Benefits of Industrial Manufacturing with Laser Technology

12 September 2019

Lindø Offshore Renewable Center
Kystvej 100
5330 Munkebo

Laser technology is applicable for a large number of industrial processes. In many cases, laser technology provides higher processing speed, better quality, and the ability to produce special products that are difficult to manufacture with other processing technologies. These benefits along with the latest developments and future trends in laser technology will be clearly demonstrated at this seminar. The seminar will also give an overview on the subject including inspiration for possible laser applications based on industrial cases and solutions.

This seminar is aimed at the metal and steel industry, especially those working with welding and surface coatings. The overall heavy-metal industry, the wind turbine industry, power plants, shipyards, but also the industries for medical and food equipment and agricultural machinery would benefit from attending this seminar.

09:00 - 09:30 Registration and breakfast
09:30 - 09:40 Welcome
09:40 - 10:10
Laser Materials Processing Activities at Lindø Welding Technology

Steen Erik Nielsen, Project Manager, FORCE Technology

At Lindø Welding Technology, a subsidiary to FORCE Technology, a 32-kwatt disc laser facility has been installed. At this facility, developments within hybrid laser welding and laser cladding have been the main focus for several years. This presentation will cover the main results related to the development of the high-power laser hybrid welding process, as well as to the perspectives for the technology as a cost-effective production tool for e.g. the windmill manufacturing industry. Laser cladding has shown to be the preferred process for repair purposes creating new surfaces to e.g. worn out high value industrial components. The laser cladding process is also the basis for new additive manufacturing and 3D restructuring technologies.

Steen Erik Nielsen is a specialist at FORCE Technology and has been working within the field of laser materials processing for more than 30 years.
10:10 - 10:40
Industrial Automation of Laser Processes

Morten Kristiansen, Associate Professor, Aalborg University

Laser processes can provide many benefits such as faster processing speed, improved quality and less rework. On the other hand laser processes do require an investment, possibly a product redesign and other preparation techniques. Solutions for laser processing will be presented with their performance, process monitoring possibilities and data logging perspectives. This presentation will include benefits and disadvantages of laser processing through general facts and a number of examples with an economical view for industrial users.

Morten Kristiansen is Associate Professor in automation of industrial processes at Aalborg University, Department of Materials and Production. He holds a PhD in Mechanical Engineering (2007) and a MSc in Manufacturing Technology (2001). His activity encompasses process modelling and control, sensory information and data processing. The last 8 years his focus has been on laser processing and automation with laser technology.
10:40 - 11:00 Break
11:00 - 11:30
Hybrid Laser-Arc Welding for the Mass-Production of Large Steel Structures

Farhang Farrokhi, Metallurgist, National Oilwell Varco Denmark I/S

Manufacturing of large steel structures requires processing of thick-section steels. Welding is one of the main processes that form a significant part of the production costs. Hybrid laser-arc welding technology can potentially increase the productivity and reduce the production costs. However, there are a number of challenges to consider before taking advantage of the technology. This presentation will discuss the potential benefits as well as a few challenges related to this process.

Farhang Farrokhi holds a PhD in laser welding from Aalborg University. His interest is welding of steel and his research has been mainly focused on the manufacturing of large steel structures. Farhang Farrokhi has recently joined National Oilwell Varco Denmark I/S as a metallurgist.
11:30 - 12:00
Possibilities with Multi Spot Laser Welding

Klaus Schütt Hansen, Senior R&D Engineer, IPU

Recent developments in multimode fiber laser has given fierce competition to CO2 and Nd:YAG lasers. The laser has become more economical, the power has been increased, and the beam quality has been improved, while the beam delivery has been simplified by optical fibers. On top of this, the laser industry has developed the single mode fiber laser. Single mode fiber laser provides nearly perfect laser beams that can be focused on spots much smaller than any other industrial laser source available, resulting in extreme intensities. The single mode spot is often “too good”, as there is risk of it passing between gaps in butt joining. By taking the “excess of the beam quality” and using it to reshape the wave front of the beam into multiple spots in the laser fusion zone, new possibilities have arisen. Research results from welding with multiple spots will presented along with results from the use of multiple spots to repair blowouts in laser welding.

Klaus Schütt Hansen holds a Master in mechanical engineering from DTU and a PhD, “Multi Beam Fiber Laser Welding”, from Aalborg University. He has been with IPU since 2008 and focuses on thermal processes and solutions for the industry.
12:00 - 13:00 Lunch
13:00 - 14:00 Tour of Lindø Component and Structure Testing

Transport by bus

14:00 - 14:30
Production and Quality of Laser Cladding Additive Manufacturing

Peter Tommy Nielsen, Team Manager, Force Technology

The potential of additive manufacturing has reached a point where the techniques are considered highly relevant for production purposes. This presentation will focus on the laser cladding method and show examples of industrial use. On-going work with the laser cladding technology for additive manufacturing purposes on existing applications will be discussed in relation to the durability of the manufactured components. Furthermore, the economical motivation and aspects will be addressed along with the question of when it makes sense to integrate the technology.

Peter Tommy Nielsen is Team Manager in the department of AM and Laser Technology at FORCE. He has been working with industrial applications using thermal spraying and laser processing for more than 10 years with a special focus on 3D printing/additive manufacturing during the last 4 years.
14:30 - 14:50 Break
14:50 - 15:10
Laser Technology in Large Two-Stroke Engines

Jesper Vejlø Carstensen, Senior Research Engineer, MAN Energy Solutions

MAN Energy Solutions drive the transition towards a carbon-neutral world and create pioneering solutions to master the technical and operational challenges of decarbonization. Higher combustion pressures and temperatures increase the engine efficiency and cleaner fuels improve the environment. But this is very challenging for the engine components. Laser technology is a flexible tool to obtain surface properties, which can resist the combustion chamber environment in decarbonized engines.

Jesper Vejlø Carstensen holds a PhD in materials science from DTU. Jesper has been with MAN Energy Solutions in Copenhagen since 2002 and focuses on metallurgy and surface technology.
15:10 - 15:40 To be announced

Lars Weber, Area Sales Manager, MarineShaft A/S

15:40 - 15:50 Closing remarks

Benefits of Industrial manufacturing with laser technology

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Registration fee
Members of ATV-SEMAPP or other promoting organizations: DKK 2,150
Non-members: DKK 2,775
M.Sc. students: DKK 200 & Ph.D. students: DKK 975 (Membership is free of charge. Early bird discount does not apply)
All prices are exclusive of 25 % VAT.
Early bird discount of DKK 200 when registering before 9 August 2019.

The fee includes talks, breakfast, lunch and coffee breaks.

Cancellation
Registration is binding, however substitutions are accepted at any time.

Questions
Please do not hesitate to contact ATV-SEMAPP by e-mailing semapp@atv-semapp.dk or phoning Jytte Laursen +45 4525 4898 or Charlotte Leser +45 4525 4899.