Suojakaasuseoksen koostumuksen vaikutus CO2-laser-MAG-hybridihitsauksessa

Hitsaavassa teollisuudessa kilpailukyvyn säilyttäminen edellyttää hitsauksen tehokkuuden nostoa. Niinpä metalliteollisuus etsii kuumeisesti uusia yhä tehokkaampia hitsausmenetelmiä. CO2-laserin ja MAG:in yhdistelmän muodostamalla hybridihitsauksella saadaan aikaan syvä tunkeuma kuten laserhitsauksessa, mutta sallitaan laserhitsausta väljemmät railotoleranssit. Samalla muodonmuutokset vähenevät huomattavasti verrattuna perinteiseen kaarihitsaukseen. Kaariavusteisessa laserhitsauksessa yhdistetään laserhitsaukseen perinteinen kaarihitsaus eli MIG/MAG-, TIG- tai plasmahitsaus. Menetelmää voidaan kutsua myös hybridihitsaukseksi ja sillä hyödynnetään molempien prosessien edut välttyen yksittäisten prosessien haitoilta. Prosessin haittapuolena on parametrien suuri määrä, joka on rajoittanut menetelmän käyttöönottoa. Diplomityössä tutkittiin suojakaasuseoksen koostumuksen vaikutusta rakenneteräksen CO2-laser-MAG-hybridihitsauksessa. Laserhitsauksen ja MAG-hitsauksen suojakaasuvirtaukset yhdistettiin siten, että heliumseosteinen suojakaasu tuotiin MAG-polttimen kaasukuvun kautta. Suojakaasun heliumpitoisuus nostettiin niin korkeaksi, että estettiin laserhitsauksen muodostaman plasman syntyminen. Samalla hitsauskokeissa opittiin paremmin ymmärtämään prosessia ja sen parametrien riippuvuutta toisiinsa. Tutkitut suojakaasuseokset koostuivat heliumista, argonista ja hiilidioksidista. Hitsauskokeiden perusteella havaittiin, että suojakaasuseoksen optimaalinen heliumpitoisuus on 40-50 %. Tällöin laserin tunkeumaa häiritsevää plasmapilveä ei synny ja prosessi on stabiili. Päittäisliitosten hitsauksessa suojakaasuseoksen 2 %:n CO2-pitoisuudella saadaan aikaan hyvin vähän huokosia sisältävä hitsi, jonka tunkeumaprofiilin muoto ja liittymä perusaineeseen on juoheva. Pienaliitoksilla 7 %:n CO2-pitoisuudella prosessi pysyy stabiilina ja vähäroiskeisena. Tunkeuma hieman levenee hitsin keskeltä ja hitsin liittyminen perusaineeseen on juoheva.CO2-laser-MAG-hybridihitsauksella aikaansaadaan laadukkaita hitsejä taloudellisesti, mikäli käytetyt parametrit ovat oikein valittuja. Parametrit on sovitettava jokaiseen hitsaustapaukseen erikseen, eikä niitä välttämättä voida suoraan käyttää toisessa tapauksessa.

