State of the art laser systems for

materials processing

Carsten Keim
International Sales Lasers and Laser Systems
TRUMPF Laser- und Systemtechnik GmbH
TWI Cambridge, UK
07 July 2009

TRUMPF - State of the art laser systems for materials processing 07 July 2009

TRUMPF Group Business Divisions

Power Tools Laser Electronics Medical
Machine Tools Technology Technology

Machine tools for Power tools for Lasers and Power supplies for Operating tables,
flexible sheet metal sheet metal Systems for induction heating, surgical lights,
processing processing production plasma and CO2 ceiling pendants
technology laser excitation
Sales (mil €) 1,874.8
1 874 8 Sales (mil €) 551.7
551 7 Sales (mil €) 126.2
126 2
Employees 5,469 Employees 1,805 Employees 513

- Ca. 2/3 of all TRUMPF products use laser technology

- Over 30 years experience with lasers in industrial environments
- Worldwide laser service with 57 TRUMPF companies
End of fiscal year: June 30, 2008; consolidated within the business division; figures rounded

TRUMPF - State of the art laser systems for materials processing 07 July 2009 2

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 The right laser source for every application
TruMark TruMicro TruDiode TruDisk TruPulse TruFiber TruCoax TruFlow

- One supplier for all laser technologies

- Wavelengths from 0,343 µm to 10,6 µm
- From low power to high power applications

UV 0,35 1,03/1,06 IR 10,6

0,1 0,3 1 3 10 µm
TRUMPF - State of the art laser systems for materials processing 07 July 2009 3

Main TRUMPF Turn Key Systems with CO2 Lasers

- TruFlow/TruCoax
u o / uCoa CO2 CO Lasers
ase s for
o 3 D and
a d 2 D High
g Power
o e Laser
ase Processing
ocess g
- Laser Cutting, Welding, Cladding, Surface Treatment, …

TruLaser Cell 7040 (3D Laser) TruLaser 3030 (2D Laser Cutting)

TruLaser Tube 7000 (Tube Cutting) TruMatic 7000 (Laser + Punching)

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Typical Applications on TruLaser Cell 7040

Tailor Welded Blanks 3D Laser Cutting

 Coating
 Remelting
 Annealing
 Glazing

Deep Welded Differentials Surface Refinement

TRUMPF - State of the art laser systems for materials processing 07 July 2009 5

Higher productivity with automation

 Removable
e o ab e sp a  for
splitt wall o dua
dual station
stat o ope
operation
at o permitting
pe tt g safe
sa e
loading/unloading of midsize parts during the laser process

 Linear changer allow to load bigger and heavy parts outside the machine

 Rotary table minimize non-productive time and offer a single loading/unloading

position

TRUMPF - State of the art laser systems for materials processing 07 July 2009 6

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Saving money by faster cutting at reduced costs
 Error free set up by optics identification and lens monitoring for operation safety
 Minimum non productive time by high machine dynamics:
max. V = 173 m/min & A = 16m/s²
 Dynamic cutting optics 40 m/s² with piercing on the fly
 High Speed Cutting Process with 4 to 6 KW & plasma resistant height regulation
 High operating safety in case of collisions by magnetic coupling
 Constant working quality by a constant raw beam diameter independent of
position or laser power

receiver

emitter

TRUMPF - State of the art laser systems for materials processing 07 July 2009 7

Reduction of the current operation costs

Reduction
educt o of
o cutting
cutt g gas consumption
co su pt o by improved
p o ed cutting
cutt g nozzles
o es and
a d processes
p ocesses
Consumption of the cutting gas

Recommendation due to
best proportion of process
stability and consumption
of cutting gas
52 % 64 %

 The more accurate the

machine …
 The smaller the nozzle
diameter …
 The lower the cutting gas
consumption …
Consumption of the cutting gas / B-pillar  The lower your costs!
Additional reduction of the cutting gas costs through compressed air
(approx. 0,30ct versus approx. 0,06ct per Nm³/h) possible
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Easy laser welding – modular optics
 Laser diversity from 2 to 15 KW depending on application and productivity
 Many applications with modular optics: basic optics body with
 3 tool lengths (short, medium, long)
 5 focal lengths (195, 230, 280, 330, 380 mm)
 4 gas supplies (slim, water-cooled, lateral with/without water cooling)
 optical or tactile measurement tools
 filler wire
 Shorter non-productive times by teaching with height regulation and
technology tables for welding applications

TRUMPF - State of the art laser systems for materials processing 07 July 2009 9

Applications - Welding with high power CO2 Lasers

Critical, clean, spatter free welds with smooth surfaces desire the CO2 wavelength

Powertrain applications Aerospace: Turbines Heat exchanger: Beer tanks

Switchgear boxes Automotive: Steering shaft Tube & Profile Processing

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Main TRUMPF Turn Key Solid State Laser Systems
- One machine concept is not limited to one laser source
- Depending
D di on ththe application
li ti th the right
i ht system
t combination
bi ti can b
be chosen
h
Possible Sources:
- TruDisk
- TruDiode
- TruFiber
- TruPulse

