Development of Robotized Laser Welding Applications for Joining Thin Sheets

Laser Welding (LW) is more often used in manufacturing due to its advantages, such as accurate control, good repeatability, less heat input, opportunities for joining of special materials, high speed, capability to join small dimension parts etc. LW is dedicated to robotized manufacturing, and the fabrication cells are using various level of flexibility, from specialized robots to very flexible setups. This paper features several LW applications using two industrially-scaled manufacturing cells at UPM Laser Centre (CLUPM) of Polytechnical University of Madrid (Universidad Politécnica de Madrid). The one dedicated to Remote Laser Welding (RLW) of thin sheets for automotive and other sectors uses a CO2 laser of 3500 W. The second has a high flexibility, is based on a 6-axis ABB robot and a Nd:YAG laser of 3300 W, and is meant for various laser processing methods, including welding. After a short description of each cell, several LW applications experimented at CLUPM and recently implemented in industry are briefly presented: RLW of automotive coated sheets, LW of high strength automotive sheets, LW vs. laser hybrid welding (LHW) of Double Phase steel thin sheets, and LHW of thin sheets of stainless steel and carbon steel (dissimilar joints). The main technological issues overcame and the critical process parameters are pointed out. Conclusions about achievements and trends are provided.

The use of arc-erosion as a patterning technique for transparent conductive materials

Within the framework of cost-effective patterning processes a novel technique that saves photolithographic processing steps, easily scalable to wide area production, is proposed. It consists of a tip-probe, which is biased with respect to a conductive substrate and slides on it, keeping contact with the material. The sliding tip leaves an insulating path (which currently is as narrow as 30 μm) across the material, which enables the drawing of tracks and pads electrically insulated from the surroundings. This ablation method, called arc-erosion, requires an experimental set up that had to be customized for this purpose and is described. Upon instrumental monitoring, a brief proposal of the physics below this process is also presented. As a result an optimal control of the patterning process has been acquired. The system has been used on different substrates, including indium tin oxide either on glass or on polyethylene terephtalate, as well as alloys like Au/Cr, and Al. The influence of conditions such as tip speed and applied voltage is discussed

Análisis de la aplicación de Soldadura de acero de calidad "A" mediante láser de Neodimio-YAG en construcción naval