The effects of some variables on CO2 laser-MAG hybrid welding

The CO2-laser-MAG hybrid welding process has been shown to be a productive choice for the welding industry, being used in e.g. the shipbuilding, pipe and beam manufacturing, and automotive industries. It provides an opportunity to increase the productivity of welding of joints containing air gaps compared with autogenous laser beam welding, with associated reductions in distortion and marked increases in welding speeds and penetration in comparison with both arc and autogenous laser welding. The literature study indicated that the phenomena of laser hybrid welding are mostly being studied using bead-on-plate welding or zero air gap configurations. This study shows it very clearly that the CO2 laser-MAG hybrid welding process is completely different, when there is a groove with an air gap. As in case of industrial use it is excepted that welding is performed for non-zero grooves, this study is of great importance for industrial applications. The results of this study indicate that by using a 6 kW CO2 laser-MAG hybrid welding process, the welding speed may also be increased if an air gap is present in the joint. Experimental trials indicated that the welding speed may be increased by 30-82% when compared with bead-on-plate welding, or welding of a joint with no air gap i.e. a joint prepared as optimum for autogenous laser welding. This study demonstrates very clearly, that the separation of the different processes, as well as the relative configurations of the processes (arc leading or trailing) affect welding performance significantly. These matters influence the droplet size and therefore the metal transfer mode, which in turn determined the resulting weld quality and the ability to bridge air gaps. Welding in bead-onplate mode, or of an I butt joint containing no air gap joint is facilitated by using a leading torch. This is due to the preheating effect of the arc, which increases the absorptivity of the work piece to the laser beam, enabling greater penetration and the use of higher welding speeds. With an air gap present, air gap bridging is more effectively achieved by using a trailing torch because of the lower arc power needed, the wider arc, and the movement of droplets predominantly towards the joint edges. The experiments showed, that the mode of metal transfer has a marked effect on gap bridgeability. Transfer of a single droplet per arc pulse may not be desirable if an air gap is present, because most of the droplets are directed towards the middle of the joint where no base material is present. In such cases, undercut is observed. Pulsed globular and rotational metal transfer modes enable molten metal to also be transferred to the joint edges, and are therefore superior metal transfer modes when bridging air gaps. It was also found very obvious, that process separation is an important factor in gap bridgeability. If process separation is too large, the resulting weld often exhibits sagging, or no weld may be formed at all as a result of the reduced interaction between the component processes. In contrast, if the processes are too close to one another, the processing region contains excess molten metal that may create difficulties for the keyhole to remain open. When the distance is optimised - i.e. a separation of 0-4 mm in this study, depending on the welding speed and beam-arc configuration - the processes act together, creating beneficial synergistic effects. The optimum process separation when using a trailing torch was found to be shorter (0-2 mm) than when a leading torch is used (2-4 mm); a result of the facilitation of weld pool motion when the latter configuration is adopted. This study demonstrates, that the MAG process used has a strong effect on the CO2-laser-MAG hybrid welding process. The laser beam welding component is relatively stable and easy to manage, with only two principal processing parameters (power and welding speed) needing to be adjusted. In contrast, the MAG process has a large number of processing parameters to optimise, all of which play an important role in the interaction between the laser beam and the arc. The parameters used for traditional MAG welding are often not optimal in achieving the most appropriate mode of metal transfer, and weld quality in laser hybrid welding, and must be optimised if the full range of benefits provided by hybrid welding are to be realised.

Laser-MAG-hybridihitsauksen käyttöönotto laivan rungon valmistuksessa

Perinteisten kaarihitsausmenetelmien suhteellisen suuri lämmöntuonti aiheuttaa huomattavia muodonmuutoksia laivan rungon valmistusprosessin alkuvaiheessa. Muodonmuutosten seurauksena rakenteiden mitta- ja muototarkkuus heikkenee, mikä lisää oikaisu- ja sovitustyötä myöhemmissä työvaiheissa. Hitsausmuodonmuutoksia voidaan vähentää siirtymällä käyttämään laser-MAG-hybridihitsausta, jossa lämmöntuonti on merkittävästi pienempi kuin kaarihitsauksessa. Näin kyetään oleellisesti leikkaamaan oikaisu- ja sovitustyöstä syntyviä kustannuksia. Tämän diplomityön tavoitteena oli kehittää tuotantovalmiiksi kuitulaser- ja MAG-hitsauksen yhdistelmäprosessi Aker Yards Oy:n Turun telakalla loppuvuoden 2006 aikana. Hitsauslaitteiston asennus oli valmistunut kesäkuussa 2006, minkä jälkeen aloitettiin luokituslaitoksen hyväksymän koeohjelman hitsaukset. Käyttöönotto suunnitelmaan sisältyvä koehitsausohjelma oli laadittu Det Norske Veritaksen julkaisemaa ohjetta (Guidelines no. 19) mukaillen. Ensimmäiseksi määritettiin hitsauskokeiden avulla prosessille laadun ja tehokkuuden suhteen optimaalinen railogeometria. Seuraavaksi optimoitiin prosessin hitsausparametrit 6 mm:n aineenpaksuudelle hyödyntäen Taguchi-koesuunnittelumenetelmää. Tämän jälkeen optimiparametreilla hitsattiin koekappale väsytyskokeisiin, jotka suoritettiin Teknillisen korkeakoulun laivalaboratoriossa. Väsytyskoetulokset täyttivät luokituslaitoksen vaatimukset. Myös hitsauksen menetelmäkoe suoritettiin hyväksytetysti. Viimeinen koeohjelman mukainen hitsauskoesarja tehtiin prosessiparametrien sallittujen vaihtelurajojen määrittämiseksi. Diplomityön tavoite täyttyi joulukuussa 2006, jolloin 'laivan kansipaneeli hitsattiin ensimmäistä kertaa uudella hitsausprosessilla. Hitsauksen laatu korreloi hyvin menetelmäkokeen tulosten kanssa ¿ hitsit olivat tasalaatuisia ja ne täyttivät B-luokan vaatimukset.

