Centre for Laser Processing of Materials (CLPM)
3.5 kW CO2Slab Laser
- Power Output : 50-3500 Watts
- Wave length : 10.6 mm
- Primary mode : TEM 00 with excellent beam quality K >0.96
- Specific Processing Capabilities: LASER WELDING, LASER CUTTING
Workstation Details
- ML 2000 is equipped with a 4-axis workstation with facility for rotary axis to process tubes.
- Maximum work sheet size: 3000 mm x 1500 mm
- Maximum weight on table: 400 kg
- X-axis travel: 3030 mm; Y-axis travel : 1520 mm ; Z-axis travel : 300 mm
- Rotary axis max. diameter: 150 mm
- Maximum positioning speed: 15 m/min
- Maximum cutting speed : 10 m/min
Applications
Laser cutting, welding and surface modifications
6 kW Fiber Coupled Diode Laser System
- Fiber coupled diode laser with 200 to 6 kW power with wave length 915, 940 and 980 nm.
- Continuous wave laser and also programmable pulsing is possible
- Spot size in circular shape with 1.5 and 3 mm diameter and rectangular shape with 4x4, 5x20, 1.5x11, 2x17 and 5x8 mm2.
- Laser optic head is fixed of 6-axis Robot arm and two additional rotary and tilt axis integrated with system. Reach of 2.3 m is possible.
- Lateral-resolving temperature measuring system (E-MAqS) integrated with system can measure temperature up to 1400oC at 50 Hz measuring rate.
- Attached with pyrometer and can measure up to 2500oC.
- Closed loop surface peak temperature control system with LompcPro application software.
- DCAM software with teach unit for easy programming and simulation of complex components
Applications
Surface Engineering (Cladding, alloying, and hardening), Conduction welding
Additive Manufacturing - Electron Beam Melting
Specifications
- Electron Beam Power: 3000 W
- Build volume: 200mm x 200mm x 380mm (W x D x H)
- Cathode type Tungsten filament
- Max. EB translation speed 8,000 m/s
- High process temperatures: upto 11000C
- Vacuum Process
- Open software for process development
- Lower residual stresses
Applications:
- Reactive and refractory alloys such as Ti alloys, TiAl, C103 etc
- Ideal for orthopedic implants
- Mesoporous structure
- Components with complex designs
- Aerospace components
Additive Manufacturing - Selective Laser Melting
Model No & Make
SLM 280HL, SLM Solutions GmbHSpecifications
- Fiber Laser 400 W
- Spot sizes 80 - 115 µm
- Vario-Scan gives processing speed up to 10 m/s
- Build area of 280 X 280 mm and Z-axis: 365 mm
- Layer thickness 20 -100 µm
- Bi-direction powder rocoating
- Platform heating upto 200°C
Applications:
- Metallic components with complicated designs
- Conformal channels,
- Light weighting - lattice and mesoporous structure
- Aerospace critical components
- Tooling and biomedical components
- Hybrid manufacturing wherein one can make use of both conventional and additive manufacturing advantages
Automated Cold Metal Transfer (CMT) welding machine
Transpuls Synergic 3200 CMT
- Main voltage:3X400
- Welding current range: 3-320 A
Operating modes
- Manual
- 2-step mode, 4-step mode
- MIG brazing, MIG/MAG CMT
- Synergic MIG/MAG pulse
Special Features
Welds sheets of 0,3 mm or thicker
Wire Feeder
- Wire feeder: VR7000CMT (0.5 to 22m/min)
- Filler: Al(Ø1.0-2.4mm) steel (Ø0.6-1.6mm
Workstation: 4 axis HUST CNC System
- Table Size: 1000 mm X 2000 mm
- Maximum Weight: 300 kg
- X-axis Travel: 2000 mm
- Y-axis Travel: 1000 mm
- Z-axis travel: 300 mm
- Rotary Axis Max. Diameter: 350 mm
Workstation: 4 axis HUST CNC System
- 6-axis Robotic System (2.5 m arm reach)
- Positioner (400 Kg Max. Load)
Automatic seam-tracking based laser brazing facility
Salient Features
- Automatic precisely controllable wire contact-based 3D seam-tracking
- High speed processing – 4 to 6 m/min
- High strength with low IMC formation
- Joining of complex contours with low fixturing setup
- Amenable for industrial production
- Variable laser-spot – diameter 1.7 to 4 mm
- Wire diameter – 0.8 to 2.4 mm
- With or without Flux brazing with cold/hot wire feed
Applications:
- Laser brazing/weld-brazing of
- Auto-body components
- Medical components
- Sheet-metal Engineering Parts
