Advantages of Conventional Welding vs Advantages of Laser Welding

 There are many challenges that welders face like working under high temperatures, striving hard for precision, etc. And guess who’s got the solution? Technology. It has almost every solution to upgrade your way of the stick. But remember, upgrading welding parts is equally important. You can invest in Amada parts for complete support in adapting new technologies.

Let us have a look at two of the most common and trusted ways of seal to understand their advantages. This will help you to choose the one best to fulfill your requirements.

Conventional Welding

Invented in: 1800s.

MIG (Metal Inert Gas) and TIG (Tungsten Inert Gas) welding are the two most common forms of conventional seal. This works by using a shielding gas to create an inert atmosphere around the head. This inert atmosphere allows the welds to be isolated from other gases in the surrounding area to stop the welds from becoming porous. An electric arc heats up the metal and metal filler, once melted it joins the material together to create a strong weld.

Advantages of conventional welding

• With laser seal, when you are welding two materials together, they need to have a good fit up due to the little to no filler used in the weld. While, with conventional welding, you can have the liberty of imperfections in fitting up to two materials by using the filler
• Conventional Welders cost considerably less in comparison to Laser machines.
• With a conventional seal, the chances of galvanic corrosion on a workpiece are minimized.

Laser Welding

Invented in: 1967

If talking about basic functionality, laser seal is not much dissimilar to conventional welding. The primary difference is the heat source. Instead of the arc of a MIG or TIG welder, laser welders use a highly focused laser beam (photons of light) as the heat source.

Almost everything, from electronics to medical devices to jewelry making, requires seal of some sort. Even precision in wristwatch welding requires laser technology. Amada laser consumables are the best option to choose for upgrading your seal experience.

The three types of lasers most commonly used in welding applications are:

• Gas Lasers
• Crystal Lasers
• Fiber Lasers

Advantages of Laser Welding

• Laser welding can weld a whole array of metals like carbon steel, high strength steel, stainless steel, titanium, aluminum, and even precious metals.
• The laser weld is narrow and has an excellent depth-width ratio. This makes the weld strength much better than TIG and MIG Welding.
• The heated area of the weld doesn’t spread to the rest of the material and this initiates rapid cooling. By this method, you can handle the materials instantly after the job is complete.
• Laser Welders don’t require the skill that conventional welding does. Laser Welding offers a much more precise weld in comparison to TIG and MIG welding. Its works from computer input whereas conventional welding requires man force to operate the machine.
• There is minimal deformation and shrinkage in the material due to the process used for laser welding.
• One-sided laser welding can replace spot welding which requires access to both sides of the material, as seal needs access to only one side.
• Due to high precision, the laser produces less scrap as there are rarely any errors.

Concluding…

If I had to choose between the two, I’d have to go with Laser because it provides impeccable precision and of course many other benefits too. One can use laser Welders with Amada parts and Amada laser consumables in industries such as Medical, Automotive, Aerospace, Manufacturing, etc. Laser Machines can also be portable. This helps to reduce downtime by taking the machines on site.

Conventional welding methods are suitable for most standard requirements. They do have some drawbacks though. In many instances, laser seal is an ideal method over conventional methods.

Original Blog: https://altpartsinc.wixsite.com/altpartsinc/single-post/advantages-of-conventional-welding-vs-advantages-of-laser-welding

5 Uses of Laser Cut Parts

Laser cutting is trusted for its accurate cutting by many industries over the past few years. Laser cutting can:

• Cut or engrave precise lines through a thin plate of steel
• Mark different materials with varying degrees of thickness And everything in between.

You can use laser cutting on a variety of materials by advancement in technology. Using good quality laser cut parts like Trumpf laser parts can increase the longevity of the final product.

