Laser Based

Manufacturing

What is Laser
LASER is the acronym for Light
Amplified Stimulated Emission of
Radiation
Laser is a device which generates or
amplifies light
Stimulated
emission
of
electromagnetic radiation
Coherent,
monochromatic,
directional and high power laser
beam is used

Elements of Laser
Lasing Medium (Gas, liquid, solid)
Pumping process
Optical feedback element

Gas
Laser

Excim
er
Laser

Types
of
Laser

Solid
State
Laser

Gas Laser
Electric current is discharged through
a gas to produce a coherent light
Operate
on
the
principle
of
converting electric energy into laser
light output
Gas acts as pumping medium to
attain the necessary population
inversion
Common gas laser are CO2
Gas
Laser, He-Ne Gas Laser

He-Ne Gas Laser

Source: Google Images

Solid State Laser

Constructed by doping a rare earth
element into a variety of host
materials
Pumped optically by arc lamps or
flash lamps
Respond well to Q-switching
Ruby or Nd:YAG is the most common
host material
7

Ruby Laser

Source: HowStuffWorks

Excimer Laser
Uses a combination
of an inert gas and
reactive gas
Excimer is form of
Ultraviolet Chemical
Laser
Excimer is short for
excited dimer
Source: Google Images

Laser Beam Machining

(LBM)
Used light energy from a laser to
remove material by vaporization and
ablation
Energy is concentrated optically
Laser emits either continuous or
pulsed light beam

Schematic diagram of Laser Beam

Machine

LBM schematic.

Material Removal Mechanism In LBM

Physical processes occurring during LBM

Parameter Affecting LBM

Working Material

Laser
Beam
Machinin
g

Assist Gases

Focusing Lenses

Laser Beam

Environment
14

Laser Beam Machining Capabilities

In laser machining there is no physical tool. Thus no
machining force or wear of the tool takes place.
Large aspect ratio in laser drilling can be achieved
along with acceptable accuracy or dimension, form
or location
Micro-holes can be drilled in difficult to machine
materials
Though laser processing is a thermal processing
but heat affected zone specially in pulse laser
processing is not very significant due to shorter
pulse duration.

Laser Beam Machining Limitations

High initial capital cost
High maintenance cost
Not very efficient process
Presence of Heat Affected Zone
specially in gas assist CO2 laser
cutting
Thermal process not suitable for
heat
sensitive
materials
like
aluminum glass fiber laminate

Laser Metal
Deposition(LMD)

Laser Metal
Deposition(LMD)

Laser beam creates molten pool on

part
Metal powder is fed into pool by
precision powder feed system
Powder is melted and incorporated
into the pool to create a weld bead

Laser Metal
Deposition(LMD)

Valve Ball & Seat Weld Development

Valve Ball & Seat Hardness Profile

Laser Metal DepositionCapabilities

Metallurgical bond (not mechanical thermal spray)
Wide variety of available powders
Very low dilution is possible
Relatively high deposition rates
Process is highly repeatable
Low impact on base material compared to similar
processes (HAZ)
Superior metallurgy compared to similar processes
Virtually unlimited build height
Very flexible tool path compared to wire applications

Laser Metal DepositionLimitations

High capital equipment costs
Powder cost is typically higher than wire
Capture ratio of additive material < 100% (based on
process parameters)
Cannot control the process manually CNC is
required
Experienced, specialized staff required (e.g. laser
safety engineer, skilled operators)
Less OEM competition than with traditional
techniques
Limited domestic application and equipment support

Selective Laser Sintering

(SLS)
Parts built up layer by layer
A CO2 laser beam selectively melts
powder into a designated shape
The component sinks into the bed, a layer
of powder is deposition above the
component
The process repeats until the component
is finished

Selective Laser Sintering

Machine

Example of SLS Part

(Drill)

Selective Laser Sintering

Capabilities

Robust System and High End Products.

Conceptual Models.
Functional Prototypes.
Pattern Masters for casting.
Rapid Tooling.
Wide Range of Building Materials.
High Throughput Capability.
intelligent powder tracking
Largest available part size

Selective Laser Sintering

Limitations
Large Amount of Up-Front Capital.
Designed for Large Manufacturing
Industries.
High Maintenance Cost
High power requirements for
Sinterstation Process.
Requires lots of open space.