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Business Introduction

Laser Processing

Do you have any problems with distortion of parts from welding and quench hardening?
We can solve these problems by using the latest laser technology!

Overview of Laser Quenching

Level of Hardness

Equipment for Laser Quenching

Case study of Laser Quenching
Cost reduction of large press Dies for automobile parts
Model name Door inner Stamping Die (Figure 14)
Material FC300
Quenched Part Beat Location and all the die Radius
Level of Hardness HRC HRC58~63
Result
  1. Cost Reduction by PROX 20% (our cost comparison) Changing the Base material from FCD 600 to FC 300.
  2. Result of Cost and time reductions on Laser Quenching, By changing the process of bead location,
    Current Condition:
    Avoid burning and scratches on Beat location or Radius After Polishing, Tig Welding and tool work to make it harder <Polishing → Tig Welding → Re Tooling → Polishing>
    Using Laser Quenching:
    We can skip Tig Welding → Re Tooling → Polishing <Polishing → Laser Quenching>
  3. Improvement on the stability on hardness (Radius Location ).
    Before: Radius location were hardened by flame quenching,
    Flame Quenching have defects ( insufficient hardness, cracks, melting, etc.,)
    After Laser Quenching: The above-mentioned defects are resolved through a uniformed hardness obtained.
  4. Improvement of surface treatment durability.
    Before: 50,000 ~ 70,000 shots for re treatment (Hard Chrome Plating)
    After Laser Quenching on Base Material:
    100,000 shots or more for re treatment (Hard Chrome Plating)
    That's because the strength of the base metal were improved.
    Also, it could prevent cohesive failure of the plating film and the base material.

Door inner Stamping Die (Figure 14)

Countermeasures against seizure of die insert for Forming Die(discarded quenching)
Model name Forming Die (Figure 15)
Material SKD-11
Quenched Part The sliding surface of the movable insert
Level of Hardness HRC50~55

Laser Quenching for high alloy tool steel for cold Dies (SKD-11)
The carbide of SKD-11 is a carbide component containing chromium.
In alloy tool steel containing a large concentration of carbon and chromium, if carbon is dissolved too much in the heating area, a large amount of retained austenite is produced and the ideal hardness cannot be obtained. Especially the surface layer is prone to soften.
For that reason, an adjustment of laser output, irradiation speed, etc.
However, it may not suitable for Laser Quenching.

Result
Before: The quenching were not performed in the trial stages Due to adjustment on the shape. Therefore, there are burning and seizure of movable insert.

After Laser Quenching on the sliding surface of the movable insert:
The seizure was eliminated and the trial time were drastically shortened and reduced A vacuum quenching is performed after trial.

Forming Die (Figure 15)

Counter Measure against seizure of the injection mold
Model name (Figure 16)Plastic Injection Mold
Material S55C
Quenched Part Locking block matching surface, Sliding surface of the movable insert
Level of Hardness HRC58~62
Result
Laser Quenching were performed on the sliding surfaces of the locking block engraved in the mold base as well as on the movable insert.
Before: Hardening treatment was performed by flame quenching.
However, an adjustment process of the variation of hardness, distortion and deformation were necessary.
After the Laser Quenching treatment:
The adjustment process became unnecessary. It only needed the removing the oxidization on the surface by sand paper. The huge cost reduction were done.

Figure 16 is a diagram of a plastic injection mold image and a pictures of Locking Block section (quenching)

Reduce cost of roller hemming mold
Model name Roof roller hemming mold (Figure 17)
Material FCD600
Quenched Part The entire hem-folded surface
Level of Hardness HRC56~62
Result
Before: After curing treatment by flame hardening, the roller hemming mold were modified and adjusted by the cutting of the distortion and deformation. If the strain after quenching is 0.1mm or less, the cutting work is unnecessary. In the case of the hemming mold shown in FIG. 17, distortion and deformation occurred because of the portion of cavities. But if we perform Laser Quenching under normal conditions It will have approximately 0.3mm distortion. However Laser Quenching can adjust it quenching conditions of laser output (Create the Jigs for Laser Quenching) The distortion were suppressed to 0.1mm or less as a result.

Roof roller hemming mold (Figure 17)

Laser Welding

Laser Welding is a precise welding method that penetrates deeply and heats up only the area that is being welded.
High density energy instantly melts the irradiated area of steel which then turns the part of the melting pool to metal vapor.
In reaction to the metal vapor blowing out, it pushes the tip of the melting pool downwards.
As a result, an elongated columnar shaped hollow called a "Keyhole" is formed in the molten metal.
Irradiating the inner surface of this Keyhole with the laser allows the heat to penetrate and melt much deeper.

Advantages of Laser Welding
  • There is almost no influence of heat distortion and under cuts.
  • Micro processing is possible such as welding the tip of a needle.
  • It is possible to weld narrow and deep areas.
  • Preheating and heat treatment are unnecessary before and after welding.
  • Grinding and after-processing time can be greatly reduced.
Applications of laser welding
Applications
  • Various molds: Plastic injection molds and Aluminum die casts
  • Repair and alterations of molding tools
  • Electronic component technology applications
  • Application of sheet metal processing and others
Weldable material
  • Steel (up to HRC60)
  • Stainless steel
  • Cast steel
  • Aluminum
  • Titanium
  • Nickel
  • Copper
  • Copper alloy (BeCu, CrCu,etc. )


We will arrange with other metals.

