Clean Lasersysteme GmbH SURFAIR Conference, June 5th 2014 Edwin Büchter SUSTAINABLE LASER SURFACE TREATMENT AND CLEANING Clean Lasersysteme GmbH Edwin Büchter CEOPresident Awardee of the “German Environmental Award“ 2010 HerzogenrathAachen Germany www cleanlaser com buechtercleanlaser com IN AERONAUTICS AND AEROSPACE APPLICATIONS SURFAIR Conference, June 5th 2014 Edwin Büchter PROCESS OPTIMIZATION BY LASERTECHNOLOGY LASERS CHANGE THE INDUSTRIAL PRODUCTION CLADDING MEASURING CLEANING HARDENING.
SUSTAINABLE LASER SURFACE TREATMENT AND CLEANING IN AERONAUTICS AND AEROSPACE APPLICATIONS Clean-Lasersysteme GmbH Edwin Büchter CEO/President Awardee of the “German Environmental Award“ 2010 Herzogenrath/Aachen Germany www.cleanlaser.com buechter@cleanlaser.com SURFAIR Conference, June 5th 2014 Edwin Büchter PROCESS OPTIMIZATION BY LASERTECHNOLOGY LASERS CHANGE THE INDUSTRIAL PRODUCTION WELDING CLADDING MEASURING CLEANING HARDENING DRILLING STRUCTURING CUTTING FINE-CUTTING RAPID PROTOTYPING courtesy: FhG-ILT SURFAIR Conference, June 5th 2014 Edwin Büchter TECHNOLOGY allows news sustainable and integrated process and workflow THE FIRST IN THE NICHE – FROM TESTING TO INSTALLATION WE PROVIDE SOLUTIONS • • • • • • • • • • EXPERIENCE: on the market since 16 years, roots: Fraunhofer ILT CONTINOUS: Both founders are acting as CEO‘s and managing the buisness COMPLETE: APPLICATION / LASERS / DESIGN / MACHINES MADE IN GERMANY: Facility (ca 1.600 m²) in technologyregion Aachen ENGINEERING: ~ 40 % engineers, >10% of turnover re-invested in R&D TEAM: >60 qualified team members NUMBERS: >500 laser units and systems produced for industrial use GROWTH 2013: Turnover >11.5 Mio € AWARDED: GERMAN ENVIRONMENTAL AWARD 2010 (highest doped European Award) ENVIRONMENT: environmental friendly production, saving resources by using our products SURFAIR Conference, June 5th 2014 Edwin Büchter Why? REPLACE DETERGENTS BY LIGHT APPLICATION: GREASE AND OIL CONVENTIONAL MULTI REMOVAL BY LIGHT STEP CLEANING cleaning prior to welding / cleaning of sealent areas ADVANTAGES: small footprint (2m² vs >30m²), media free, no waste disposal high uptime, direct in line, process monitoring SAVINGS: No cleaning media, no detergents up to ten times less power consumption POLITICS: savings of ressources in wash processes is already part of environmental guidlines at major AUTOMOTIVE OEM‘s such as Volkswagen Political requested reduction in industrial energy consumption 20%! COST: typically: > 10 ct/part (e.g gear part) SURFAIR Conference, June 5th 2014 Edwin Büchter ADVANTAGE CLEAN-LASER OUR PATENTED ABLATION STRATEGY – SCAN AND MOVE ABLATION PRINCIPLE • Up to 50.000 very short pulses per second • Line-shaped beam deflection • Very short impact times due to scanned laser-beam • Exclusive licensed Patent Pending for manual cleaning with scanned beam SURFAIR Conference, June 5th 2014 Edwin Büchter HOW DOES IT WORK? LASER RADIATION FOR CLEANING AND ABLATION ABLATION PRINCIPLE • • • • • SURFAIR Conference, June 5th 2014 Edwin Büchter Coating and dirt layer is removed by absorbing the focused laser spot Very powerful but short laser pulses (~56-72mN/m Area rate up to 15m²/h Improved shear strength Extended open time before bonding/coating (up to days) OXIDE REMOVAL FROM TITANIUM PRIOR TO ADHESIVE BONDING APPLICATION EXAMPLE: LEADING EDGE Titanium Panels half side cleanLASER treated • • • • Oxide removal and cleaning Low impact to substrate Replacement of chemical treatment or media blasting Initial testing indicates excellent applicability Typical application: Leading edge surface preparation in process SURFAIR Conference, June 5th 2014 Edwin Büchter Cold treatment (lab tests) PREPARATION OF CFRP FOR PRODUCTION AND REPAIR