Laser Marking Steers a New policy in Manufacturing

Employment - Laser Marking Steers a New policy in Manufacturing

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As the technology of laser marking has advanced, new markets have evolved to take advantage of increasingly faster marking speeds as well as greater marking precision and imaging capabilities. Lasting developments in laser-cavity design, beam-steering and focusing optics, and computer hardware and software are increasing the role of the systems.

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Steering the beam

Of the ready marking technologies, beam-steered laser marking systems contribute users with the most amount of image flexibility in a fast, permanent, noncontact marking process. As manufacturing processes come to be more self-acting and after-sale tracking more prevalent, laser markers are often the only recipe ready to furnish individually unique, permanent images at high speed.

Beam-steered laser marking systems ordinarily couple whether a Co2 or Nd:Yag laser. The Co2 laser emits a continuous-wave production in the far-infrared (10.6-um wavelength) while the Nd:Yag laser emits in the near-infrared (1.06 um) in whether a Cw or pulsed mode (1 to 50 kHz). The Nd:Yag laser is also unique in its potential to furnish very short, high-peak-power pulses when operated in the pulsed mode. For example, a typical 60-W-average-power Nd:Yag laser can furnish peak powers on the order of 90 kW at 1-kHz pulse rate.

The delivery optics consist of whether a uncomplicated focusing lens assembly or a combination fixed upcollimator and flat-field lens assembly. In whether instance, the laser beam is directed over the work exterior by mirrors mounted on two high-speed, computer-controlled galvanometers.

The uncomplicated focusing assembly offers the advantages of low cost and fewer optical components and is routinely used with Co2 lasers. The flat field lens design, though more expensive, maintains the focal point of the marking beam on a flat plane for more consistent image characteristics throughout the marking field. The flat-field lens also produces higher power density on the work exterior than the uncomplicated focusing assembly due to the shorter sufficient focal length. The flat-field lens organize is always beloved for high-accuracy and high-image-quality applications and is ordinarily incorporated with Nd:Yag lasers.

Both designs contribute the user with a choice of lenses that organize both the diameter of the marking field and the marking-line width. Longer-focal-length lenses contribute larger working areas, but the line width is also enlarged, thus reducing the power density on the work surface. The user must compensate by whether increasing the laser production power and/or decreasing the marking speed which ordinarily consists of two lenses and may be placed anywhere in the beam path before the focusing lens. A beam expander often is used instead of extending the beam path practically 10 more feet, in which the beam expands straight through its possible tendency to diverge as it exits the resonator cavity. A spatial filter inserted within the beam expander produces the best mode potential in close-coupled systems, by passing the beam straight through a small aperture.

The last optical element that a laser beam encounters is the focusing lens. With Co2 lasers, this lens is ordinarily made from one of any materials: Zinc selenide (ZnSe), gallium arsenide (GaAs) or germanium (Ge). ZnSe, a dense, yellow material that is transparent to illustrated wavelengths, is by far the most coarse of these materials, and it allows a low-power, HeNe laser beam straight through for alignment purposes. This is a great advantage over GaAs or Ge which are opaque to light from the illustrated quantum of the spectrum.

Nd:Yag lasers practically always hire beam expansion, ordinarily in the 2x to 5x range, because of their initially small beam diameters. Spatial filters for Co2 lasers must be external, but those for Nd:Yag lasers can be placed inside the laser cavity itself, and many distinct sizes are ready for mode selection.

Nd:Yag lasers hire optical glasses such as Bk-7 or fused silica for lenses. The 1.06-um wavelength of these lasers is close enough to the illustrated spectrum to permit adaptation of suitable optical devices with the correct Ar coating to direct the laser light. For example, microscope objectives can deliver Nd:Yag laser light to the exterior of Vlsi circuitry for micromachining of conductor paths. As discussed earlier, delivering a Nd:Yag laser beam with fiber optics offers expected advantages over fixed-optic delivery. The fiber advantage is unique to Nd:Yag lasers and has created an titanic growth in their use for market materials processing.

Fiber optic delivery for Nd:Yag

The use of fiber delivery with Yag lasers is so extensive in the manufactures that it should be discussed in more detail. practically 90 percent of new Nd:Yag welding installations involve fiber optic delivery. Because the 1.06-um wavelength is transmitted by glass optics, it can be used in suitable fiber optics. Approved beam delivery is highly cumbersome, prone to misalignment and contamination to the optics, and can be very high-priced due to practice layouts. Fiber provides a real rejoinder to all of these problems. The benefits are:

Fibers deliver laser power over distances which, in practice, would be impossible to accomplish using Approved optics. Distances of up to 50 meters are achieved quite routinely. Stability and accuracy are improved since only the final focus optics need to be held in an correct relationship to the workpiece.
Most applications can be handled with suitable delivery hardware (avoiding practice design). Fibers are flexible and, within the limitations of minimum bend radius, can result any desired route to the workpiece.
The workpiece may be held stationary while the fiber and production optics move while processing making them the ideal delivery principles for use with robotic manipulation. Fibers make the organize of time and power sharing beam distribution systems a practical possibility. The use of such systems significantly increases the flexibility and versatility of private lasers by allowing them to address manifold workstations or furnish manifold simultaneous outputs. way to the laser head for habit maintenance is improved since the positioning of the head is not dictated by the beam delivery system.
The low-cost fiber can be delivered to areas that are risky because of explosives or radiation while the laser head is placed in a non-hazardous area. Spot size at focus does not alter with changes of mean power.