Comparison between laser welding and TIG Welding

Ideal Welding = narrow thermal impact range and welding with deep penetration

It is possible to weld with deep penetration and the heat affected range can be narrowed because the laser light has high energy density, TIG Welding with low energy density melts only the base metal and it cannot penetrate deeply with heat conduction.

Low energy density
(The heat effect range is wide)

High energy density
(The heat effect range is narrow = ideal welding)

Laser Welding

Laser Welding has high energy density and instantly melts the base material.
Since heat does not diffuse, penetration deepens in the vertical direction and it is possible to reduce the thermal influence and strong welding is possible.

TIG Welding

Since TIG welding has low energy density, it cannot melt the base material instantaneously. Therefore, penetration spreads in the horizontal direction.
In order to deepen penetration, it is necessary to apply for a long time, excess heat is transmitted in the lateral direction, and the thermal influence (strain and hardness change) of the base metal becomes large.

About Laser Welding
Types of Welding Rods

Welding rods can procure most kinds from each welding material manufacture.

Please slide sideways.

Material Welding rod Component (%) Hardness (HRC)
S55C Mold 90 C0.1 Si0.6 Mn1.2 Mo0.5 Fe97.6  
NAK80 Mold 90 C0.1 Si0.6 Mn1.2 Mo0.5 Fe97.6 45(Nitriding is not possible)
Cu type Mold 100 Fe0.1 Si2.8 Cu97.1  
SUS303 White 11 C0.08 Si1.0 Mn2.0 Cr17.5 Fe79.42  
SKD11 Mold 10 C0.4 Si3.1 Mn0.4 Cr9.0 Fe87.1 55 - 60(Nitriding is possible)
SKD61 Mold 55 C0.2 Si0.5 Mn0.7 Cr5.0 Fe93.6 40 - 45(Nitriding is possible)
FCD450 Ni C0.04 Si0.2 Mn6.0 Cr13.4 Ni80.36  
HPM38 Mold 20 C0.2 Si0.5 Mn1.0 Mo1.0 Fe97.3 40 - 45(Nitriding is not possible)
Laser Welding processing sample
Laser welding for the corner
Laser welding for reproduction of protrusions
Laser welding on steel
Example of mold repair ・correction (fixing) by Laser Welding

1. Laser Welding to bottom of groove

The position laser light and welding wire can be placed in precise areas and work on narrow groove areas and gap in the bottom of rib area can be possible.

2. Laser Welding to the vertical face section

It is excellent for correcting products because of the dense welding layer and has few pinholes

3. Welding corners

It is possible to repair products with laser welding regardless of the shape of the circle to curve.

4. Dissimilar metal welding (the corner) copper alloy + iron type welding

It is possible to laser weld iron-based padding with a different material from copper insert and mold to them.

5. Surface welding with reduced thermal impact is possible.

Laser welded products have extremely few sink marks and blow holes.
Since there is no appearance of pinholes after polishing it is possible to apply to the mold font side.

6. It is possible to rebuild simple shapes.

However, there are size limitations

7. Copper and copper alloys can also be welded with Laser Welding, Laser Welding for the corner.

Example of padding of copper alloy of common material

 
Example of Laser Welding Graining surface or Etching Surface ( designed surface)

In ordinary welding, it is almost impossible to repair the designed surface of the mold and the surface of the grain.
The occurrence of nests (holes), reduction of surface roughness due to heat, problems that cannot be dealt with by post-processing such as distortion and cracks occurs.
Laser Welding has little thermal influence and fine Laser Welding can modify the front face of the mold.
It can also cope with troubles during mold manufacturing process and molding.

Before welding

There is a nest hole or dent scratches on the embossed surface and it is transferred to the product.
If there are nest holes, dents or scratches on the embossed surface and it will be transferred to the product.

After welding

Laser Welding is done little by little along the defect hole. Collapse of the embossed pattern due to heat can be avoided.

After engraving

Reproduce an embossed pattern by the process of engraving.

latest laser technology of Mold processing

examples of large capacity welding using Expanding applications of Laser Welding.
From fine Laser Welding to large capacity Laser Welding.

With the introduction of the latest Laser Welding machine, we have powered up to 500W average power and 15KW peak power.
With the expanded range of usages of welding rod from 300W Φ 0.8 mm to Φ 1.2 mm of conventional machines, there is a significant reduction in man-hours The high output of 500W makes it possible to have a wider range, large-capacity Laser Welding.
With the advent of 500W high power Laser Welding machines, it is now possible to use it for welding rods of Φ 0.8 mm to Φ 1.2 mm.
This has resulted in a substantial reduction in man–hours for welding for a wide-range of Laser Welding.

Please slide sideways.

Material Products Laser Welding
FC250
Press Die (design changes)
Area of Laser Welding 150×150×6mm Laser Welding
Machining time 22 H
Welding rod Φ 1.2 mm
Welding rod type Nickel
Output(W) 15 KW
FCD600
Press Die (design changes)
Area of Laser Welding 20×350×1mmLaser Welding
Machining time 7 H
Welding rod Φ 1.2 mm
Welding rod type Nickel
Output(W) 15 KW
SKD11
Restoration of broken press mold
Area of Laser Welding 15×350×8mmLaser Welding
Machining time 13.5 H
Welding rod Φ 1.2 mm
Welding rod type Mold 10
Output(W) 15 KW
SS400
Injection Mold (design changes)
Area of Laser Welding 100 × 100 × 150
Machining time 40 H
Welding rod Φ 1.2 mm
Welding rod type Mold 90+
Output(W) 15 KW

Chunichi Craft Co., Ltd.