- Laser joining of thin-sheet components of Al alloy, Mg alloy, steel and Ti alloy
- Wire laser overlay / cladding
Characterization and Testing Facilities
a)Abrasive cutoff machine
Make
Chennai Metco pvt ltd
Model - BAINCUT UM
- Cutting capacity: 80 mm
- Press Spindle speed: 2800 rpm
- Cut-off wheel dia: 12",10",8"
features
Sturdy table model cutter for sectioning metals, ceramics and mineral samples
Make:Scientific technologies
- Operation: Automatic
- Mould Cylinder Sizes: 1", 1-1/4",1-1/2", 2" cylinder
- Moulding material: Bakelite / Phenolic resin
Special features
- Digital display with Temperature/Timer Controls
- Feather touch control panel
- Alarms for cycle completion
Automatic Single & Twin Disc Grinding/polisher
Make:Buehler
- Platen Size : 8in [203mm]
- Platen Speed :50-500rpm
- Specimen holder :Round
VectorT LC Power Head
- Model No : 60-1996-230 (230volts/50Hz)
- Force style : Single
- Head RPM Max :60
- Specimen holders :1.5" and 1"
- Max Single force : 50 Newton
- Max no of specimens :4
b) Microhardness Tester
The fully automatic microhardness system of UHL make (UHL VMHT 104) has load range of 0.001 to 2 kg and operates with both Vicker's and Knoop's indenter.
c)Ball/Pin-on-disc sliding (controlled atmosphere) wear testing rig
- Sliding wear testing as per ASTM standards to evaluate wear as well as friction characteristics under dry as well as controlled atmosphere environments.
- Test conditions of set load, rotational speed, wear track, controlled humidity and pin/ball contact diameters depending on the required wear regime.
- Drip-feed system can be used to evaluate tribo-corrosion properties.
- Provisions to monitor temperature of controlled atmosphere chamber as well as in the close vicinity of pin/ball-holder are also available.
- Windcom-2010 software integrated to the system facilitates to monitor record and evaluate wear and friction characteristics.
d)Pin-on-disc sliding wear testing rig
- Sliding wear testing as per ASTM standards to evaluate wear as well as friction characteristics under dry as well as lubricating environments.
- Test conditions of set load, rotational speed, wear track, lubricating and pin contact diameters depending on the required wear regime.
- Windcom-2003 software integrated to the system facilitates to monitor, record and evaluate wear and friction characteristics.
e)Erichsen Testing Machine [Model RET:20/Sr.No:2K6/04]
Specifications
- Width of the Sample: 70 to 90 mm
- Thickness of Sample: 0.1 to 2mm
- Least count of micrometric device: 0.01/0.02
f)Flexible Ceramic-Pad Pre-heating Equipment
Custom-designed pre-heating system facilitates in situ pre-heating of metal components during laser cladding process. Custom-designed heating pads be utilized for heating the steel components utilizing flexible ceramic pad coils fabricated. The equipment facilitates monitoring and control of pre-heating of jobs with specific temperature requirements. Appropriate sensors, circuit breakers, energy regulators and safety circuits are provided to ensure smooth and secure functioning. The system is useful for onsite pre-heating requirements for various coating processes.
g)Thermal Fatigue Resistance Test Rig
- A specially designed computer controlled simulation test rig containing molten aluminium alloy (A380 with Si-7.5-9.5%) melt maintained at 660-680o C.
- Surface temperature of the testing sample can be recorded online
- A resistance heating furnace (3 kW) with 150 mm x 150 mm top opening and a graphite crucible of adequate size housed inside
- The mechanical assembly consists of an overhead frame that carries a horizontal pneumatic cylinder that slides horizontally to and fro and another vertical cylinder) attached to the horizontal cylinder moves vertically up and down, on which, the sample holder is fixed. Test samples were alternatively dipped in Al-alloy (A380 with Si-7.5-9.5%) melt maintained at 660-680oC and commercially available water based die coat solution (DIECOAT 01, supplied by M/s Quality Technologies Pvt. Ltd., India) maintained at 30-40oC.
