FabShop Magazine - March 2012 - 7

››› lasERs
the laser would shut down completely and not allow the operator to override it unless the filter was replaced. “So beyond the initial purchase cost issue, we didn’t have these service parts in-house for our lasers. We had to order them, and while we waited for them, the system was down and we were scrambling to get it back up and running. This was just starting to happen at the time that we were making the decision on the IPG laser,” says Dutzy. What helped their decision with the IPG laser was that Utica Enterprises made arrangements to have a tryout between both laser systems at its facility. After the tryout, they found that the results for using its current laser manufacturer weren’t as positive. There were also some problems with the laser’s connection to the Utica Enterprises’ collimator. “Therefore, under the circumstances, we decided to go with the IPG laser,” says Dutzy. Currently Ogihara has six stamped part processing cells using five lasers. Three are IPG lasers and all of which are 4kW. “Today our specifications for welding cells is using an IPG laser. These lasers have done very well for us. Plus, the customer service we receive when we do have an issue is very responsive. IPG’s warranty is outstanding. It really helps us to avoid needing spare parts on hand to service these lasers,” remarks Dutzy. Another important issue of laser welding is weight savings for a vehicle and overall production costs, as the weight of a vehicle will affect its fuel economy. Dutzy says that a laser needs a much smaller flange overlap for welding compared to a spot welder. other advantages for laser welding include: -A stonger part: A laser weld is 40 percent stronger than a spot weld and allows for decreased material thickness. -Low maintenance: No weld tip change downtime or consumables are needed. -Single-sided weld access: A laser offers the ability to weld difficult part sections that can't be accessed with a weld gun. -Reduced utility costs: A laser uses less electricity to produce a weld than a traditional resistance spot welder. -Elimination of sealers and/or adhesives: In some cases (depending on OEM requirements) a full seam laser weld can eliminate the need to apply sealer between parts. In these cases, material cost savings will be realized. “Typically we are looking at a 20-mm-wide flange to spot weld, because of the electrode size. But by using a laser you only need a 5-mm flange area. Now add up the amount of material around a door’s perimeter and it helps to reduce the vehicle’s weight. Then if you look at the volume of parts produced for a line of vehicles, the material savings costs become significant. “Also, although our typical laser weld is a 20-mm stitch, we do have some 6-mm circles and 20-mm staples that we use on mating surfaces where we aren’t able to weld a 20mm stitch. With a laser weld, you can literally make any shape you want. You could even write words on parts if you wanted to,” he concludes. IPG Photonics Ogihara America Corp.

A fiber laser’s beam is focused through a collimator to get the proper beam size for welding. Here is the collimator mounted to the robot.

FabShop Magazine - March 2012

Table of Contents for the Digital Edition of FabShop Magazine - March 2012