El proceso de soldadura por láser desarrollado en los últimos años ha puesto de manifiesto las posibilidades de aplicación de esta tecnología en diferentes sectores productivos, principalmente en la industria automovilística, en la cual se han demostrado sus ventajas en términos de productividad, eficiencia y calidad. El uso de la tecnología láser, ya sea híbrida o pura, reduce el input térmico al limitar la zona afectada por el calor, sin crear deformaciones y, por tanto, disminuye los re-trabajos post-soldadura necesarios para eliminarlas. Asimismo, se aumenta la velocidad de soldadura, incrementando la productividad y calidad de las uniones. En la última década, el uso de láseres híbridos, (láser + arco) de gran potencia de Neodimio YAG, (Nd: YAG) ha sido cada vez más importante. La instalación de este tipo de fuentes de láser sólido de gran potencia ha sido posible en construcción naval debido a sus ventajas con respecto a las instalaciones de láser de C02 existentes en los astilleros que actualmente utilizan esta tecnología. Los láseres de C02 están caracterizados por su gran potencia y la transmisión del haz a través de espejos. En el caso de las fuentes de Nd:YAG, debido a la longitud de onda a la cual se genera el haz láser, su transmisión pueden ser realizada a través de fibra óptica , haciendo posible la utilización del cabezal láser a gran distancia de la fuente, aparte de la alternativa de integrar el cabezal en unidades robotizadas. El proceso láser distribuye el calor aportado de manera uniforme. Las características mecánicas de dichas uniones ponen de manifiesto la adecuación de la soldadura por láser para su uso en construcción naval, cumpliendo los requerimientos exigidos por las Sociedades de Clasificación. La eficiencia energética de los láseres de C02, con porcentajes superiores al 20%, aparte de las ya estudiadas técnicas de su instalación constituyen las razones por las cuales este tipo de láser es el más usado en el ámbito industrial. El láser de gran potencia de Nd: YAG está presente en el mercado desde hace poco tiempo, y por tanto, su precio es relativamente mayor que el de C02, siendo sus costes de mantenimiento, tanto de lámparas como de diodos necesarios para el bombeo del sólido, igualmente mayores que en el caso del C02. En cambio, el efecto de absorción de parte de la energía en el plasma generado durante el proceso no se produce en el caso del láser de Nd: YAG, utilizando parte de esa energía en estabilizar el arco, siendo necesaria menos potencia de la fuente, reduciendo el coste de la inversión. En función de la aplicación industrial, se deberá realizar el análisis de viabilidad económica correspondiente. Dependiendo de la potencia de la fuente y del tipo de láser utilizado, y por tanto de la longitud de onda a la que se propaga la radiación electromagnética, pueden existen riesgos para la salud. El láser de neodimio se propaga en una longitud de onda, relativamente cercana al rango visible, en la cual se pueden producir daños en los ojos de los operadores. Se deberán establecer las medidas preventivas para evitar los riesgos a los que están expuestos dichos operadores en la utilización de este tipo de energía. La utilización del láser de neodimio: YAG ofrece posibilidades de utilización en construcción naval económicamente rentables, debido su productividad y las buenas características mecánicas de las uniones. Abstract The laser welding process development of the last years shows broad application possibilities in many sectors of industry, mostly in automobile production. The advantages of the laser beam process produce higher productivity, increasing the quality and thermal efficiency. Laser technology, arc-hybrid or pure laser welding, reduces thermal input and thus a smaller heat-affected zone at the work piece. This means less weldment distortion which reduces the amount of subsequent post-weld straightening work that needs to be done. A higher welding speed is achieved by use of the arc and the laser beam, increasing productivity and quality of the joining process. In the last decade use of hybrid technology (laser-GMA hybrid method) with high power sources Nd:YAG lasers, gained in importance. The installation of this type of higher power solid state laser is possible in shipbuilding industrial applications due to its advantages compare with the C02 laser sources installed in the shipyards which use this technology. C02 lasers are characterised by high power output and its beam guidance is via inelastic system of mirrors. In the case of Nd:YAG laser, due to its wavelength, the laser beam can be led by means of a flexible optical fibre even across large distances, which allows three dimensional welding jobs by using of robots. Laser beam welding is a process during which the heat is transferred to the welded material uniformly and the features of the process fulfilled the requirements by Classification Societies. So that, its application to the shipbuilding industry should be possible. The high quantum efficiency of C02 laser, which enabled efficiency factors up to 20%, and relative simple technical possibilities of implementation are the reasons for the fact that it is the most important laser in industrial material machining. High power Nd: YAG laser is established on the market since short time, so that its price is relatively high compared with the C02 laser source and its maintenance cost, lamp or diode pumped solid state laser, is also higher than in the case of C02 lasers. Nevertheless effect of plasma shielding does not exist with Nd:YAG lasers, so that for the gas-shielding welding process the optimal gases can be used regarding arc stability, thus power source are saved and the costs can be optimised. Each industrial application carried out needs its cost efficiency analysis. Depending on the power output and laser type, the dangerousness of reflected irradiation, which even in some meters distance, affects for the healthy operators. For the YAG laser process safety arrangements must be set up in order to avoid the laser radiation being absorbed by the human eye. Due to its wavelength of radiation, being relatively close to the visible range, severe damage to the retina of the eye is possible if sufficient precautions are not taken. Safety aspects are of vital importance to be able to shield the operator as well as other personal. The use of Nd:YAG lasers offers interesting and economically attractive applications in shipbuilding industry. Higher joining rates are possible, and very good mechanical/technological parameters can be achieved.

Residual stress distribution in ferritic-austenitic steel joints made by laser welding

The present investigation addresse the influence of laser welding process-ing parameters used for joining dis-similar metals (ferritic to austenitic steel), on the induced residual stress field. Welding was performed on a Nd:YAG laser DY033 (3300 W) in a continuous wave (CW), keyhole mode. The base metals (BM) employed in this study are AISI 1010 carbon steel (CS) and AISI 304L austenitic stainless steel (SS). Pairs of dissimilar plates of 200 mm x 45 mm x 3 mm were butt joined by laser welding. Different sets of parameters were used to engineer the base metals apportionment at joint formation, namely distinct dilution rates. Residual strain scanning, carried out by neutron diffraction was used to assess the joints. Through-thickness residual stress maps were determined for the laser welded samples of dis-similar steels using high spatial reso-lution. As a result, an appropriate set of processing parameters, able to mi-nimize the local tensile residual stress associated to the welding process, was found.

Residual stress distribution in ferritic to austenitic steel joints made by laser welding,

In this study, autogenous laser welding was used to join thin plates of low carbon ferritic and austenitic stainless steel. Due to the differences in the thermo-physical properties of base metals, this kind of weld exhibits a complex microstructure, which frequently leads to an overall loss of joint quality. Four welded samples were prepared by using different sets of processing parameters, with the aim of minimizing the induced residual stress field. The dissimilar austenitic-ferritic joints obtained under all welding conditions were uniform and free of defects. Variations in beam position did not influence the weld geometiy, which is a typical keyhole welding. Microstructural characterization and residual strain scanning (by neutron diffraction) were used to assess the features of the joints. By varying laser beam power density and by displacing the laser beam towards the carbon steel side, an optimum combination of processing parameters was found.