- It is possible program cycle time and holding time.
CO2 Laser-MIG Hybrid welding system
Laser Source
- DC035 Slab CO2 Laser
- Wavelength: 10.6 µm
- Nominal Output Power: 350 -3500 Watts
- Frequency: 1 to 5000 Hz
- Beam Mode: Gaussian and Doughnut
- Operation: Continuous wave and Modulated pulse
MIG Source (KEMPPI PRO EVOLUTION 4200)
- Welding current range:10-420 A
- Welding voltage:10-46 V
Wire Feeder (Pro MIG 530)
- Four roll wire feed mechanism
- Wire feed speed: 0 - 25m/min
- filler wires (Fe Ø 0.6 - 2.4mm; cored wire Ø 1.0 - 2.4mm; Al Ø 1.0 - 2.4)
- Gantry mounted gas cooled torch
Features
- Synergic MIG/MAG and Synergic Pulse-MIG/MAG
- Double Pulse-MIG/MAG
- Traditional MIG/MAG
Workstation (3-Axis FANUC CNC)
- Work table Size: 3000 mm x 1500 mm
- X-axis travel: 3030 mm
- Y-axis travel: 1520 mm
- Z-axis travel: 300 mm (non-programmable)
- Rotary axis max. diameter: 150 mm
- Maximum weight on table: 400 kg
DC035Slab CO2 Laser /Laser MIG hybrid welding system
Laser
- Nominal Output Power: 350 -3500 Watts
- Wavelength: 10.6 µm
- Primary mode: TEM00 with excellent beam quality K >0.96
- Frequency: 1 to 5000 Hz
- Raw Beam diameter: 22 mm
- Excitation: RF (Radio Frequency)
- Power Stability: ±2%
- Beam Mode: Gaussian and Doughnut
- Operation: Continuous wave and Modulated pulse
Workstation (3-Axis FANUC CNC)
- Work table Size: 3000 mm x 1500 mm
- X-axis travel: 3030 mm
- Y-axis travel: 1520 mm
- Z-axis travel: 300 mm (non-programmable)
- Rotary axis max. diameter: 150 mm
- Maximum weight on table: 400 kg
- Maximum positioning speed: 15 m/min
- Maximum processing speed: 10 m/min
Laser Assisted Machining with 6kW Diode Laser
Salient Features
- Laser Assisted Machining facility is being developed
- A lathe machine has been integrated with 6kW Diode Laser
- A 5-axis flexible fixture was designed to mount the optical unit on the lathe machine
- Simultaneous movement of Laser spot with tool
- A pyrometer with high data acquisition rate is being integrated to the system
- A dynamometer for cutting force measurement is being integrated
- LAM setup will be upgraded shortly by integrating a CNC Turn-mill machine
Applications
Laser Assisted Machining of hard to machine materials such as Ni-based super alloys, Ti-alloys, ceramics etc
Pulsed NdYAG Laser System (JK-704, GSI Lumonics)
Specifications
- Max Average Power: 400 Watts
- Peak Power: 20 kW
- Pulse Duration: 0.3 - 20 ms
- Repetition rate: up to 500 Hz
- Wave length: 1064 nm
Workstation
- 3-axis workstation with facility for rotary axis to process tubes.
- Maximum work sheet size: 800 mm x 800 mm
- Maximum weight on table: 20 kg
- X-axis travel: 1000 mm; Y-axis travel: 1000 mm; Z-axis travel; 180 mm
- Rotary axis max. diameter: 150 mm
- Maximum positioning speed: 15 m/min
- Maximum cutting speed: 10 m/min
Applications
Laser drilling, Micro-welding
Ultrafast Laser Processing
- Ti:Sapphire regenerative amplifier (Model: Spitfire Ace, Spectra Physics)
- Pulse duration: 100 fs, 50 ps and 100 ns
- Power:12 W
- Repetition Rate:10 kHz
- Computer controlled multiple wavelength (800, 400, 266 and 527 nm) beam delivery system.
- XYZ with rotation and tilt positioning system having nm resolutions.
- Galvanometer scanner synchronized with motion system