Several industries like:

• Construction
• Industrial fabrication/manufacturing
• Military and Defense
• Recreational Vehicles
• OEM
• Agricultural
• Furniture
• Communications/telecom
• Alternative Energy uses the Laser cutting method

Apart from these industries and cutting metal bodies, there are many other uses of laser cut parts to like:

1. In Jewelry Making

How come jewelry? Well, think of those small gears in a wristwatch or those tiny headphone gears. This precision of laser cutting lends itself to the jewelry-making process. With the impeccable accuracy of the laser cutting process, you can make gears with less waste and less production time.

While talking about uses in the jewelry industry, we should not forget about the engraving capabilities of laser cuts. It can engrave designs and inscriptions onto the interior or exterior surface of the piece. Lasers can cut precise shapes and give desired thickness. And all this makes it reliable to use in the jewelry-making process.

Creating a ring or an anklet of an exact width, depth, and diameter becomes easy with a laser. You can use laser cutting to engrave designs and inscriptions onto the interior or exterior surface of the piece.

2. In Medical Device Manufacturing

One of the most significant uses includes using it for laser surgery in the medical industry. This helps surgeons to make more precise cuts and patients heal much faster after laser surgery. Use Laser cut parts to create medical devices and improve the quality and reliance of the surgery.

Made by using laser cut parts includes Stents, vascular clips, flexible shafts, valve framers, injection molds, etc.

3. In Automotive Manufacturing

The automotive industry is always in a need of exact replicas of a part of different shapes and sizes. Applying cutting methods can reproduce those parts quickly and precisely.

The automotive industry uses cutting to cut down metals and plastics to form body pieces of vehicles, electronic components, interior covers, etc.

Laser cutting processes can cut hydro-formed parts too. These are usually strong tubes that provide support within the structure of the vehicles. Here, the quality ensures trust, thus opting for Trumpf consumables is one of the best choices for the automotive industry.

4. For Dye and Tools Manufacturing

With the laser’s ability to cut a variety of depths into the metal, an accurate dye gets ready or stamping pieces. This will last through the repetitive process of dye-cutting. To increase the longevity of dyes, use Trumpf laser parts in the cutting process.

Within the tool manufacturing industry, cutters can be used for:

• Marking and engraving
• Manufacturing of simple hand tools
• Engraving company logo and tool information onto the rubberized handles of most tools.

The speed of cutters might even make it better than die-cutting on sturdy metals.

5. For Silicon and Ceramic Manufacturing

The laser cutting method allows accurate cutting to produce smaller silicone parts. These can be further used in computers and electronics, textiles, architecture, automobiles, etc.

Lasers cut ceramics in order to reduce processing time without compromising edge quality.

Examples: Airplane jet engines, electric motors, headphones, power plant generators, electric cooktops, etc. Here, using Trumpf laser consumables proves to be reliable.

Laser cutting is one of the most versatile methods used by different industries all over the world. The advancement of technology brought new upgrades to this method. And due to this, the use of cut parts is increasing every day to sharpen or smoothen your manufacturing needs. If you have a cutter for manufacturing, or if you are thinking about investing in one, knowing its current uses might clear your head.

Original Blog : https://altpartsinc.wixsite.com/altpartsinc/single-post/5-uses-of-laser-cut-parts

Different Types And Techniques of Laser Cutting

 Laser cutting has evolved from the 1960s to the tech-savvy age and this evolution brought huge technical updates. Laser cutting process is much more efficient today than the mechanical tooling and cutting process because it costs less and is much more accurate. The laser performs the cut by melting, burning, or vaporizing away the material and leaving a sharp, clean edge.

Materials you can to process by laser cutting include:

• Paper
• paper board
• Adhesive tapes
• Plastics
• Films
• Textiles
• Abrasives
• Metals, and
• Photovoltaic

Bystronic laser parts and Bystronic spare parts make the laser cutting process smooth and efficient. There are different types of lasers and various techniques used for cutting. We shall have a deep discussion on it to know which option this decade has for us.

