ENABLING AL DIE CAST LASER WELDING
Civan Lasers' Dynamic Beam Laser (DBL) technology has revolutionized the welding of die-cast aluminum materials, a process traditionally fraught with challenges due to the entrapped hydrogen gas in the material. This innovation enables manufacturers to achieve high-quality, high-strength aluminum die-cast parts with significantly reduced porosity, leading to faster production speeds, reduced costs, and fewer COâ‚‚ emissions.
The die-casting process allows for intricate designs and shapes that would be difficult or impossible to achieve with other manufacturing methods. Additionally, the mechanical properties of aluminum die-cast parts, such as high impact strength, make them ideal for the demanding mechanical standards in a variety of industries.
DYNAMIC BEAM LASERS
Civan Lasers conducted a successful demonstration utilizing a 120 kW DBL to remotely cut through 100 mm thick steel from a distance of 10 meters. The laser beam was transmitted through a pipe in free space, then redirected using a mirror inside a closed chamber to perform the cut. This innovative setup showcased the laser's exceptional beam quality and precision, enabling the cutting of thick sections from considerable distances.
THE CHALLENGES OF TRADITIONAL WELDING
FOR AL DIE CAST APPLICATIONS
The casting process involves a significant amount of hydrogen gas entrapped in the material due to the high temperatures and pressures involved, as well as processing additive materials.
When welding, this gas expands, resulting in an excessive porosity and spatter, where the former can weaken the mechanical properties of the material and reduce its overall strength. Furthermore, the excessive porosity can also promote keyhole instability and collapse.
Blow Holes. High heat input during traditional laser welding causes distortion in thicker metal pasrts, resulting in high investment in fixturing and waiting time for cooling.
Porosity. Traditional laser welding often results in solidication cracks, and small holes within the metal that weaken the structure, particularly with thicker metal parts.