Overall vs. local mechanical behaviour of ferritic austenitic steel joints made by laser welding

The present investigation addresses the overall and local mechanical performance of dissimilar joints of low carbon steel (CS) and stainless Steel (SS) thin sheets achieved by laser welding in case of heat source displacement from the weld gap centreline towards CS. Welding was performed on a Nd:YAG laser DY033 (3300 W) in a continuos wave (CW), keyhole mode. The tensile behavior of the joint different zones assessed by using a video-image based system (VIC-2D) reveals that the residual stress field, together with the positive difference in yield between the weld metal and the base materials protects the joint from being plastically deformed. The tensile loadings of flat transverse specimens generate the strain localization and failure in CS, far away from the weld.

Ensayo no destructivo de soldaduras en pernos conectores mediante inspección acústica = Non-destructive test of welding headed studs through acoustic emission

Los pernos conectores aportan múltiples ventajas de uso, entre las que se encuentra el elevado margen de seguridad que ofrecen sus soldaduras ejecutadas mediante arco eléctrico. Estas soldaduras, aunque ampliamente fiables, son difícilmente comprobadas mediante ensayos no destructivos. Aparte de la inspección visual, que aporta gran información sobre la calidad de ejecución de la soldadura, el resto de ensayos no destructivos (líquidos penetrantes, partículas magnéticas, ultrasonidos, radiografías, etc.) resultan inviables en estos elementos. Por otro lado, los ensayos acústicos de piezas metálicas han existido siempre. Su comprobación se basaba en el análisis por medio de ¿un oído fino¿ del sonido resultante tras ser golpeado el elemento a evaluar. Con estas premisas se plantea el presente estudio de inspección de las soldaduras en pernos conectores mediante su espectro acústico. Analíticamente, la investigación se ha centrado en el cálculo informático de los primeros modos propios de vibración mediante elementos finitos. Se han modelizado diferentes grados de penetración de la soldadura mediante la modificación de las condiciones de contorno. Se ha observado que variando el número de movimientos coaccionados en los nodos pertenecientes a la soldadura se produce una reducción en su frecuencia de vibración.

Selectively filled photonic liquid crystal fibers = Fibras de cristal fotónico selectivamente llenas con cristal líquido