Types of Laser Cutting:

There are three main types of lasers used for cutting:

1. Gas Lasers

Invented in: 1964

Gas laser known as CO2 laser cutting- completed by using a carbon dioxide mixed laser. In the initial stages of the invention of the gas laser, it wasn’t that powerful to cut metals. Although it is still best suited on non-metals, with the advancement of technology, gas lasers can cut metals too. It has a wavelength of 10.6 micrometers.

Gas laser cutting also uses pure nitrogen to work with metals such as steel and aluminum. But if the nitrogen you are using is not pure then the chances of oxidation are high on the metal you are working with.

Usage: In medical and industrial settings

2. Crystal Lasers

Invented in: 1964

Crystal laser cutting is a process that uses lasers made from nd:YAG (neodymium-doped yttrium aluminum garnet) and nd:YVO (neodymium-doped yttrium ortho-vanadate). These crystals belong to a solid state group that allows high powered cutting. It can be used with both- metals and nonmetals.

Bell lab- the one that created gas layers, same lab created crystal cutting too. It has a wavelength of 1.064 micrometers.

Usage: In medical, dentistry, military and manufacturing industry

3. Fiber Lasers

Invented in: 1961

Fiber lasers have several similarities to the crystal process. Fiber lasers too belong to the solid state group. It has a wavelength of 1.064 micrometers.

This laser cutting type provides a much longer service life than that of the previous two cutting types, probably 25,000 hours. It works with metals, alloys and nonmetals alike, even including glass, wood and plastic. And it requires very little maintenance; even the replacement parts are very inexpensive. Bystronic spare parts come as a best option while replacing laser parts.

Usage: Mainly for metal marking by way of annealing, metal engraving and marking thermoplastics

Different Techniques of Laser Cuttings:

1. Total Control of the laser beam

You have total control of the beam of your laser when you use Bystronic laser parts for fiber lasers. By this, you can control everything from the beam heat output to the intensity of the beam on your material, and even the duration of your beam.

The benefit of this control is that it allows you to work with a range of materials, as well as ensuring that no damage is caused to the material that you are working on.

2. Marking

Marking process involves the melting of a surface layer of a material to leave a mark behind. This process is also possible to complete with a fiber laser.

3. Engraving

Engraving process is very similar to the marking process; the only difference is that the aim here is to create a deep and engraved mark which manufacturers often use for applications such as creating barcodes.

Being the most accurate cutting method, laser cutting has been a hype of many manufacturing industries for years. Specifications and precise cuttings are the reasons for its reliability. Technology is upgrading every day and so will the types and techniques of laser cutting. And it is important to know about the types and techniques of laser cutting, so that you can make the most of them by creating different usage options.

Original Blog : https://altpartsinc.wixsite.com/altpartsinc/single-post/different-types-and-techniques-of-laser-cutting

How Does A Laser Cutting Work?

 Laser cutting is used in everything from cutting metal plates while manufacturing to cutting skin layers while surgeries. Lasers are highly accurate in cutting mild steel, stainless steel, and aluminum plate. With a very small kerf width and a small heat-affected zone, cutting small holes and intricate shapes becomes easy. Laser cutting is a stable, reliable, and one of the most accurate cutting processes if performed according to instructions and by using the right products. For buying cutter parts or replacements, you can go for esab plasma cutter parts and esab replacement parts.

With many uses, laser cutting might have interested you to apply it for your business, but you will need a guide on ‘how to use laser cutting’ right? So, here it is:

How it Works

A laser cutter is a form of digital manufacturing technology that utilizes 2D vector files in order to guide lasers for perfect cutting. It contains glass fibers or a gas mixture of a crystal body. The laser beam is a column of extremely high-intensity light, of a single wavelength, or color. The laser beam is about ¾ of an inch in diameter as it travels from the laser resonator. It then creates the beam through the machine’s beam path.

To begin cutting, the machine will require energy to send the beam through various mirror lenses. There is a possibility of it bouncing in different directions by a number of mirrors known as ‘beam benders.’ Then the focused laser beam goes through the bore of a nozzle before it hits the metal.

