Laser machining of CFRP composites using. a ultra short pulsed laser

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Aubrey Booker
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1 5th International Conference on Laser Processes and Componets ( LPC2010) at Shanghai, Mar Laser machining of CFRP composites using a ultra short pulsed laser Muneharu Kutsuna and Hiroki Inoue Advanced Laser Technology Research Center,Co.Ltd. altrec-kutsuna@nifty.com

2 1, Introduction Concept of the ALIMS since 2002 ; Advanced Laser Integrated Manufacturing System

3 Recent applications of ALIMS in industries High power/high speed laser welding Laser-arc hybrid welding Remote laser welding Laser brazing/soldering Laser welding of plastics Laser roll welding of dissimilar metal joint Laser direct fabrication Laser peening Laser forming Laser Micro fabrication Laser ablation process

4 Ablation process range in materials removal Ablation process range Reaction time for laser process ( Dr. Yuxing Zhao)

5 Laser Peening for reducing the fatigue and stress corrosion cracks High peak power Short pulsed Laser Lens Water Work piece High pressure Plasma Shock wave

6 Laser pulse and Plasma pressure in laser peening(r.fabbro ETCA)

7 Ablation phenomena 1. Heating and melting 2. Plasma explosion 3. Particle explosion Photos taken by a ultra high speed video camera, 1/40,000 Material: Aluminium alloy

8 2. Laser Ablation Process for CFRP composite materials

9 Background of developments Atomosphelic problems on earth Energy development for the future Lack of natural resources Solution (1)Reducing the weight of transportation vehicles and developing new engine such as motor engine (2)Saving natural resources (3)Using CFRP composite instead of metals (the density of CFRP =1.4~1.6) however, CFRP is still very expensive and not easy to fabricate CFRP = Developments of Innovative Laser Technology

10 CFRP composites for Aircraft Industry Strong, Very Light Weight of airplane can be reduced 30% of weight using CFRP CO2 gas emission can be reduced 2,700ton / airplane Ex:B787

11 Application of CFRP to airplane Toray report

12 CFRP composite for Car panel and parts

13 Examples of application of CFRP in automotive Industry 童夢カーボンマジック Racing car sheet Car Body panel Intake manuhold Gear box

14 Other CFRP products Helmet Roller Bag Instrument

15 Problems for application of CFRP 1)CFRP is expensive 2)Materials processing is not easy. In cutting, drilling and joining 3)NDT is not easy for CFRP products 4) Standardization is not enough

16 4.1 Laser Cutting and laser ablation for CFRP Laser cutting by fiber laser Laser ablation by Q switch YAG laser

17 SM Fiber laser for cutting

18 Laser cutting result of CFRP by 300W SM fiber laser Appearance of CFRP after cutting Cross section

19 CFRP のファイバーレーザ切断 (200W) 10m/min

20 Laser ablation for CFRP (a) Cross section of CFRP (b) Cross secton of carbon fiber after ablation

21 Waterjet cutting for CFRP Cross section after cutting Cross section of carbon fiber Cross section of CFRP

22 Adbantages of Laser Ablation 1) Increase the process speed 2)Possible micro fabrication of CFRP with high accuracy 3) Low cost process is available. 4)Flexible cutting and joining are possible. 5) Not only cutting and drilling, but also forming, peening, cleaning(removal of paint) are possible. 6) No damage on the carbon fiber and CFRP 7) Fabrication of ultra light structures is possible.

23 Laser ablation of CFRP

24 Cross section of laser ablated CFRP

25 Tandem torch laser cutting for thick CFRP plate ファイバーレーザ SM Fiber laser ナノ秒レーザ Nano pulsed laser

26 Q-switch YAG (532 nm)

27 Q-switch YAG and Scanner

28 CFRP handle for racing car

29 Laser ablation of CFRP composite material for racing car handle Process time for 7 Holes = 20 mins if the thickness is 1.2 mm CFRP 顕微鏡のステージ Observation by laser microscope

30 Cross section of CFRP after laser ablation 断面マクロ写真 (200 倍で観察 ) 断面ミクロ写真 (1000 倍で観察 )

31 4.2 Mosaic Joint of CFRP composite レーザ切断によるモザイク継手の製作

32 Laser heating of mosaic joint for CFRP Laser Mosaic butt joint of CFRP

33 Overlaying of mosaic butt joints for heavy CFRP plate ( 単層 :FRP 材 ) 第 1 層第 2 層第 3 層第 4 層第 5 層 ( 積層板 ) 積層板は第 1 層目と 2 層目は接合部を図のように層厚さの 3 倍以上離す

34 Cutting pattern for Mosaic joint

35 Edge preparation for Mosaic joint

36 4.3 Applications of laser drilling and cutting for CFRP composite Laser cutting and drilling of body panel for airlpane 工 3D Laser forming of panel

37 Applications of Laser processing for CFRP in the field of automotive industry, Dome co. Floor Panel or underbody Bonnet Intakemanuhold Rear panel

38 Applications of laser processing Wheel and cover Fender Chair with a wheel Gear box

39 Application of laser processing of CFRP in the other fields Artificial bone Mannequin

40 5. Summary Laser ablation process was developed as a ALIMS for materials processing of CFRP. The thick CFRP can be cut by laser ablation process using a Q switch YAG laser for the industries Mosaic Joint preparation is useful to make a butt joint of CFRP.

41 ご静聴ありがとうございました. Thank you for your kind attention! Advanced Laser Technology Research Center, Co Muneharu Kutsuna,

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