The new Coherent PowerLine FL series is a fibre laser based subsystem that is specifically designed for precision welding and precision cutting of metals such as steel, titanium, aluminium alloys and copper alloys. These robust and compact systems meet all criteria for optimized industrial laser processing of materials. For laser joining, the PowerLine FL enables very small seam geometries at very high welding speeds. It therefore provides the required weld strength with minimum heat input to the workpiece. Precision laser cutting with PowerLine FL results in clean cuts with low HAZ and high edge quality. The new PowerLine FL series replaces and expands on older Coherent StarFiber products.
The PowerLine FL is available in a range from 200 W to 1,500 W as CW laser subsystems, as well as in pulse modes of 150 (average) / 1,500 (peak) W and 300 / 3,000 W. The PowerLine FL subsystems are supplied with Laser FrameWork software, which includes integrated features such as PartVision and SmartSense+.
KEY BENEFITS
Coherent PowerLine FL packages are integrated, cost-effective fiber laser-based subsystems. They build on more than 15 years of experience to offer industry-leading solutions that reduce investment risk and accelerate time-to-market for our customers.
Benefits of PowerLine FL single mode (SM) welding
The single mode laser offers unique features and welding capabilities. Coherent's single-mode PowerLine FL laser sources (PowerLine FL 200, PowerLine FL 400, PowerLine FL 600, PowerLine FL 1000, PowerLine FL 1500 and the optional single-mode PowerLine FL 150 P) can be focused to a spot diameter in the 25 micron (0.001") range using a focal length of 150 mm (6"). When we combine the single-mode laser with the galvanic scan head, we have the flexibility to use a 25-micron laser spot that can be moved to create any shape or weld size that fits within the scan head's working window. In the field of micro welding, this capability is a significant process enabler enabling the following capabilities:
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Any shape or size spot weld - it can be a circle, a ring, a spiral, a square, a smiley face or anything that can be optimized to reduce the thermal stress on the part and the mechanical demands of the weld.
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Dynamic weld scaling - different welds on the same part can be individually sized and shaped based on toolpath only, no need to change parameters.
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Reduced cycle time for multi-point welds - movement between spot welds is relatively slow when using linear steps compared to a scanning head. It can move from point to point in fractions of a second. Typically, 25 spot welds are made in less than 1 second.
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Customizing weld dimensions - the lateral movement can be overlapped along the weld to precisely control the width and depth of the weld. For example, a pulsed QCW or Nd:YAG weld section depth decreases from the centerline to the edge. Using a single mode laser and scanning head, we can create a square cross-section profile so that the penetration at the center and edge of the weld is the same. Therefore, for butt or fillet welds, any seam misalignment can be accounted for without reducing the strength of the weld.
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Minimize heat input - Heat input is directly proportional to the strength of the heat source and the time it is applied to the part. The lateral effect of the heat source is a function of its size. By using a 25micron point that moves quickly over the part in any shape, we now have precise control over the heat input and all the control levers for optimization.
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Large process windows, increased material selection - with minimal heat input. Ideal for welding a variety of materials. The laser, which operates in continuous wave mode, reduces the cooling rate of the part, increasing the range of materials to be welded while reducing any likelihood of weld cracks.
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3D motion capability - the scan head can be equipped with additional axes of motion to move the focal plane in the z-axis, offering even more features.
Replacement of the Nd:YAG laser with PowerLine FL multi-mode (MM) welding
The PowerLine FL 150 P features a multi-mode filament option and the PowerLine FL 300 P is only offered in a multi-mode version. For some micro-welding applications, the multi-mode laser profile can be advantageous, especially when transitioning a process from Nd:YAG laser-based assemblies to fiber laser-based assemblies. Available fiber core sizes of 50 or 100 microns result in a "flat top" beam profile with a more uniform distribution of laser power across the mode size. This can create a melt zone that is larger and still wide enough to join parts without oscillation. Oscillation is still possible with the MM laser.
PowerLine FL and laser cutting
The PowerLine FL series subsystems, equipped with Coherent fixed optics for cutting or galvanic scanners for special applications, are suitable for cutting applications especially in:
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E-mobility and battery production: cutting battery foils for all types of li-ion battery cells (cylindrical, sleeve, prismatic), cutting stator pins of e-motors, notching of battery foils.
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manufacture of medical devices: precision cutting of implants and medical instruments: stents, endoscopes, tubes, etc.
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Electronics manufacturing: resistance trimming, cutting of mobile phone components (antennas).
For more information on Coheren PowerLine FL laser subsystems, please click HERE.
