SAN Fiber Laser Cutting Machine

1. Output power intensity

Generally speaking, the greater the power of the laser cleaning machine, the higher the cleaning efficiency. The power range of the pulse laser cleaning machine is 200 watts to 1000 watts, and the power of the continuous laser cleaning machine is 1000 watts to 3000 watts. In this way, the continuous laser cleaning machine has more advantages in cleaning efficiency.

However, it should be noted that during the cleaning process with too high power, the substrate temperature will be too high, causing more obvious damage to the surface of the material.

2. Cleaning depth

For stubborn dirt, the cleaning effect of the pulse laser cleaning machine will be more thorough.

Due to the working principle of the pulse laser cleaning machine, the energy of the pulse laser is more concentrated and the spot is smaller, so it can deeply clean the dirt accumulated for a long time. For example, oxides, rust, coatings, paint oil stains, etc.

3. Cleaning effect

After the pulse laser cleaning machine cleans the material, there is almost no damage to the bottom of the substrate. Not only that, after cleaning the material, it can also be very close to the original base color of the material. After the continuous laser cleaning machine is finished, slight white marks will be left on the surface of the metal material. Although the cleaning is very good, its appearance may be better than that of the pulse laser cleaning machine.

4 .Different materials are suitable for cleaning

We used a 1000W pulsed laser cleaning machine and a 1500W continuous laser cleaning machine to test rust and oil stains.

For light rust, both pulse and continuous lasers can easily remove it. Both have good cleaning speed and effect. However, for thicker rust and larger areas, continuous laser can provide better cleaning results.

For oil stains, pulse laser cleaning is more thorough and effective, and it hardly damages the material. However, continuous laser is less effective in removing oil stains and may leave some black residue on the surface.

If you need to clean a thicker rust layer, it is recommended to use a continuous laser cleaning machine. If you need to clean oil stains and thinner rust layers, pulse laser is a better choice.

5. Effect of heat on materials

The pulse laser cleaning machine uses short pulses for cleaning, so the laser will not always irradiate the surface of the material, and the heat accumulation is minimal. It is suitable for processing heat-sensitive materials.

During the long cleaning process of the continuous laser cleaning machine, due to the large light cutting power, the accumulated heat is large, which may cause thermal effects on the cleaning materials.

6. Light uniformity

The laser of the pulse laser cleaning machine is continuously output at very short intervals, with a high peak power, while the laser output of the continuous laser cleaning machine is stable and continuous, so its beam uniformity will be better.

7. Price and cost

The cost of the pulse laser cleaning machine is higher because it requires a more complex control system to generate high peak power laser pulses, coupled with a high-precision optical system and cooling device, the overall price is higher than that of ordinary continuous laser systems.

The price of continuous laser cleaning machines is relatively cheap, especially the continuous laser system with mature technology, because the output power is stable and relatively simple, the production and maintenance costs are low.

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So what are the advantages of galvanometer laser welding machine compared with ordinary welding methods? Take a look at SAN LASER's galvanometer welding machine, it has the following advantages:

1. High precision:

Galvanometer technology can achieve high-precision laser welding. The accuracy of the welding point can reach 0.1mm.

2. High speed:

Galvanometer laser welding machine adopts high-speed galvanometer scanning. It can achieve high-speed welding, and the production efficiency is many times higher than that of traditional welding methods.

3. High efficiency:

The laser beam of the galvanometer laser welding machine directly irradiates the surface of the workpiece for welding. It greatly improves the welding efficiency.

4. Low temperature deformation:

Laser welding has concentrated energy, fast welding speed and reduced heat input. Thereby reducing temperature deformation and ensuring welding quality.

5. Can weld a variety of materials:

Laser welding can weld various metals and their alloy materials. Non-metallic materials can also be welded by adjusting the laser power.

6. Environmental protection and energy saving:

Laser welding does not require the use of flux, which reduces environmental pollution and saves energy.

In summary, the galvanometer laser welding machine is not only time-saving and labor-saving, but also highly efficient. It is a rare welding tool. If you have welding equipment like SAN LASER, I believe it can save you a lot of cost and time.

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At present, battery shells made of aluminum alloy materials account for more than 90% of the entire power battery. The difficulty of welding is that aluminum alloy has extremely high reflectivity to lasers, and is highly sensitive to pores during welding. Some problems and defects will inevitably occur during welding, among which pores, thermal cracks and explosions are the most important.

Pores are easily generated during the laser welding of aluminum alloys, and there are two main types: hydrogen pores and pores generated by bubble collapse. Because the cooling speed of laser welding is too fast, the hydrogen pore problem is more serious, and there is an additional type of pores generated by the collapse of small holes in laser welding.

Thermal crack problem. Aluminum alloy is a typical eutectic alloy. It is easy to have thermal cracks during welding, including weld crystallization cracks and HAZ liquefaction cracks. Due to the segregation of components in the weld zone, eutectic segregation will occur and grain boundary melting will occur. Under stress, liquefaction cracks will form at the grain boundary, reducing the performance of the welded joint.

Explosion (also known as spatter) problem. There are many factors that cause explosions, such as the cleanliness of the material, the purity of the material itself, the characteristics of the material itself, etc., and the stability of the laser plays a decisive role. The shell surface is convex, pores, and internal bubbles. The main reason is that the fiber core diameter is too small or the laser energy is set too high. It is not the "better beam quality, better welding effect" advertised by some laser equipment providers. Good beam quality is suitable for superposition welding with a large penetration depth. Finding suitable process parameters is the magic weapon to solve the problem.

