☆ 4.4 Article

Laser specific energy consumption: How do laser systems compare to other manufacturing processes?

JOURNAL OF LASER APPLICATIONS (2022)

Journal

JOURNAL OF LASER APPLICATIONS

Volume 34, Issue 4, Pages -

Publisher

AIP Publishing

DOI: 10.2351/7.0000790

Keywords

Energy Intensity; Processing Rate; Selective coating removal; Laser Welding; Laser Cutting

Funding

Engineering and Physical Sciences Research Council UK (EPSRC)
Project of International Cooperation and Exchanges National Natural Science Foundation of China (NSFC)
[EP/S018190/1]
[51861165202]

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Abstract

This paper presents the results of a collaborative UK and China research project to improve the understanding of total energy consumption and carbon emissions in laser-based manufacturing. The study evaluates the energy efficiency of various laser cutting, welding, and cleaning processes, with a focus on the auxiliary subsystems of laser systems. The research findings show that laser processes have relatively high energy intensity compared to conventional manufacturing alternatives.

Laser material interactions are routinely praised for their selective processing and high processing rates. However, this does not guarantee that the total manufacturing system has a low energy intensity compared to conventional manufacturing processes. This paper presents the results of a collaborative UK and China research project to improve the comprehension of the total energy consumption and carbon emissions for laser-based manufacturing. A range of individual laser cutting, welding, and cleaning processes were studied to assess their energy efficiency, including the laser and its ancillary subsystems (e.g., cooling and extraction). The project developed a systematic analysis method, adapted from BS ISO 14955-1:2017, which incorporated time and subsystem level studies to quantify all energy consumption components of a laser system. Previous research has identified that the laser system's most significant contributor to the total energy consumption are the auxiliary or supporting subsystems, not the laser emission. This identified that using only the absorbed radiation to evaluate manufacturing efficiency is misleading. All the processes evaluated followed a negative correlation between processing rate (kg/h) and specific energy consumption (J/kg). The new data conclude that laser processes have a relatively high energy intensity compared to conventional manufacturing alternatives. The results can be used to identify where the most significant improvements to individual laser systems can be made. The comprehensive comparison of processes allows manufacturers to select processes to improve environmental impact.

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Indentation and sliding contact testing of three laser-textured and PVD-coated cemented carbide tools

Shiqi Fang, Carles Colominas, Christoph Pauly, Nuria Salan, Luis Llanes

Summary: This study presents a new concept for cemented carbide tools with laser-generated abrasive-like protrusions on their machining surfaces. The surface structure of the tools is protected by different PVD ceramic hard coatings, and their effectiveness is assessed through indenting and sliding contact testing. The results show that both laser texturing and coating deposition alter the hardness of the tools, and the tool coated with a two-layer film achieves the best performance in terms of hardness enhancement and damage prevention.

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