RESULTS OF AIRCRAFT RELATED PROJECT Adhesive bonding Pre-treatment of CFRP lead to High shear Strength Applications: • Repair • Bonding in Production • Clips / mounts Bonding • Strength allow generally structural bonding • Several ongoing public funded R&D Projects F&E-PROJEKT PARTNER (Forschungseinrichtungen): MoLab (TU-Braunschweig/IFS) / Plaser (Laser Zentrum Hannover) / IFAM / IWS PLASER Projekt gefördert durch Kennziffer: 01QE0906 SURFAIR Conference, June 5th 2014 Edwin Büchter DAMAGE FREE COMPOSITE MOLD CLEANING Aluminium Work piece after 100 treatments (500 W) without any dirt layer • • • • • • • In use at several Aircraft makers! AIRCRAFT APPROVED Technology 10 units in use already first since 2004 UPCOMING POTENTIAL in AUTOMOTIVE! SURFAIR Conference, June 5th 2014 Edwin Büchter • • Removal of process residuals Economical cleaning of large segments with a beam width of up to 100mm and more Sensitive structures of aluminium, invar and steel will not be damaged Homogeneous cleaning results Cleaning speed of more than 15 m²/hr (depending on layer thickness and laser power) GANTRY UNIT IN CO-OPERATION WITH OUR PARTNER SURFAIR Conference, June 5th 2014 Edwin Büchter | 23 | IMPRESSIONS: COMPOSITE MOULD CLEANING TURN KEY SOLUTION AND MARKET READY PRODUCTS AVAILABLE SURFAIR Conference, June 5th 2014 Edwin Büchter Cost analysis MOLD CLEANING: CO2 Ice Blasting vs Laser Cleaning criteria: 24/7 with 5000 h/a; 0,15 €/kWh; CO2: 0,30 €/kg; amortization years without recovery value cleanLASER CO2-ice-blasting € TYPICAL INVESTMENT COSTS: Ice blasting machine incl pelletizer (Cold Jet) 110.000,00 Air compressor 125.000,00 CO2-tank 50.000,00 Noise protection and suction 10.000,00 TOTAL: 295.000,00 € € Laser CL500 with Laseroptic (cleanLASER) 230.000,00 Suction 7.000,00 Safety curtains and googles 5.000,00 TOTAL: 242.000,00 € €/hour RUNNING COSTS: €/hour RUNNING COSTS: INVESTMENT COSTS: Energy: 6.2 kW 0,93 Energy: 130 kW 19,50 Maintenance: 5% of invest/a 1,60 CO2 consumption: 110 kg/h 33,00 Amortization 6,40 Maintenance: 5% of invest/a 2,00 Amortization 7,90 TOTAL: 62,40 €/h SURFAIR Conference, June 5th 2014 Edwin Büchter TOTAL: 8,93 €/h ENVIRONMENTAL CO2 emissions: CO2 Ice Blasting vs Laser Cleaning CO2-ice-blasting CO2 consumption CO2 in kg Energy: 130kW 72,0 CO2 consumption 110,0 TOTAL: 182,0 kg CO2 cleanLASER CO2 consumption CO2 in kg Energy: 6.2kW 3,0 TOTAL: SURFAIR Conference, June 5th 2014 Edwin Büchter 3,0 kg CO2 SUMMARY – CLEANING WITH LIGHT • • • • • • Laser cleaning is an environmental friendly alternative for conventional wet chemical cleaning Especially on metal substrates it is very well applicable for: – Oxide removal – Removal of organic layers Low running costs (typ 0,2-2 €/h) Automated and in-line applicable Easy integration and small footprint Maintenance free cleaning technology Sustainability: • Low energy and ressources consumption • No noise and dust • Better workplace conditions • No secondary waste removal SURFAIR Conference, June 5th 2014 Edwin Büchter ONE STEP TOWARDS GREEN PRODUCTION - cleanLASER THANK YOU! DANKE! SURFAIR Conference, June 5th 2014 Edwin Büchter ... BY LIGHT APPLICATION: GREASE AND OIL CONVENTIONAL MULTI REMOVAL BY LIGHT STEP CLEANING cleaning prior to welding / cleaning of sealent areas ADVANTAGES: small footprint (2m² vs >30m²), media free,... restrictions) cleanLASER TECHNOLOGY SUITABLE FOR DIFFERENT SPEED DEMANDS LOW POWER MID POWER LASER HIGH POWER LASER Backpack / CL12 - CL 100 CL 150 – CL 600 CL 1000 cleanCELL adapted cleanCELL SURFAIR... Economical cleaning of large segments with a beam width of up to 100mm and more Sensitive structures of aluminium, invar and steel will not be damaged Homogeneous cleaning results Cleaning speed