Optimization of parameters for fiber laser-MAG hybrid welding in shipbuilding applications

The Arctic region becoming very active area of the industrial developments since it may contain approximately 15-25% of the hydrocarbon and other valuable natural resources which are in great demand nowadays. Harsh operation conditions make the Arctic region difficult to access due to low temperatures which can drop below -50 °C in winter and various additional loads. As a result, newer and modified metallic materials are implemented which can cause certain problems in welding them properly. Steel is still the most widely used material in the Arctic regions due to high mechanical properties, cheapness and manufacturability. Moreover, with recent steel manufacturing development it is possible to make up to 1100 MPa yield strength microalloyed high strength steel which can be operated at temperatures -60 °C possessing reasonable weldability, ductility and suitable impact toughness which is the most crucial property for the Arctic usability. For many years, the arc welding was the most dominant joining method of the metallic materials. Recently, other joining methods are successfully implemented into welding manufacturing due to growing industrial demands and one of them is the laser-arc hybrid welding. The laser-arc hybrid welding successfully combines the advantages and eliminates the disadvantages of the both joining methods therefore produce less distortions, reduce the need of edge preparation, generates narrower heat-affected zone, and increase welding speed or productivity significantly. Moreover, due to easy implementation of the filler wire, accordingly the mechanical properties of the joints can be manipulated in order to produce suitable quality. Moreover, with laser-arc hybrid welding it is possible to achieve matching weld metal compared to the base material even with the low alloying welding wires without excessive softening of the HAZ in the high strength steels. As a result, the laser-arc welding methods can be the most desired and dominating welding technology nowadays, and which is already operating in automotive and shipbuilding industries with a great success. However, in the future it can be extended to offshore, pipe-laying, and heavy equipment industries for arctic environment. CO2 and Nd:YAG laser sources in combination with gas metal arc source have been used widely in the past two decades. Recently, the fiber laser sources offered high power outputs with excellent beam quality, very high electrical efficiency, low maintenance expenses, and higher mobility due to fiber optics. As a result, fiber laser-arc hybrid process offers even more extended advantages and applications. However, the information about fiber or disk laser-arc hybrid welding is very limited. The objectives of the Master’s thesis are concentrated on the study of fiber laser-MAG hybrid welding parameters in order to understand resulting mechanical properties and quality of the welds. In this work only ferrous materials are reviewed. The qualitative methodological approach has been used to achieve the objectives. This study demonstrates that laser-arc hybrid welding is suitable for welding of many types, thicknesses and strength of steels with acceptable mechanical properties along very high productivity. New developments of the fiber laser-arc hybrid process offers extended capabilities over CO2 laser combined with the arc. This work can be used as guideline in hybrid welding technology with comprehensive study the effect of welding parameter on joint quality.

Comparative study of upper lip frenectomy with the CO2 laser versus the Er, Cr: YSGG laser

Objectives: To compare upper lip frenulum reinsertion, bleeding, surgical time and surgical wound healing in frenectomies performed with the CO2 laser versus the Er, Cr:YSGG laser. Study design: A prospective study was carried out on 50 randomized pediatric patients who underwent rhomboidal resection of the upper lip frenulum with either the CO2 laser or the Er,Cr:YSGG laser. Twenty-five patients were assigned to each laser system. All patients were examined at 7, 14, 21 days and 4 months after the operation in order to assess the surgical wound healing. Results: Insertion of the frenulum, which was preoperatively located between the upper central incisors, migrated to the mucogingival junction as a result of using both laser systems in all patients. Only two patients required a single dose of 650 mg of paracetamol, one of either study group. CO2 laser registered improved intraoperative bleeding control results and shorter surgical times. On the other hand, the Er,Cr:YSGG laser achieved faster healing. Conclusions: Upper lip laser frenectomy is a simple technique that results in minimum or no postoperative swelling or pain, and which involves upper lip frenulum reinsertion at the mucogingival junction. The CO2 laser offers a bloodless field and shorter surgical times compared with the Er,Cr:YSGG laser. On the other hand, the Er,Cr:YSGG laser achieved faster wound healing.