The optics of fiber delivery are uncomplicated and straightforward. Fiber optics used for laser delivery are typically step-index fibers. This type of fiber consists of an optically uniform core between 200 and 1500 um in diameter, surrounded by a thin cladding which has slightly distinct optical properties.

There are any options to fiber optic beam delivery. The first is single-fiber delivery from a particular laser. This type of delivery is commonly used for a dedicated production process or in development labs where lively the beam delivery to other workstations is infrequent. The choice of a single-fiber delivery is certainly justified by its ease of use, ease of integration to workstations, and the potential for upgrading the principles with other options in the future. Other reasons for single-fiber delivery are for robotic delivery of the laser beam and other multiaxis systems where Approved delivery would be a nightmare. With fibers, the production housing is mounted on the final-motion component so integration is incredibly thrifty and simple.

Another fiber delivery choice is time sharing, whereby all of the laser production can be directed into any one of the any fibers on demand. A particular laser with this principles can contribute laser power to any distinct workstations switching among them at up to 40 Hz. These systems are typically used for laser welding at many distinct workstations, or to deliver the laser beam to isolate areas of one large assembly station.

The last choice is termed power sharing. These systems divide the laser production and send the power into any fibers at the same time. Mirrors skim portions of the beam from the laser and divert them into the input housings for each of the fibers.

The relative extent that each skimming mirror is moved into the beam path determines the sharing ratio. Typical energy-share systems can split the beam into as many as four fibers. These systems are used to weld many parts simultaneously, in order to growth throughput, or to eliminate the part distortions that often result from sequential welding of a particular assembly.

The principles computer creates marking images by sending beam-motion signals to the galvanometer drivers while simultaneously blanking the laser beam between marking strokes. The petition of the galvanometer-mounted mirrors directs the marking beam over the target exterior much like a pencil on paper to draw alphanumeric and illustrated images.

Laser selection

Laser marking uses the high power density of the focused laser beam to originate heat on the work exterior and induce a thermal reaction. A readable, contrasting line is produced by increasing the target exterior to annealing temperatures, the melting point or to vaporization temperatures. Annealing and melting are employed to induce a contrasting color change on a wide variety of metallic's as well as plastics, earthenware and other nonmetallic's. The fastest marking speeds are obtained by increasing the temperature to the vaporization point to engrave metallic's and many nonmetallic's.

The near-infrared wavelength of the Nd:Yag laser is well grand to most metallic's and many plastics. The Nd:Yag can anneal or melt in both the Cw and pulsed mode and can contribute the valuable peak pulsed power to engrave. With many materials, the Nd:Yag can simultaneously engrave the exterior and induce a contrasting color change in the engraved trough.

The far-infrared wavelength of the Co2 laser is compatible with plastics, earthenware and organic materials. However, without the high-peak-power potential required to accomplish vaporization temperatures, the Co2 laser is exiguous to annealing or melting the surface.

Advantages

Beam-steered laser marking offers any advantages over other marking methods. Most apparent is the unique combination of speed, permanence and the flexibility of computer control. Although other technologies can contribute one or two of these attributes, no other recipe offers all three to the same degree.

Many users also advantage from the noncontact nature of laser marking. The only force applied to the part while the marking cycle is the very localized thermal result of the laser beam. No added corporeal force is applied, with the exception of any suitable part-handling petition designed into the system. Silicon wafers, silicon disk drive read/write heads and many healing devices are examples of components that are too brittle for any type of mechanical marking. In addition, laser marking provides the permanence valuable to satisfy image-lifetime requirements, while printed marking does not.

Laser-marking systems also excel at creating intricate illustrated images. Nd:Yag lasers can furnish marking-line widths on the order of 0.001 inch or less, which, when combined with marking resolution of 0.0002 inch/step, can furnish images with much more information than mechanical perceive or stencil systems.

Regardless of the definite process justifications for incorporating laser marking, the application of the technology can result in valuable cost savings. With operating costs for the Nd:Yag system, users have reported cost savings of greater than 90 percent and linked reductions in potential operate and inventory expenses.

As manufacturing industries continue to automate their manufacturing processes, couple aftershipment traceability, reduce manufacturing cycle times, apply more sophisticated graphics and organize products requiring new marking techniques, the laser-marking manufacturers will continue to heighten the power, speed, image-generation capabilities and user-friendliness of their products.

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