Other difficulties

Soft-package pole ear welding has high requirements for welding tooling. The pole ear must be pressed firmly to ensure the welding gap. It can achieve high-speed welding of complex trajectories such as S-shaped and spiral shapes, increase the weld joint area and strengthen the welding strength.

The welding of cylindrical battery cells is mainly used for the welding of positive electrodes. Because the shell of the negative electrode is thin, it is very easy to weld through. For example, some manufacturers currently use the negative electrode free welding process, and the positive electrode uses laser welding.

When welding square batteries, the poles or connecting pieces are contaminated. When welding the connecting pieces, the contaminants decompose and easily form welding explosion points, resulting in holes. Batteries with thin poles and plastic or ceramic structural parts underneath are easy to be welded through. When the poles are small, it is also easy to weld off-center and burn the plastic, forming explosion points. Do not use multi-layer connecting pieces, as there are gaps between the layers and it is not easy to weld firmly.

The most important process of square battery welding is the encapsulation of the shell cover, which is divided into the welding of the top cover and the bottom cover according to the different positions. Some battery manufacturers use the "deep drawing" process to manufacture battery shells because the batteries they produce are not large in size, and only the top cover needs to be welded.

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The galvanometer laser welding machine has the advantages of high efficiency and high precision. Therefore, it is widely used in many industries, including but not limited to the following fields:

Automobile manufacturing industry:

Such as automobile wheel hub, body welding, etc.

Electronic manufacturing industry:

Welding of stainless steel shell, battery cover and other parts of smart phones, TVs and other products.

Metal manufacturing industry:

Welding and repair of metal parts in fields such as aerospace, machinery manufacturing, etc.

Medical device manufacturing industry:

Welding of stainless steel parts of dental instruments, scalpels and other products.

Home appliance manufacturing industry:

Welding of kitchen and bathroom equipment, stainless steel stoves, gas stoves and other products.

Aluminum alloy product manufacturing industry:

Welding of products such as aviation aluminum alloy parts and sports equipment.

New energy industry:

Connector welding, terminal welding, soft package series welding, flip welding, spot welding, cover welding, sealing welding, pole welding.

Hardware industry:

Radiator welding, water-cooled and air-cooled edge welding.

Kitchen and bathroom industry, home appliance industry, stainless steel doors and windows, advertising industry, mold industry, etc.

In short, the galvanometer laser welding machine is widely used in many industries. It can improve production efficiency and reduce costs. At the same time, it also provides a guarantee for product quality. If you have such equipment, you can not only use it in your own industry, but also rent it to other industries, which is also a very cost-effective way.

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In order to achieve the highest service life of the mold, the surface surfacing technology of flux-cored wire can obtain a thicker surface layer and a stable surface structure, which is easier to form a wear-resistant and heat-fatigue-resistant surface layer, saving materials and reducing processing and manufacturing costs.

Mold welding process and precautions

1. Welding parameters

Beijing Guben KB968 mold welding wire diameter 1.6mm, welding current 220-280A, welding voltage 22-28V, shielding gas is pure carbon dioxide or pure argon, shielding gas volume 20L/min, wire extension length 15-20mm, welding speed 35cm/min, welding gun inclination 80 degrees, current type is DC reverse connection.

2. Mold welding process

Strictly implementing the correct surfacing process is the decisive factor to ensure the quality and success of surfacing. The cladding process includes the following steps

(1) Preparation before welding

Before cladding, mechanical processing methods are used to rough-process the cladding hole type to remove the fatigue layer and defects on the substrate surface. In particular, cracks must be thoroughly removed. For parts that have been cladding multiple times, ultrasonic testing should be performed to check the internal conditions. Welding can only be carried out when it is confirmed that there are no cracks.

(2) Preheating

In order to prevent the occurrence of cracks, it must be preheated before cladding. The preheating temperature depends on the substrate and the composition of the cladding material. In order to obtain uniform hardness on the surface, the preheating temperature should be above the Ms point of the material. In order to reduce thermal stress, the heating rate should also be controlled. The heating rate starts at about 20℃/h at 100℃, and then can be 40℃/h. Uniform heating is required.

(3) Welding

Welding is the key link in the success of cladding. To obtain an ideal cladding layer, certain variable factors must be considered comprehensively, such as welding voltage, welding speed, welding current, welding materials, etc.

(4) Post-weld treatment

In order to reduce the cracks caused by volume stress due to different cooling rates between the surface and the inside, the cooling rate must be controlled. In order to eliminate welding residual stress, tempering treatment must be carried out. The tempering temperature depends on the use conditions of the hot forging die and is generally controlled between 450-600℃. The higher the tempering temperature, the more complete the internal stress is eliminated, but the hardness is reduced. Therefore, the choice of tempering temperature must ensure a certain hardness of the hot forging die surface and try to eliminate internal stress. The tempering holding time is usually 3-10 hours.

3. Precautions

(1) Before welding, it must be thoroughly cleaned, otherwise pores will be generated during the welding process;

(2) After the start of surfacing, it must be carried out continuously and cannot be stopped in the middle;

(3) The lap width of the weld must not be less than 5mm, otherwise strip wear will occur during use. When welding fillet, pay attention to the position of the weld. When welding, the wire guide distance should be appropriate;

(4) During surfacing, the surfacing materials should be kept at a certain temperature, and the interlayer temperature should be kept at around 150℃;

(5) When reserving machining allowance for surfacing, the temperature factor should be considered.

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