CO2 Laser Cutting of Particleboard, HDF and MDF

The purpose of this thesis is to reveal how the laser cutting parameters influence lasercutting of particleboard, HDF and MDF. The literature review introduces the basic principle of CO2 laser, CO2 laser equipment and its usage in cutting of wood-based materials. The experimental part focuses on the discussion and analysis ofthe test data and attempts to draw conclusions on the influence of various parameters, including laser power, focal length of the lens and cutting gas, on the cutting speed and kerf quality. The tested materials include various thicknesses of particleboard, HDF and MDF samples. A TRUMPF TLF2700 HQ laser equipment was used for the experiments. To obtain valid data, the test samples must be completely cut through without any bonding of wood fibre. The maximum cutting speed is linear dependent on the laser power in thecondition that the other parameters are constant. For each thickness of a specific material type, there is a minimum laser power for cutting. Normally, the topand bottom kerf widths increase with the enhancement of laser power. There may be a critical laser power which can generate the minimum cross-sectional kerf width. Lens of larger focal length may achieve higher cutting speed. As the focal length becomes larger, the top kerf width tends to increase while the bottom andcross-sectional kerf widths to the opposite. Of all cutting gases, oxygen can help achieve higher cutting speed. The gas pressure of nitrogen does not seem to have strong influence on the cutting result. Generally, 2 bar air is more preferable for higher cutting speed. For particleboard and MDF samples of larger thickness than 12 mm, 2 bar argon can be used to reach remarkably higher cutting speed than the 5 bar. Generally, the 190.5 mm lens can produce smallest total kerf width. The kerf sides of thicker samples are darker than the thinner ones. The sample darkness tends to be lower as laser power increased. 63.5 mm lens seemed tocause more darkness than other lens. 5 bar cutting gases can produce less dark side kerfs than 2 bar ones. Oxygen normally causes darker kerfs than other gases. No distinct differences were found between nitrogen and argon.

Thermal increment due to ErCr: YSGG and CO2 laser irradiation of different implant surfaces. A pilot study

Objective: An evaluation and comparison is made of the thermal increment at different implant surfaces during irradiation with CO2 and ErCr:YSGG lasers. Study design: Five threaded and impacted implants with four types of surfaces were inserted in an adult pig rib: two implants with a hydroxyapatite surface (HA)(impacted and threaded, respectively), a machined titanium surface implant (TI mach), a titanium plasma spray surface implant (TPS), and a sandblasted, acid-etched surface implant (SBAE). A 0.5-mm diameter bone defect was made in the implant apical zone, and a type-K thermocouple (Termopar)® was placed in contact with the implant. The implants were irradiated in the coronal zone of each implant with a CO2 (4 W continuous mode) and an ErCr:YSGG laser (1.5 W, pulsed mode) first without and then with refrigeration. The temperature variations at the implant apical surface were recorded. Results: An apical temperature increase was recorded in all cases during CO2 and ErCr:YSGG laser irradiation without refrigeration. However, when the ErCr:YSGG was used with a water spray, a decrease in temperature was observed in all implants. The acid-etched and sandblasted surfaces were those most affected by the thermal changes. Conclusions: The ErCr:YSGG laser with a water spray applied to the sealing cap or coronal zone of the implants does not generate thermal increments in the apical surface capable of adversely affecting osseointegration and the integrity of the peri-implant bone tissue

Surface modification and crystallization of the BaO-B2O3-SiO2 glassy system using CO2 laser irradiation

The surface modification and crystallization process of BaO-B2O3-SiO2 glass compositions when exposed to CO2 laser irradiation was evaluated as a function of the laser power, irradiation time and surface condition. The glass surface was modified by the application of laser power exceeding 0.40 W and an irradiation time of more than 300 s. Micro-Raman and X-ray diffraction measurements revealed at high laser power the formation of beta-BaB2O4 (beta-BBO) crystalline phase. The crystallization of the irradiated region was enhanced when beta-BBO micrometer sized particles were dispersed on the surface of the glass sample. The intensity of the second harmonic generation observed in the crystallized region was found to depend mainly on the condition of the glassy surface prior to glass irradiation. (C) 2007 Elsevier B.V. All rights reserved.

