Lasers are playing a new role in milling, bending and surface treatment. Engineers in the manufacturing industry are using lasers to process a wider variety of materials and apply them more in production. Applications range from rapid prototyping of samples and tools to laser hardening of molds and joining and engraving of metal parts.
The use of laser technology to replace traditional surface treatment methods can extend tool life and improve tool and part performance.
Incorporating an alloy material into the surface layer with a laser beam can change the chemical composition of the surface and its characteristics. Currently, laser surface treatments are primarily used in manufacturing tools, particularly in the manufacture of molds for forging and pressure casting. With the theoretical thermochemical model, engineers have developed new surface layers for tools and parts.
For example, extrusion molds generate large strains due to long time contact under high temperature conditions. When a tool is incorporated into the phase and vanadium carbide, the surface of the tool is modified to improve its hardness retention, increase the hardness at high temperatures and improve the resistance to wear. Other alloys, including those containing tungsten and diamonds, are also very useful. In general, the use of a laser beam incorporation into the alloy can increase the tool life by 100%-500% compared to conventional methods, thereby reducing costs associated with consuming tools and replacing tools, thereby saving money.
Laser surface treatment technology can also enhance the performance of product parts. Researchers at the Fraunhofer Institute use lasers to harden the sealing surfaces and sliding guides, re-melting the laser surface of the camshaft and coating the valves and seats of the internal combustion engine. Lasers can be used to harden, re-melt, alloy and coat metals, creating many opportunities for thermochemical modification of the outer surface. The workpiece produced by this modification treatment has a higher ability to withstand various stresses. The laser beam can be focused and precisely positioned, which makes laser technology suitable for localized surface treatment. The user can selectively handle areas that are prone to wear while also having high reproducibility.
Using laser technology, engineers can produce the best surface profile (toPograhy), especially for products in the bearing and sealing industries. In this relatively new application, the pulsed laser beam can produce a defined micro-lubrication aperture on the surface that is subjected to frictional stress. The crater-like structure produced in this way is mainly affected by the geometry of the laser beam reaching the surface of the workpiece and the intensity distribution.
In general, any system with a contact surface will have a friction strain, such as a floating ring, etc., and a laser component such as a high-grade ceramic or metal can be used. The laser-modified functional surface is mainly composed of fine steps, with a reproducible, regular uniform micro-lubricator L-gap. The user can adapt the diameter, depth and distribution of these holes to the load applied to the part. For example, for ceramic slip ring seals, properly sized and properly distributed bumps can greatly reduce friction and wear. The processing speed in this process depends on the type of laser, typically 1000 holes per second.
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