Enhanced performance of EV batteries is a major factor in the steady increase in electric vehicle sales. And better performance stems, in part, from recent developments in laser welding of dissimilar metals which increases efficiency by increasing energy storage, reducing size, and preserving reliability. It’s a fact that welding a less resistive metal to the standard stainless-steel terminal of a lithium ion battery can reduce resistance and improve battery efficiency. Traditional resistance spot welding, however, can’t effectively join highly-conductive dissimilar metals like copper and aluminum because the resultant intermetallic mix is brittle. But lasers CAN do the job with surprising results!
Delta motion control software is used to program motion on Amada Miyachi laser welding systems. Many of the terms are standard G&M codes, which can be applied to other CNC style motion programming. Here are a few tips for using the software to program nearly every type of weld joint configuration. In this post, we are just hitting the highlights to get you started on the right “path.” Full instructions on essentials for each configuration type can be found in Quick Start Guide to Programming in Delta Motion.
Topics: laser welding
Today’s post is about using “teach mode,” a fairly standard software function that enables a laser operator to customize tool paths without having to write complex code. This feature aids the operator when there is significant part to part tolerance issues. Here’s an example of how teach mode works for a complex tool path:
Topics: laser welding
The nanosecond fiber laser is the most recent addition to AMADA MIYACHI's broad portfolio of micro welding solutions. Its output parameters are a bit different than other laser welding sources like pulsed Nd:YAG ,quasi-continuous-wave (QCW) fiber and the CW fiber laser. As the name suggests, the nanosecond fiber laser’s pulse widths are in the nanosecond range - under 250 nanoseconds (ns) - with pulse energies around 1 millijoule (mJ).
Application engineers are a funny breed. They get their kicks from solving real-life manufacturing challenges – and the thornier the better! They like to get up close and personal with an application and help those having trouble to find the right way to weld, mark, cut, bond or machine a part. They also get a great deal of satisfaction from fixing a process that is taking too much time and affecting output (and the bottom line), one that results in unnecessary scrap or one that is out of limits. If the solution doesn’t work out the first time, they stick with it until they develop a one that works.
In hermetic and seam sealing applications utilizing pulsed laser welding, it is critically important that weld spots are evenly spaced, overlapping to form a continuous welded seam. Traditional pulsed laser welding approaches attempt to do this by firing the laser at a constant repetition rate. While this can be made to work along straight lines or other paths that can be traversed at constant speed, the result is sub-optimal and the approach really falls short when welding along irregular contours. For example, it does not work well for hermetically sealed packages, such as implantable medical devices, aerospace sensors or electronics modules.
Are you looking to use lasers for micro welding? If so, you have four excellent options: pulsed neodymium-doped yttrium aluminum garnet (Nd:YAG) and three different fiber lasers: continuous wave (CW) fiber, quasi continuous wave (QCW) fiber, and nanosecond fiber. In today’s post, I am going to compare the pulsed Nd:YAG laser with the three fiber laser options, and give some general comments on why and when one might be chosen over the other. I’m going to follow that up with another post with more information on how to choose.
Not long ago I worked on an interesting project with an aerospace customer looking to develop an in-house laser welding process for a major turbine component. Thanks to our joint efforts, they were able to bring the operation in-house, achieving an impressive seven to eleven day cycle reduction. What’s more, the new process helped them reduce their inventory, translating to a large cost savings - all without sacrificing quality.
Topics: laser welding
You heard it here first: there is no single materials processing technology that fits all applications. Manufacturers looking for a robust, production-ready solution must follow a rigorous process to determine the best choice of equipment. There are no short cuts or magic wands – you have to carefully review process feasibility and part design to maximize production reliability. The evaluation must also consider overall system needs.
The laser is a high energy density process that provides a unique welding capability – maximum penetration with minimal heat input. There are three basic weld modes, which correspond to the level of peak power density contained within the focus spot size: conduction mode, transition keyhole mode, and penetration or keyhole mode. Figure 1 is a graphic illustration of the three weld modes.