Surgical treatment of earlobe keloid with CO2 laser radiation: Case report and clinical standpoints

Keloids are considered to be benign hyperproliferative growths of dense fibrous tissue and overabundant deposition of disorganized, thick, hyalinized collagen that result from an abnormal tissue response to cutaneous injury. Keloids do not have a specific cause, although genetic predisposition is heavily implicated. We present a case report of a patient with an earlobe keloid that was treated with carbon dioxide laser radiation (CO2) with an 0.8-mm focus, 7 W, a power density of 2.5 W/cm(2), in a continuous mode. The patient was seen for follow-up 6 months later. An intact hole for placement of an earring was observed with a very good esthetic and functional result.

High resolution spectroscopy of (CH3OH)-C-13 around the 10R(20) CO2 laser emission: New FIR laser lines, frequency measurements and assignments

We investigated the IR absorption spectrum of (CH3OH)-C-13 around the frequency of the 10R(20) CO2 laser line. We found two absorption lines which can be excited by 10R(20) and studied the FIR laser emissions excited by this pump line using a waveguide CO2 laser of 300 MHz tunability: We report two new FIR laser lines of large offset, not previously observed due to their weakness and closeness to other stronger lines. We measured the frequencies of five FIR laser lines for the first time by an accurate heterodyne technique and present the complete assignments of the IR-FIR laser systems relative to this pump line. Furthermore we present new frequency values for two FIR laser lines whose frequencies had been previously wrongly measured. Copyright (C) 1997 Elsevier B.V. Ltd.

Optically pumped submillimeter laser lines from CD2Cl2 using a large tunability CW CO2 laser

Twenty-five new laser lines have been obtained is the wavelength region from 155 to 830 mu m by optically pumping the CD2Cl2 (deuterated dichloromethane) molecule with a CW CO3 laser having a tunability range of 300 MHz. The wavelength, polarization relative to that of CO2 pumping radiation, and offset relative to the CO2 center frequency were determined for all of the new lines and some other already known laser emissions. For all of them we give also the relative intensity and the optimum pressure of operation.

Use of carbon dioxide (CO2) laser radiation in exposure of implants (stage II): A metallography evaluation in dogs

In this study we analyzed possible damages that vaporization from laser radiation could cause to implant material. Fifteen standard titanium implants, measuring 3.75 mm in diameter by 7 mm in length, were placed into the upper and lower jaws of three dogs according to Branemark's system. After osseointegration, all implants were exposed. In group I (control) conventional exposure with a punch was used; in group II, a CO2 laser with 2 W (power density: 256 W/cm(2); fluency: 0.077 J/cm(2), and a pulse mode of 0.30 ms) was used, and in group III 4 W (power density: 512 W/cm(2), fluency: 0.154 J/cm(2), and a pulse mode of 0.30 ms) was used. After vaporization, the cover screws were removed and sent for metallographic examination. The results showed that cover screws irradiated with 2 and 4 W power caused no superficial or microstructural alteration. The results also showed that the prescribed power densities, fluencies, and the use of the pulse mode were suitable for exposing implants without damage to tissue or implant material. (C) 2002 Laser Institute of America.

High resolution spectroscopy of 13CH3OH around the 10R(20) CO2 laser emission: New FIR laser lines, frequency measurement and assignments

We investigated the IR absorption spectrum of 13CH3OH around the frequency of the 10R(20) CO2 laser line. We found two absorption lines which can be excited by 10R(20) and studied the FIR laser emissions excited by this pump line using a waveguide CO2 laser of 300 MHz tunability. We report two new FIR laser lines of large offset, not previously observed due to their weakness and closeness to other stronger lines. We measured the frequencies of five FIR laser lines for the first time by an accurate heterodyne technique and present the complete assignments of the IR-FIR laser systems relative to this pump line. Furthermore we present new frequency values for two FIR laser lines whose frequencies had been previously wrongly measured. Copyright © 1997 Elsevier Science Ltd.

Intrapulpar temperature during continuous CO2 laser irradiation in human molars: An in vitro study

To establish safety parameters, we in vitro studied the increase in intrapulpal temperature caused by the use of a cw CO2 laser. A thermistor was implanted in the inner part of the pulpal chamber of 25 human lower third molars to measure the intrapulpal temperature produced by laser powers between 2-10 W and exposure times of 0.5-25.0 s. The Pearson linear correlation factor applied to the measured values showed there is a direct relationship between the independent variable and the applied power. A variance analysis produced the linear regression equation: T=1.10+(0.127)E where T is the temperature and E the energy. The results showed that, with a power of 4 W and maximum exposure time of 2.5 s (10 J) and a power density of 12738.85 W cm-2, there will be no damaging reactions affecting the pulpal tissues.