Micrometric’s laser welding capability facilitates precise and permanent assembly of precision components. High quality welds can be achieved. Finish machined or pressed components can be joined, as little or no distortion takes place during the welding process. Due to the finely focused beam and precise control of energy, small, delicate and heat-sensitive parts can be joined.
Automotive Steering Sensor
This part is used to sense torque on an electrical power steering system. The legs on the electrical sensors, manufactured in a copper alloy, are welded to the main part of the body of the unit using a series of spot welds. Due to the size, material and thickness of the legs, good and consistent spot welds can only be achieved within a very narrow range of laser parameters.
Scientific Instrument Mount
The problem: to fix the 1mm dia high carbon steel, hardened and tempered ball bearing to the stainless steel mount without any distortion or loss of its mechanical properties. This is difficult to do by any method other than laser welding. Three 0.3mm diameter spot welds, equispaced around the ball bearing, firmly attach it to the internal surface of the machined cup.
An intricate component used in surgical operations. The 1.5mm thick stainless steel rectangular flag is spot welded to the 1mm dia stainless steel tube that has a wall thickness of 0.1mm. This needs to be done without any penetration through to the inside of the tube. This is important, as the inside diameter of the tube acts as guide for a small diameter wire. In addition to standard metallurgical tests, the welded joint needs to withstand a pull of 20kgs.
Spherical Float For Steam Trap
The stainless steel steam trap is made from two 0.5mm thick halves. A permanent and leak-free joint was achieved by laser welding. The low heat input of a laser weld ensures that there is no distortion. As the process requires no filler material, the weld does not stand proud of the surface. These aspects are essential, as the sphere must conform to extremely tight manufacturing tolerances.
The spring assembly is made up of a main body and two 4-fingered springs. The springs are laser cut by Micrometric. Laser welding was selected as the method of joining the spring fingers to the main body. This is because the heat input is extremely localised and causes no change to the material properties.
Laser welding is a low heat process so it is ideal for welding thin sections to thicker machined components, as in this torque disc application used in electrical motors. The assembly consists of a machined stainless steel disc and a stainless diaphragm 0.5mm thick. The weld depth and width need to be maintained within tight tolerances.