To cut the metal precisely, you need to focus on the spot and the density for perfectly round, consistent, and centered in the nozzle. To focus on a laser beam you can use:

• Special lens
• Curved mirror

Focusing the large beam to a single pinpoint increases the heat density at that spot at its extreme. Because when 6 KWatts of energy focuses on a single spot, the heat extreme will reach its extreme. When the high power density focuses on one spot, it results in rapid heating, melting, and partial or complete vaporizing of the material. While cutting mild steel, the heat of the laser beam is enough to start an “oxy-fuel” burning process, and the laser cutting gas will be pure oxygen there. While cutting stainless steel or aluminum materials, the laser beam melts the material, and high-pressure nitrogen is used to blow the molten metal out of the kerf. Cutters like esab plasma cutter parts will help you for a smooth kerf finishing. On a CNC laser cutter, the laser cutting head moves over the metal plate in the shape of the desired part which cuts the part out of the plate giving you a wanted shape.

The distance between the end of the nozzle and the plate is very important because it determines where the focal point is relative to the surface of the plate. Raising or lowering the focal point from just above the surface of the plate, at the surface, or just below the surface affects the cut quality. Now the question would be, ‘How can one control or maintain an accurate distance between the end of the nozzle and the plate?’ A capacitive height control system is the answer. There are many other factors too that affect cut quality, but there are ways to control it.

You can use advanced nesting software to utilize the majority of the raw material and eliminate metal waste. This will even maximize the value for your customers.

Industries that use the Laser cutting method are:

• Construction
• Industrial fabrication/manufacturing
• Military and Defense
• Automotive
• Recreational Vehicles
• OEM
• Agricultural
• Furniture
• Communications/telecom
• Alternative Energy

Laser cutting is a stable, reliable, and one of the most accurate cutting processes if performed according to instructions and by using the right products. Replacing the cutter parts is the best option to avoid quality problems, esab replacement parts are worth your trust and money.

Original Blog: https://altpartsinc.wixsite.com/altpartsinc/single-post/how-does-a-laser-cutting-work

How to Balance Machine Performance and Value

In manufacturing businesses, being best is not enough. Shops need to improve constantly in order to stay ahead of the competition. They must keep acquiring new technologies, use branded parts like Mazak parts and Amada parts to maximize profitability. However, better machine monitoring data and equipment have made capital purchasing decisions complicated.

Many businesses prefer simplifying machine tool acquisition processes by prioritizing value - but it comes at the cost of performance. To attain high ROI, it's necessary to have a balance between the two. It may seem daunting at first, but it's easier to keep up with technological advancement and grow business with the right methods.

1. Performance v/s Value

Performance and value together serve as a solution for all the factors that make up the machine. And thus, shops must consider all kinds of performance - from equipment to exceptionally versatile machines, important factors, decision-making time, etc.

Small shops, for instance, should evaluate external factors such as what OEM tools are included with machine purchase or how they can help in operations. So, as it grows, they would have resources to dedicate to process analysis and decision making.

2. Total Ownership Costs

This is the most important factor that businesses need to consider - despite their shop size. The more information they would be able to gather, the easier it would be to make sound decisions. For example, information on OEM's scheduled maintenance program can help estimate future service costs.

As the size increases, they can add more context to maximize ROI, such as cost of educational opportunities, application support provided by various OEMs, etc.

But, at last, they need to look for effective OEMs and spare parts like Mazak parts that can reduce the total ownership cost by offering comprehensive support packages.

3. Pre-Part Costs

As the operational volume grows, the importance of pre-part costs increases too. Besides, high volume is the norm in many industries. If these large manufactures have to cut a fraction of seconds from a part's cycle time, it could save them thousands and more dollars in a year. This is possible if they can balance performance and value, considering every factor from energy consumption to coolant evaporation.

OEMs like Mazak have experience and can help with pre-plan costs at a granular level. Besides, machine tool builders can help optimize the process.

