Benefits of Industrial Manufacturing with Laser Technology

At Lindø Welding Technology, a subsidiary to FORCE Technology, a 32-kwatt disc laser facility has been installed. At this facility, developments within hybrid laser welding and laser cladding have been the main focus for several years. This presentation will cover the main results related to the development of the high-power laser hybrid welding process, as well as to the perspectives for the technology as a cost-effective production tool for e.g. the windmill manufacturing industry. Laser cladding has shown to be the preferred process for repair purposes creating new surfaces to e.g. worn out high value industrial components. The laser cladding process is also the basis for new additive manufacturing and 3D restructuring technologies.

Laser processes can provide many benefits such as faster processing speed, improved quality and less rework. On the other hand laser processes do require an investment, possibly a product redesign and other preparation techniques. Solutions for laser processing will be presented with their performance, process monitoring possibilities and data logging perspectives. This presentation will include benefits and disadvantages of laser processing through general facts and a number of examples with an economical view for industrial users.

Manufacturing of large steel structures requires processing of thick-section steels. Welding is one of the main processes that form a significant part of the production costs. Hybrid laser-arc welding technology can potentially increase the productivity and reduce the production costs. However, there are a number of challenges to consider before taking advantage of the technology. This presentation will discuss the potential benefits as well as a few challenges related to this process.

Recent developments in multimode fiber laser has given fierce competition to CO2 and Nd:YAG lasers. The laser has become more economical, the power has been increased, and the beam quality has been improved, while the beam delivery has been simplified by optical fibers. On top of this, the laser industry has developed the single mode fiber laser. Single mode fiber laser provides nearly perfect laser beams that can be focused on spots much smaller than any other industrial laser source available, resulting in extreme intensities. The single mode spot is often “too good”, as there is risk of it passing between gaps in butt joining. By taking the “excess of the beam quality” and using it to reshape the wave front of the beam into multiple spots in the laser fusion zone, new possibilities have arisen. Research results from welding with multiple spots will presented along with results from the use of multiple spots to repair blowouts in laser welding.

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The potential of additive manufacturing has reached a point where the techniques are considered highly relevant for production purposes. This presentation will focus on the laser cladding method and show examples of industrial use. On-going work with the laser cladding technology for additive manufacturing purposes on existing applications will be discussed in relation to the durability of the manufactured components. Furthermore, the economical motivation and aspects will be addressed, motivating the integration of the process.

MAN Energy Solutions drive the transition towards a carbon-neutral world and create pioneering solutions to master the technical and operational challenges of decarbonization. Higher combustion pressures and temperatures increase the engine efficiency and cleaner fuels improve the environment. But this is very challenging for the engine components. Laser technology is a flexible tool to obtain surface properties, which can resist the combustion chamber environment in decarbonized engines.

MarineShaft specialize in repair of propeller equipment and rudder arrangements for ship companies and yards worldwide. One of our many repair solutions is laser cladding. This presentation will cover how to deal with laser technology in a low-tech company along with examples from some of our jobs, how did the idea occur, the implementation and reactions from customers and class societies.