TruLaser Cell Series 3000 TruLaser Station

TruLaser Cell Series 7000 TruLaser Robot 5020 TruLaser 7040 NEW
TRUMPF - State of the art laser systems for materials processing 07 July 2009 11

Multiple Processes with TruLaser Robot 5020

 I t
Integration
ti off allll lasers
l off the
th
TruDisk, TruPulse and TruDiode
series

 Standard options enable config-

uration acc. to customer’s wishes

 Comprehensive range of services to

support production and development

 Technology packages allow

 Laser welding
 Laser cutting
 Deposition welding
 Remote welding

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Turn Key Solution all from one Supplier: TRUMPF

Solid State Remote Welding: Welding: Roof Seam of VW Passat

Robot with PFO

Laser Metal Deposition Laser Welded Parts of VW Golf

TRUMPF - State of the art laser systems for materials processing 07 July 2009 13

Principles of Programmable
Focusing Optics PFO 3D
Synchronized
S h i d motionti off scanner
mirrors and robot path

PFO 3D
 3D scanner, max. 8 kW
 Until end of 2008,
TRUMPF sold > 800
PFO‘s worldwide
 applied since 1999
Source: Kuka
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Cost efficient
The TRUMPF LASERNETWORK
 Full use of the laser capacity is
made possible by the TRUMPF
LASERNETWORK 

 One laser can serve up to 6

different machining stations

 Each station is connected

directly to the laser by means of
a fiber optic laser cable and a
control cable (field bus system)

TRUMPF - State of the art laser systems for materials processing 07 July 2009 15

External Programming
TruTops Cell 
 Import the most common
3D CAD standard formats

 Contour preparation and

technology data

 Simulation and collision check

 Integration of fixtures

 Automatic generation of robot

program

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Process schematics Laser Metal Deposition

TRUMPF - State of the art laser systems for materials processing 07 July 2009 17

Technology package laser deposition welding

Powder conveyor

Delivery hose

Powder splitter

Focusing optics

Powder nozzle(s)

Chiller for optics and

nozzle

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Deposition Welding Process
Coaxial Nozzle 3-Beam
3 Beam Nozzle Off-Axis
Off Axis Nozzle

Working Plane

 2D nozzle for precise  3D nozzlel for

f welding
ldi  2D nozzlesl with
ith minimal
i i l
deposition in forced position interference contours
 Powder focus ≥ 0.3 mm  Powder focus ≥ 1.5 mm  Linear seam –
 Laser power ≤ 2000 W  Laser power ≤ 6000 W trailing powder feed
 Oxygen contamination  Oxygen contamination  Laser power ≤ 12,000 W
≤ 20ppm ≤ 50 ppm

TRUMPF - State of the art laser systems for materials processing 07 July 2009 19

Main TRUMPF Turn Key Marking Systems and

Low Power TruLaser Cells & Work Stations
- Manual or Automated Laser Cells and Work Stations
with TruPulse Lasers for Precision Cutting and Fine Welding, Drilling and Scribing

TruMark Station 5000 TruLaser Cell 3010

- Marking by colour change, engraving, ablation, …
- Please visit our marking laser stand outside!
TruLaser Station 5004
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TruPulse Systems - Application Examples

Spot welding Seam welding Trephine for hip joints

Precision cutting Scribing Endoscopic devices

TRUMPF - State of the art laser systems for materials processing 07 July 2009 21

The right pulsed laser for each application

Grading according to

 Average Power

 Focusability /
beam quality

 Maximum pulse energy

 Optimization of the
investment costs

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 Accurate pulse shaping and burst mode
 Welding optimization by defined variation of the pulse peak power
within one pulse (max. 50 ms) and Programmable time steps: 10 µs
 Burst Mode: Instead of e.g. 10 pulses/s
10 in 0,25 s and then refresh during handling time Burst Mode Option
 more productive  lower investment Time for
workpiece handling
Pulse power

time
0.25 s 0 75 s
0.75

Energy storage

Max.

Min. time

Programmed pulse shape

TRUMPF - State of the art laser systems for materials processing 07 July 2009 23

Applications TruMicro Laser

Ablation
Wafer Dicing/Isol. solar cells Micro structuring cylinder wall Ablation

Processing of turbine blades Drilling fuel injection nozzels Precision drilling in ceramics
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Applications TruMark – Marking on metal and platics

Water meter Safety switch Marking by tempering

Printed circuit board Gear wheel Day/Night Design

TRUMPF - State of the art laser systems for materials processing 07 July 2009 25

And next ? … Operation “Space Elevator”

In tthe
e baking
ba g heat
eat of
o the
t e Mojave
oja e dese
desertt …
TruDisk Laser delivers 8 KW photonic power to climb into space …

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But most innovative in real world applications …

Key Supplier Award 2009:

Innovation

Daimler AG awarded prizes to 14 companies for

their outstanding achievements at the first Key
Supplier Meeting, which was held on March 12,
2009 at the Mercedes-Benz Center in Stuttgart.
For the first time ever, the awards included a prize
for innovation.

TRUMPF - State of the art laser systems for materials processing 07 July 2009 27

Thank you for your attention!

And
d now
o let
et us talk
ta about your
you application
app cat o – p
please
ease visit
s t us …

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