4. Total LifeCycle Costs

For shops to maximize ROI, they need to go beyond the total cost of ownership and the cost spent over the machine's lifecycle, including resale value. After all, many manufacturers who purchase new machines plan to fund their next capital purchase by selling the old equipment. So, it's necessary to look at how quickly machines wear out and how much aftermath support is available.

The total lifecycle costs can change how businesses purchase machines. Hence, it's essential to choose brand manufacturers. Because the machines of those manufacturers are well-supported and durable, which decreases the lifetime cost compared to others. While the initial investment is high, the total lifetime cost remains less.

And when the businesses bring in faster cycle times, greater throughput, and durability of the brand solution, the costs further go down.

5. Capabilities and Capacity

Considering that minimizing capital cost increases ROI, many businesses create purchasing plans with a schedule for upgrading the equipment. This pre-planning ensures businesses that they have the equipment that meets the technological needs and requires less than planned maintenance.

So, the good rule of thumb is to replace 10% of capital investment annually to maintain competitiveness and sell the used machines to fund new ones.

Adding capabilities tend to increase the store's capacity. For example, many shops replace their single-use machine with multi-tasking equipment, which provides flexibility and helps get the work done in one.

In short, they need to partner with brand OEMs like Mazak and use branded parts to maintain productivity and budget.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/how-to-balance-machine-performance-and-value

Everything You Need to Know About Laser Etching

Speed and durability are the factors that make laser etching suitable for marking applications.

So, in this article, we’ll learn everything about laser etching – how does it work? What kind of materials can you etch? Why should you brand spare parts like Trumpf spare parts or Prima spare parts? What are the various types of laser etching? And how to implement it?

Let’s start by understanding the laser etching process. 

What is Laser Etching

It is a process that melts the surface of the material and creates marks on it. It belongs to the category of laser marking that also includes laser engraving and laser annealing. Laser etching is highly versatile and can be used with most metals.

It is mainly used to produce permanent markings such as data matrix codes, serial numbers, barcodes, and logos. 

How Does Laser Etching Work

Whichever laser marking method you use, there’s one thing common in all. The laser beam is pulsed, which then releases sudden bursts of energy at specific time intervals. A 100W laser pulse can release 100,000 pulses within a second. Each pulse consists of 1 millijoule of energy and can reach a max of 10,000W power.

In laser etching, the metal requires less energy than engraving. Hence, in etching, the pulses are more distant compared to engraving.

For marking, the beam hits the surface, and materials absorb the energy. It reflects most of it while absorbing a proportion, converting it to heat. For laser etching, the material should absorb enough heat to melt the surface and expand. 

When the beam’s energy is transformed to heat, the temperature increases. At such a high temperature, the material becomes malleable, allowing its shape to change.

As the material cools down within milliseconds, the surface roughness of the material changes, making a permanent mark. Also, the color change occurs as a result of permanent marking. For high-quality, black and white make the best contrast. 

This is a generic process. However, each material would have its own course of the process. The process would be optimized and different from the general process. 

What Materials Can You Etch with Laser?

Laser etching is a versatile process, and you can etch almost all the materials. Here are the few from the list of non-exhaustive. 

• Aluminum
• Lead
• Magnesium
• Steel
• Steel Stainless
• Zinc
• Anodized Aluminum

Types of Laser Etching Laser

You can only use fiber lasers for laser etching. The reason is that etching is a process used for metals and thus reacts better with a fiber laser. To be precise, the laser depends on the material you want to etch and not on the marking process.

But why do you exactly need fiber lasers? Let us find out!

Lasers release beams and energy at specific intervals. The material reflects most of the energy while absorbs the remaining, converting it to heat. For etching, the material should absorb enough heat to melt the surface. 

Now, fiber and Co2 lasers generate different wavelengths, and each material reflects these wavelengths differently. To maximize the heat transfer, the material should absorb enough wavelength. If you test it, you will find that material absorbs fiber wavelength more efficiently than Co2 lasers, making it a better choice for marking materials.

