Standard Operating Procedure (SOP) - LaserStar FiberStar Laser Welder

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Fig 1. Overview of Laser Welding System

Section 1 : Emergency Shutdown Procedures

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Fig 2. Emegency Shutdown

Step 1: Turns MAINS POWER switch located on the left side of the machine anti-clockwise to the “OFF” position .

Section 2: What to do in case of an accident?

• Alert nearby personal if assistance is required

• Turns MAINS POWER switch anti-clockwise to the “OFF” position

• If emergency medical attention is required call 911

• Notify Laser Safety Officer (LSO) or member of staff immediately if LSO is unavailable

• Report incident to Health, Safety and Environment

Section 3: Equipment / Safety Contacts

Laser Safety Officer: Michel Gautier | mgauthie@ualberta.ca | 587-920-8236

Secondary Contact: Don Wilson | don4@ualberta.ca | 780-203-8991

Section 4: Introduction to Equipment

The LaserStar FiberStar Workstation is a movable, stand-alone, single-user operated fiber laser welder that can be used to weld almost all metals and metal alloys quickly, reliably, and precisely.

The product is equipped with a stereo microscope with a crosshair to facilitate the exact positioning of the parts. The crosshair marks the exact position on the work piece where the laser pulse spot will occur. The system is also equipped with a 4 axis motorized stage (XYZR) and a 4K (24-150x zoom) camera to record and take still images. Argon and Nitrogen welding gas is also available for use during welding. Please contact staff if required.

Main Specifications:

• 1064nm wavelength

• Up to 1500W pulsed power

• Up to 250W continuous wave

Section 5: Before using the equipment

Section 6: Turning on and using the Laser Welder

6.1 Turning on the laser welder

1. Turn on the Laser Welder Laptop on top of the laser welder

2. Turn the “MAINS POWER” located on the upper right side of the welder clockwise to the the “ON” position

3. Turn the key to the right of “MAINS POWER” switch to the “1” position

4. Wait for the self test during startup of welder to complete

5. On the windows login screen press “Login”

6. Open the program named “Motion FX”

7. When prompted click “Home All Axis”

6.2 Using the touch display on the laser welder

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Fig 3. Touch Display

1. Touch the green square with the parameter to be changed

2. Use the up and the down arrows to increase or decrease the values

3. Press “OK” to apply the parameters

6.3 Safety shutter, interlocks and laser safety precautions

The laser welder contains a safety shutter to disable laser output. The status of the shutter is indicated on the touch display and can be shown in red on fig 3. It also contains interlocks at each door, the laser will not fire when any door is open.

The laser welder status can also be shown by looking at the status indicator box below the laptop. The meaning of the lights are as follows:

• Shutter light off: Laser Shutter is closed

• Shutter light red: Laser Shutter is open

• Interlock light off: Doors are open

• Interlock light on: Doors are closed

The laser will only be able to fire when both lights are ON

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Fig 4. Indicator box, doors closed, shutter open, laser will fire

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Fig 5. Indicator box, doors open, shutter closed, laser will not fire

6.4 Mounting samples inside the laser welder

The laser welder is equipped with a rotary stage for mounting and has an adjustable chuck.

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Fig 6. Axis of Movement

The chuck is able to grip round objects up to 1.5” in diameter. Flat surfaces can also be gripped by the chuck. If custom mounting is required please make a request and a member of the team will be in contact to discuss options.

6.5 Focusing on an object

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Fig 7. Pendant Controller

The motion stage can be moved using the pendant controller. The movement axis and directions are noted in figure 4.

1. Make sure the laser shutter is closed and the shutter indicator light on the box is off.

2. Open up the access panels

3. Use the pendant to move the sample under the focusing lens in the X and Y positions, looking through the access panel gaps and making sure the object will not collide with the lens

4. Use the pendant to move the sample in the Z direction until it is in focus with the microscope and screen

5. Once in focus move the sample in the X and Y direction until the sample is in position.

6. Close the access panels the interlock light on the box will be green.

6.6 Firing the laser welder using the pendant

1. Make sure all three access panels on the machine are closed, the interlock light on the box will be green.

2. Adjust the laser parameters as needed, following instructions in section 6.2

3. Confirm the laser marking spot is in focus and the cross hair on the screen is where the weld needs to be

4. Press the “Safety Shutter” button on the laser welder display and confirm that it is now green, a mechanical click will be heard and the shutter indicator light on the box will be RED, noting the shutter is open

5. Press the red “FIRE” button on the pendant, the laser will fire at the specified rate until the button is released

6. When lasering is completed press the “Safety Shutter” button and confirm the indicator on the screen is red and the shutter indicator on the box is now off.

7. The laser access panels are now safe to open

6.7 Firing the laser using the computer software

1. Follow steps 1-3 on section 6.6 above

2. On the Motion FX software, input the G-Code movement patterns on the “Design” Tab

3. Once the G-Code is completed, hit the “Setup Run” button located on the top section of the program this will run the program created WITHOUT firing the laser

4. Once satisfied with the program, Press the “Safety Shutter” button on the laser welder screen and confirm that it is now green, a mechanical click will be heard and the shutter indicator light on the box will be RED. noting the shutter is open.

5. Press the “Run” button on the laptop screen to run the program with lasering enabled

6. Once the program is complete, completed press the “Safety Shutter” button and confirm the indicator on the screen is red and the shutter indicator on the box is now off.

7. The laser access panels are now safe to open.

Section 7: Standard shutdown routine

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Fig 8. Standard Shutdown Procedure

1. Allow the laser to cool down for 10 minutes after use

2. Turn the key to the “0” position

3. Turn the “MAINS POWER” to the OFF position

4. Ensure the access panels are closed and samples/work holding is taken out of the system

Section 8: Special procedures / operating conditions

8.1 Using the system with the access panels open

In very specific scenarios the laser welder might need to be run with the access panels open. A user must request and discuss with the LSO to determine if it is absolutely necessary. In the event that it is necessary to run the laser with the access panels open the following must be completed:

• Book out the laser room to ensure other users do not need access to the room for the duration

• Eyewear with an OD>6.5 must be worn, these are available upon request

• The Danger sign must be posted on the door (Fig 7), this is available from a member of staff

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Fig 7 Danger Sign for Exposed Laser Beam