro-system technology industries for plastic joining. We specialize in finding customized, cost-effective solutions ranging from common joining problems to the most critical and complex customer demands. As an example, Leister’s patented and award-winning GLOBO Optic is an exclusive technology module that can weld three-dimensions plastic components in a single step to eliminate the complex tooling requirements of other joining technologies. In addition to our laser technologies, our highly-trained specialists can assist in the design and component construction, material selection, process optimization and equipment integration for new and existing manufacturing platforms. Leister Technologies has been a global leading provider of plastic welding equipment for over 70 years. With comprehensive theoretical and practical knowledge in a wide range of plastics processing techniques, Leister is able to confidently apply multi-faceted, “big picture” solutions with ease.