M D T Fox

Applications of optical sensing for laser cutting and drilling

Any reliable automated production system must include process control and monitoring techniques. Two laser processing techniques potentially lending themselves to automation are percussion drilling and cutting. For drilling we investigate the performance of a modification of a nonintrusive optical focus control system we previously developed for laser welding, which exploits the chromatic aberrations of the processing optics to determine focal error. We further developed this focus control system for closed-loop control of laser cutting. We show that an extension of the technique can detect deterioration in cut quality, and we describe practical trials carried out on different materials using both oxygen and nitrogen assist gas. We base our techniques on monitoring the light generated by the process, captured nonintrusively by the effector optics and processed remotely from the workpiece. We describe the relationship between the temporal and the chromatic modulation of the detected light and process quality and show how the information can be used as the basis of a process control system.

OPTICAL SENSOR TO MONITOR AND CONTROL TEMPERATURE AND BUILD HEIGHT OF THE LASER DIRECT-CASTING PROCESS

A nonintrusive optical sensor system is applied to real-time process control of the recently developed laser direct-casting process, in which a stream of metal powder is introduced into the beam of a high-power (500-W) cw laser to fabricate complex three-dimensional structures. The sensor system allows two critical parameters, temperature and build height, associated with this process to be monitored and controlled continuously. We achieved a height-sensing resolution of ?0.25 mm and temperature control with a resolution of ?10 degrees C at a typical working temperature of 1500 degrees C with an evident improvement in process quality, especially for complex workpieces comprising relatively high, thin walls at which the conductive heat transfer varies substantially as the process proceeds.

Compact effector optics for processing in limited physical access situations

A major advantage of fiber-optic beam delivery in laser materials processing is the ability to guide the laser power to the location where it is needed, leaving the laser itself remote and protected from the process. This is of special importance if the processing is to be performed in a hazardous environment. Particular problems are faced by the nuclear industry where weld repair and surface treatment work are required inside radioactive installations. By use of fiber beam delivery, only part of the delivery system and effector optics become contaminated, but the expensive laser system does not. However, in many cases the region where repair is required is not only radioactive but has only limited physical access, e.g., inside tubes or into corners, which prevents use of standard effector optics. We present a new design to deal with such constraints of a 2-mm outer diameter employing a hollow waveguide and gas shielding. This design is optically characterized and its performance assessed in welding and surface treatment applications. The potential of this compact effector optics in limited physical access situations is clearly demonstrated.

Real-time, nonintrusive oxidation detection system for the welding of reactive aerospace materials

We describe the development of a real-time nonintrusive monitor to detect degradation of a gas shield condition during laser welding by use of on-axis spectrally resolved detection of light emitted from the workpiece. Failure of gas shielding to the point at which there is a risk of contamination from the air is revealed by the marked increase in the intensity of a spectral feature around 426 nm. To avoid unwanted sensitivity to the overall intensity of the radiation, the intensity at 426 nm is normalized by that at 835 nm, where the spectrum is insensitive to gas shielding. We collected the radiation by using the same optics as are used to deliver the processing beam, and thus the detection process is entirely nonintrusive. We demonstrate successful operation for welding stainless steel and titanium under both helium and argon gas shielding.

Non-intrusive optical sensor for laser welding

An optical sensor suitable for detecting the main faults which can occur during the laser welding process is described. Process-generated light is collected using an optical fibre and welding errors are detected by analysis of the temporal and chromatic characteristics of this light.