{"id":22237,"date":"2023-06-28T07:17:29","date_gmt":"2023-06-28T04:17:29","guid":{"rendered":"https:\/\/apellaser.ro\/better-laser-polymer-welding\/"},"modified":"2023-11-13T09:10:38","modified_gmt":"2023-11-13T07:10:38","slug":"better-laser-polymer-welding","status":"publish","type":"post","link":"https:\/\/apellaser.ro\/en\/better-laser-polymer-welding\/","title":{"rendered":"BETTER LASER POLYMER WELDING"},"content":{"rendered":"\n

Laser polymer welding can consistently deliver superior results in volume production \u2013 if it is implemented right. \n<\/p>\n\n

The unique properties of polymers \u2013 lightweight, corrosion resistant, biocompatible, electrically and thermally insulating, and low cost \u2013 are driving their increased use in medical devices, automobiles, consumer electronics, and more. Assembling polymer components often involves welding parts together. For demanding applications, the welding process must achieve high mechanical precision, no part distortion, minimal particulate debris production, and excellent bond strength. \n \n<\/p>\n\n

Laser welding delivers on all these requirements. And one type of laser welding in particular \u2013 quasi-simultaneous (QS) through transmission laser welding (TTLW) \u2013 offers the best results in applications where part distortion must be completely avoided, or those involving complex weld seam geometries. \n \n<\/p>\n\n

But putting a consistent, high-quality QS welding process into production requires a couple of steps. First, careful process monitoring, usually including closed loop clamping force control and thermal imaging. Second, a part design which lends itself to the process. \n \n<\/p>\n\n

COLLAPSE CONTROL<\/h3>\n\n

A popular form of QS welding for precision applications is the \u201ccollapse rib\u201d method. This technique can produce strong welds with good cosmetics while avoiding the need for post-processing to trim or remove flash. Plus, this method can yield good results even if the parts aren\u2019t perfectly flat or tightly toleranced. \n<\/p>\n\n

In the collapse rib process, one part has a thin ridge which sticks out and mates into a corresponding (and slightly wider) groove in the other part. To weld the parts, the ridged part is placed in a holder, and the grooved part is put on top of it. A laser heats the rib to partially melt it while clamps actively press the two parts together. Molten material flows and fills some of the gap between the parts. The resolidified material forms the weld joint. \n \n<\/p>\n\n

\"Collapse<\/figure>\n\n

One key element in successfully implementing this process in production is \u201ccollapse control.\u201d This means actively monitoring and controlling how much the top part moves down during welding (called the \u201ccollapse height\u201d). \n \n<\/p>\n\n

Coherent has developed its own unique form of collapse control that consistently delivers superior results. To implement it, our ExactWeld<\/a> 230 P and ExactWeld IP polymer welding tools all incorporate force-sensing transducers. These continuously measure the pressure the clamps are applying to the top part. The collapse height (the distance the top part has moved) is measured, as well. These signals are used as feedback to control the servomotors which drive the clamping.<\/p>\n\n

No other manufacturer employs this method. Some use the servo motor current as a feedback signal, but this doesn’t deliver the same measurement accuracy and degree of dynamic control. Some just measure the collapse height, rather than the clamping force. And some use pneumatic actuators for clamping; these can\u2019t provide the precision or response speed needed to accurately control the clamping, even if they did measure the force. \n \n<\/p>\n\n

Measuring the true clamping force enables Coherent welders to control it as needed to respond to the exact conditions of the part being welded. It can correct for part-to-part dimensional variations, changes in material absorption characteristics, fluctuations in the ambient environment, and much more. This is the key to consistent results. It also delivers flexibility because it enables the clamping force to be purposefully varied, if desired. For example, sometimes it\u2019s better to apply less pressure during the cooling phase in order to control part stress. \n \n<\/p>\n\n

\"Figure<\/figure>\n\n

Monitoring both the actual clamping force and the amount the part has “collapsed” during the process is key to getting consistent welds, even when there are part-to-part variations.<\/em><\/p>\n\n

The overall result is improved yields, quality, and consistency \u2013 because it eliminates process variations caused by changes in the machine, environment, or parts themselves. Another benefit is that a welding system can be configured in one location \u2013 and then shipped to another \u2013 and still perform the same. Additionally, it compensates for machine-to-machine variations. This allows a process to be configured on one system and then transferred to others with consistent results and makes processes scalable. \n<\/p>\n\n

THERMAL IMAGING IS COOL<\/h3>\n\n

Another critical tool for successful polymer welding is thermal imaging using an infrared camera system. After welding is complete, the thermal vision check images the entire weld seam. Any breaks in the image along the path reveal gaps in the weld seam, and variations in line thickness indicate weak spots in the weld. \n<\/p>\n\n

This allows the manufacturer to immediately identify and reject bad parts. It saves the manufacturer money because it prevents building more value into a bad part. And, of course, it prevents shipping a bad part to a customer. \n \n<\/p>\n\n

DESIGN FOR MANUFACTURING<\/h3>\n\n

The other part of successful polymer welding happens before production \u2013 during product development. It\u2019s important that the part design allows enough space at the right locations for the clamps to engage and deliver the required downward force during welding. Plus, the weld tooling must be configured so that the clamps don\u2019t block the laser beam from reaching the weld path at any point. \n<\/p>\n\n

The dimensions and shapes of the ridge and groove must provide enough molten material for the welding process. They must also have enough space to contain the molten material that is produced. Additionally, the part design must permit a sufficient collapse height. The goal is to achieve a strong weld with good cosmetics, while eliminating the need for post-processing to trim or remove flash. \n<\/p>\n\n

With extensive experience in polymer welding, applications engineers at Coherent Labs can provide guidance in the design of both the parts and the welding tooling. Plus, Coherent can assist in developing the process recipe. This is valuable because there is often a fairly large \u201cparameter space\u201d which must be explored for laser welding. Prior experience enables our applications development staff to quickly find the optimum approach. \n<\/p>\n\n

Finally Coherent can aid in installing equipment, getting the process running, and training staff. Utilizing this combination of expertise, equipment, and support available from Coherent provides the best way to realize all the benefits of laser polymer welding in production. \n<\/p>\n","protected":false},"excerpt":{"rendered":"

Laser polymer welding can consistently deliver superior results in volume production \u2013 if it is implemented right.<\/p>\n","protected":false},"author":4,"featured_media":18723,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[3045,3003],"tags":[],"class_list":["post-22237","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-automotive-en","category-production-manufacturing"],"yoast_head":"\nBETTER LASER POLYMER WELDING - APEL LASER<\/title>\n<meta name=\"description\" content=\"Aflati cum Coherent Labs poate contribui la succesul procesului de sudura cu laser a polimerilor in productie\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/apellaser.ro\/en\/better-laser-polymer-welding\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"BETTER LASER POLYMER WELDING - 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