El presente trabajo de Tesis se ha centrado en el diseño, fabricación y caracterización de dispositivos basados en fibras de cristal fotónico infiltrado selectivamente con cristales líquidos, polímeros y una mezcla de ambos. Todos los dispositivos son sintonizables, y su área de aplicación se centra en comunicaciones ópticas y sensores. La manipulación y fusionado de fibras fotónicas, el llenado selectivo de determinadas cavidades y la alineación recíproca de fibras mantenedoras de polarización son tareas muy específicas y delicadas para las que se requieren protocolos muy estrictos. Previo a la fabricación de dispositivos ha sido necesaria por tanto una tarea de sistematización y creación de protocolos de fabricación. Una vez establecidos se ha procedido a la fabricación y caracterización de dispositivos. Los dispositivos fabricados se enumeran a continuación para posteriormente detallar una a una las singularidades de cada uno. • Interferómetros intermodales hechos a partir de una porción de fibra fotónica soldada entre dos fibras estándar, bien monomodo o PANDA (mantenedora de polarización). Estos interferómetros han sido sumergidos o bien llenados selectivamente con cristales líquidos para así sintonizar la señal interferométrica guiada a través de la fibra. • Infiltración de fibras fotónicas con cristales líquidos colestéricos con especial énfasis en la fase azul (blue phase) de estos materiales. Las moléculas de cristal líquido se autoalinean en volumen por lo que la infiltración de fibras fotónicas con estos cristales líquidos es muy interesante, pues es conocida la dificultad de alinear apropiadamente cristales líquidos dentro de cavidades micrométricas de las fibras fotónicas. • Grabación de redes holográficas de forma selectiva en las cavidades de una fibra fotónica. Estas redes holográficas, llamadas POLICRYPS (POlymer-LIquid CRYstal-Polymer Slices), son redes fabricadas a base de franjas de polímero y cristal líquido alineado perpendicularmente a dichas franjas. Las franjas son a su vez perpendiculares al eje de la fibra como lo puede ser una red de Bragg convencional. El cristal líquido, al estar alineado perpendicularmente a dichos franjas y paralelo al eje de la fibra, se puede conmutar aplicando un campo eléctrico externo, modificando así el índice efectivo de la red. Se puede fabricar por lo tanto una red de Bragg sintonizable en fibra, muy útil en comunicaciones ópticas. • Llenado selectivo de fibras fotónicas con polidimetilsiloxano (PDMS), un polímero de tipo silicona. Si se realiza un llenado selectivo asimétrico se puede inducir birrefringencia en la fibra. El índice de refracción del PDMS tiene una fuerte dependencia térmica, por lo que se puede sintonizar la birrefringencia de la fibra. • Estudio teórico de llenado selectivo de fibras fotónicas con PDMS dopado con nanopartículas de plata de 5, 40 y 80 nm. Estas nanopartículas poseen un pico de absorción en torno a los 450 nm debido a resonancias superficiales localizadas de plasmones (LSPR). La resonancia del plasmon tiene una fuerte dependencia con el índice de refracción del material colindante, y al ser éste PDMS, la variación de índice de refracción se ve amplificada, obteniendo una absorción sintonizable. Se ha propuesto la fabricación de polarizadores sintonizables usando esta técnica. Como ya se ha dicho, previamente a la fabricación ha sido necesaria la protocolización de diversos procedimientos de fabricación de alta complejidad, así como protocolizar el proceso de toma de medidas para optimizar los resultados. Los procedimientos que han requerido la formulación de protocolos específicos han sido los siguientes: • Llenado selectivo de cavidades en una fibra fotónica. Dichas fibras tienen generalmente un diámetro externo de 125 μm, y sus cavidades son de entre 5 y 10 μm de diámetro. Se han desarrollado tres técnicas diferentes para el llenado/bloqueado selectivo, pudiéndose combinar varios protocolos para la optimización del proceso. Las técnicas son las siguientes: o Llenado y bloqueado con un prepolímero. Dicho prepolímero, también llamado adhesivo óptico, está inicialmente en estado líquido y posee una cierta viscosidad. Las cavidades de la fibra fotónica que se desea llenar o bloquear poseen un diámetro diferente al resto, por lo que en el proceso de llenado aparecen dos frentes de llenado dependientes de su diámetro. A mayor diámetro, mayor velocidad de llenado. Polimerizando cuando existe dicha diferencia en los frentes se puede cortar por medio, obteniendo así una fibra parcialmente bloqueada. o Colapsamiento de las cavidades de menor diámetro mediante aplicación de calor. El calor producido por un arco voltaico de una soldadora de fibra estándar fusiona el material exterior de la fibra produciendo el colapsamiento de las cavidades de menor diámetro. En esta técnica también es necesaria una diferencia de diámetros en las cavidades de la fibra. o Bloqueo una a una de las cavidades de la fibra fotónica con adhesivo óptico. Este procedimiento es muy laborioso y requiere mucha precisión. Con este sistema se pueden bloquear las cavidades deseadas de una fibra sin importar su diámetro. • Alineación de una fuente de luz linealmente polarizada con una fibra mantenedora de polarización ya sea PANDA o fotónica. Así mismo también se han alineado entre sí fibras mantenedoras de polarización, para que sus ejes rápidos se fusionen paralelos y así el estado de polarización de la luz guiada se mantenga. • Sistematización de toma de medidas para caracterizar los interferómetros modales. Éstos son altamente sensibles a diversas variables por lo que el proceso de medida es complejo. Se deben aislar variables de forma estrictamente controlada. Aunque todos los dispositivos tienen en común el llenado selectivo de cavidades en una fibra fotónica cada dispositivo tiene sus peculiaridades, que van a ser explicadas a continuación. ABSTRACT The present Thesis has been centered in the design, fabrication and characterization of devices based on photonic crystal fibers selectively filled with liquid crystals, polymers and a mixture of both. All devices are tunable and their work field is optical communications and sensing The handling and splicing of photonic crystal fibers, the selective filling of their holes and the aligning of polarization maintaining fibers are very specific and delicate tasks for which very strict protocols are required. Before the fabrication of devices has therefore been necessary task systematization and creation of manufacturing protocols. Once established we have proceeded to the fabrication and characterization of devices. The fabricated devices are listed below and their peculiarities are detailed one by one: • Intermodal interferometers made with a portion of photonic crystal fiber spliced between two optical communication fiber pigtails, either single mode or PANDA (polarization-maintaining) fiber. These interferometers have been submerged or selectively filled with liquid crystals to tune the interferometric guided signal. • Infiltration of photonic fibers with cholesteric liquid crystals with special emphasis on their blue phase (blue phase). The liquid crystal molecules are self-aligning in volume so the infiltration of photonic fibers with these liquid crystals is very interesting. It is notoriously difficult to properly align liquid crystals within micron cavities such as photonic fibers. • Selectively recording of holographic gratings in the holes of photonic crystal fibers. These holographic gratings, called POLICRYPS (POlymer-LIquid CRYstal-Polymes Slices), are based on walls made of polymer and liquid crystal aligned perpendicular to them. These walls are perpendicular to the axis of the fiber as it can be a conventional Bragg grating. The liquid crystal is aligned perpendicular to the walls and parallel to the fiber axis, and can be switched by applying an external electric field and thus change the effective index of the grating. It is thus possible to manufacture a tunable Bragg grating fiber, useful in optical communications. •Asymmetrically selective filling of photonic crystal fibers with a silicone polymer like called polydimethylsiloxane (PDMS) to induce birefringence in the fiber. The refractive index of PDMS has temperature dependence, so that the birefringence of the fiber can be tuned. • Theoretical study of photonic crystal fibers selectively filled with PDMS doped with silver nanoparticles of 5, 40 and 80 nm. These nanoparticles have an absorption peak around 450 nm due to localized surface plasmon resonances (LSPR). Plasmon resonance has a strong dependence on the refractive index of the adjacent material, and as this is PDMS, the refractive index variation is amplified, obtaining a tunable absorption. Fabrication of tunable polarizers using this technique has been proposed. Before starting the fabrication, it has been necessary to optimize several very delicate procedures and different protocols have been designed. The most delicate procedures are as follows: • Selective filling of holes in a photonic crystal fiber. These fibers generally have an outer diameter of 125 μm, and their holes have a diameter around between 5 and 10 μm. It has been developed three different techniques for filling / selective blocking, and they can be combined for process optimization. The techniques are: o Filling and blocked with a prepolymer. This prepolymer also called optical adhesive is initially in liquid state and has a certain viscosity. The holes of the photonic crystal fiber that are desired to be filled or blocked should have a different diameter, so that in the filling process appear two different fronts depending on the hole diameter. The holes with larger diameter are filled faster. Then the adhesive is polymerized when there is such a difference on the front. A partially blocked fiber is obtained cutting between fronts. o Collapsing of holes of smaller diameter by application of heat. The heat produced by an arc of a standard fusion splicer fuses the outer fiber material producing the collapsing of the cavities of smaller diameter. In this technique also you need a difference of diameters in the fiber holes. o Blocking one by one the holes of photonic crystal fiber with optical adhesive. This procedure is very laborious and requires great precision. This system can block unwanted cavities regardless fiber diameter. • Aligning a linearly polarized light source with a polarization-maintaining fiber (either a PANDA fiber as a photonic crystal fiber). It is needed also an aligning between polarization-maintaining fibers, so that their fast axes parallel merge and that is state of polarization of light guided is maintained. • Systematization of taking measurements to characterize the modal interferometers. These are highly sensitive to several variables so the measurement process is very complicated. Variables must be fixed in a very controlled manner. Although all devices have the common characteristic of being selectively filled PCFs with some kind of material, each one has his own peculiarities, which are explained below.