Why you Should Choose Branded Spare Parts

We often talk about lasers – how to choose lasers and maintain them. But we forget that a spare part or a consumable is what defines the further use of that laser during a wear-and-tear.

To ensure that the marking quality is as precise as it was in the initial stages, use spare parts such as Trumpf spare parts. These branded parts are high-quality, have better resistance, and don’t wear quickly. As in laser etching, the energy release is high, and the spare parts would ensure that they are high temperature resistant and can withstand energy. 

How to Implement Laser Etching

Consult an expert that offers laser marking machines and OEM laser markers. Specify your requirements and take their guidance about the same.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/everything-you-need-to-know-about-laser-etching

Tips to Improve CNC Plasma Quality

Achieving better quality is the ultimate goal of plasma technology. 

For this, you can always ask the customer support team for guidance or replace the parts with Mazak used parts. However, with proper information and some cool tips, you can improve your plasma cutting quality on your own. 

 Keep reading to learn more!

1. Cut in the Right Direction

Make sure that you cut properly. While using standard consumables, the plasma arc spins in the clockwise direction as the torch moves forward to cut. The squarest angles are on the right side, and thus, contour shapes are cut in a clockwise direction. It is opposite with internal features. There, the torch needs to travel anti-clockwise. So, adjust the current direction if needed. 

2. Refer to the Cut Charts

Check out the cut charts in your system manual and select the appropriate cutting process for your application. Select the process depending on your material type, thickness, desired cut quality, precision, and productivity goals. Based on these details, the cut chart would show the appropriate consumables, amperage, cut and pierce height, shield gases, etc. The arc voltage measurement, cutting speed, torch to work distance are other parameters listed in the chart. 

3. Use Good Consumables

See if your consumables are worn or damaged. They are essential for precision, and any damage could affect the quality and system performance. Therefore, do a visual check and replace it when needed. Use branded alternatives like Mitsubishi spare parts, or Mazak used parts. Always lubricate o-rings while replacing consumables. Don’t over lubricate, as it may affect the system performance. 

Also, make sure that you choose right consumables. Double-check the part numbers on your consumables with the numbers in the manual. 

4. Level your Table and Workpiece

Always level your torch to the workpiece before you start squaring. Because if the metal is bent or wrapped, it would be impossible to square the torch with the workpiece. Or, in the worst case, you may have to accept the poor cut quality. 

5. Hold Right Torch to Work Distance

Ensure that your torch is not close or far away from work, or it would cause rounded cut edges. On top of that, if the torch is too close, the metal splatter would cause severe damage to the torch and nozzle. So, refer to the distance in the manual and adjust accordingly. If your parts are old, adjust them manually as the distance may vary. 

6. Cut at the Right Speed

If the cut speed is low, it may result in broader kerf, dross, and warpage on thin materials. Often, the low-speed dross is collected at the bottom of the cut edge and is easy to remove and flake off. In contrast, high-speed dross causes a thinner bead of molten metal to collect at the bottom of the cut. It is harder to remove and requires grinding. However, you can eliminate it by reducing the cut speed to allow arc time to catch up with the arc torch. 

7. Use Clean and Dry Air

If you’re using air plasma, make sure it’s clean and dry. The same applies to oxygen or multi-gas systems. Use pure and high-quality gases. Make sure that the regulators and gas lines are of appropriate size. Purge-it manually if required. Also, confirm that the purging cycle is completed. Lastly, see if there are any leakages. In case of emergency, contact your gas distributor and get it resolved immediately. 

8. Tune-up your Table

Is the speed of table cutting appropriate? Is the torch secured tightly to the gantry? Is the table vibrating? 

Check all these as often the plasma cutting problem is not with plasma cutters but the poor motion or table issues. So, tune up your table before proceeding with the cut. 

Most importantly, keep implementing these tips. Share your experience with us. If you have any problem with your system or consumables, contact your manufacturer or supplier immediately.

Source: https://altpartsinc.wixsite.com/altpartsinc/single-post/tips-to-improve-cnc-plasma-quality