Theme : Performance & Process Improvement - …

1 Theme : Performance & Process Improvement LASER WELDING : A New Assembling Method for a Production Benefit Positions of the LASER Welding Assembly Embrio Mature Technology Adhesion Snap-fit Bolt Ultrasonic Spin Vibration Linear/Orbital Over-Mold Weight DSI Reduction DRI. Module LASER Integration Total Cost Reduction 2. LASER Welding Summary Diode Laser Nd:YAG CO2. 800 950nm m 10 m UV IR. 380nm Visible 780nm Near IR Mid IR Far IR.. Part's move Scanning mirror Special optic Simultaneous Rapid multi-scanning multi-head 3. LASER Welding Principle LASER. Surface Reflection Reflecting Energy Clamping Pressure Power / Speed Transmissive Scattering Energy Focus Diameter Material Absorb Part Design Absorbed Energy 4. Benefits of LASER Welding Assembly Clean no flash/no barrs Fast no holding cycle time Strong cross link of GF at joint surface Inexpensive Facility/total cycle 5.

2 Comparison 3 methods Welding Time Burst Strength 35. Burst Strength(Mpa). 30. Burst Strength(MPa). Welding Time(sec). Welding Time(sec). 25. 20. 15. 10. 5. 0. LASER. Orbital Linear LASER. LASER. Orbital LASER. LASER. Linear Orbital Linear Orbital Orbital Linear Linear 6 . PA6 PA66 PET GR UR HTN. 30%GR 30%GR (exp.) PA66 35%GR. no flash less facility cost Break at typical area Not a joint 6. Comparative Look ; cross sectional observation Orbital vib. welding Linear Vibration Welding Laser Welding Ultrasonic welding Adhesion . Seal joint 7. Comparison with the other assy. mehods Bolting Adhesion LASER Hot Plate Linear welding Reliability - . Effect to inner . Thermal Vibration . Aesthetic - . color change Flsdh (Flash . Design freedom . Warpage Warpage separation Separation . Productivity.)

3 Curing weld time . 8. Du Pont Development Approach Design Molding Materials Testing Systems Welding Process . Confirm Laser welding technology as a production method 9. Considerations for polymer laser welding optimization Materials Transmittance Polymer Pigment Additives Absorbent Polymer heat Pigment Design Wall thickness Basic part geom Joint design Molding Warpage/Sink mark Welding Process Power Speed Cycle time Focus spot 10. Transmittance & Absorbent relation between the polymer & Laser light Wave length (nm). 400 800 1200 1600 2000 2400. (%). 100. 80. transmittance PA 6. 60 PA 66. POM. 40 PBT. PC. 20. typ. BK. 0. LD YAG Laser (800 950nm) (1064nm). 11. Material / Wall Thickness & Transmittance Zytel UR. 100. Zytel GR. (%). 80 Delrin POM. Crastin GRPBT. transmittance 60. 40. 20.

4 0. 0 1 2 3 4 5. Wall Thickness (mm). (@ 940nm). 12. Polymer Laser Welding Optimization - Laser Power & Irradiation Time Laser Irradiation Time Surface degradation Void . Carbonized Adequate Welding Zone No melt Laser Power 13. Polymer Laser Welding Optimization - Productivity Speed & Power 250. 1m/min 3 m/min 5 m/min 250. 200. 200. Strength (kgf). Strength (kgf). 150 150. 6 m/min 100 4 m/min 100. 2 m/min 50 50. 0. 0. 0 0 100 200. Energy Density(J/mm2). Laser Power (W). (Zytel HTN51G35 HSL). 14. Polymer Laser Welding Optimization - Mn 250 250 12,500. (kgf). (kgf). 200 200 10,000. 150 150 7,500. Strength Strength 100 100 5,000. Weld strength 50 50 2,500. Mn 0 0 0. Energy Density(J/mm 2) Energy Density (J/mm 2). HTN51G35 HSL NC + BK (2mm ovlp TP). 15. Polymer Laser Welding Optimization - Absorbent material Process Window Weld strength (kgf).

5 150. 100. 50. 0. 0 10 20. Scan speed (m / min). Power (W) constant 16. Polymer Laser Welding Optimization - Moldability Retention of transmittance (%). 100. Laser Transmittant BK. 80 Dev't grade 60. Typ. grade 40. 20. 0. Std. 15 30. (min). 17. Polymer Laser Welding Optimization - Process Easiness Weld strength Before After optimization optimization Scanning speed 18. LASER Welding Assembly - Case Study Door Lock actuator Camshaft position sensor Leakage Test Sensor Customer: Hella Customer: Delphi Customer: Bosch Zytel 73G15 NC Zytel LT 74G33 HSL BK Crastin SK603 NC. Minlon FE260001BK Zytel 74G33 HSL BK Crastin SK603 BK. 19. LASER Welding Assembly - Case Study Gearshift housing Trap Canister Daimler Chrysler ASIAN Kogyo Zytel 70G30 NC Zytel 103 FHS NC. Zytel FE110003 BK. Zytel 70G30 BK.

6 Cost reduction on production (faster production cycle), Door locking More design freedom, precise housingno flash positioning, 20. Development Support As a Total Solution DESIGN/CAE support for proposed basic geometry minimize mold deformation & sink mark Propose adequate material selection Including optimized pigment and heat stabilized Collaborate with system supplier & pigment supplier Development support for production facilities Development support by utilizing various TP and co-relate to the real applications Total development coordination for on-line monitoring & quality assurance 21. EP Material & LASER welding PA POM. FR. LASER Weldable NC Possible to use as Transmittance side No transmittance some exceptions . BK Possible to use as Absorbent side PET/PBT/PCT MR. LASER Weldable but, difficult than PA/POM No transmittance, cannot use T side NC Possible to use as Transmittance side BK Possible to use as Absorbent side BK Possible to use as Absorbent side LCP.

7 GF/Impact resistance No transmittance, cannot use T side NC/WT LASER Weldable Possible to use as Transmittance side but,PBT/PET is rather difficult than BK Possible to use as Absorbent side PA/POM. 22. Du Pont various test pieces Koma . Burst Box: warp/corner Pure tensile Burst/tensile Sphere: Burst T-joint overlap Tensile Shear 23. Global Technical Link & technical support EU ETC JPN UTC US. ATC. 24. Contacts: DuPont & System Suppliers : DuPont Korea : Byung-Gul Ham Engineering Polymers -TEL +82-2-2222-5377. **. Hakuto (Fine Device Co., Ltd.) : KANG, Myeon-Koo -TEL +82-2-529-8910. (Parker Corporation) ;. -TEL. Branson Korea Co., Ltd. : YOO, Jae Du -TEL +82-31-422-9572. Miyachi Korea Corporation : PARK, Seung-Kwo -TEL +82-31-707-5855. 25.