The forced oscillations of submerged bodies

The increasing use of very light structures in aerospace applications are given rise to the need of taking into account the effects of the surrounding media in the motion of a structure (as for instance, in modal testing of solar panels or antennae) as it is usually performed in the motion of bodies submerged in water in marine applications. New methods are in development aiming at to determine rigid-body properties (the center of mass position and inertia properties) from the results of oscillations tests (at low frequencies during modal testing, by exciting the rigid-body modes only) by using the equations of the rigid-body dynamics. As it is shown in this paper, the effect of the surrounding media significantly modifies the oscillation dynamics in the case of light structures and therefore this effect should be taken into account in the development of the above-mentioned methods. The aim of the paper is to show that, if a central point exists for the aerodynamic forces acting on the body, the motion equations for the small amplitude rotational and translational oscillations can be expressed in a form which is a generalization of the motion equations for a body in vacuum, thus allowing to obtain a physical idea of the motion and aerodynamic effects and also significantly simplifying the calculation of the solutions and the interpretation of the results. In the formulation developed here the translational oscillations and the rotational motion around the center of mass are decoupled, as is the case for the rigid-body motion in vacuum, whereas in the classical added mass formulation the six motion equations are coupled. Also in this paper the nonsteady motion of small amplitude of a rigid body submerged in an ideal, incompressible fluid is considered in order to define the conditions for the existence of the central point in the case of a three-dimensional body. The results here presented are also of interest in marine applications.