White Powder Contamination: Industrial Laser Service Case Study

Posted on April 7, 2020June 15, 2020 by Scott Kiser

Take a little Time to Save a lot of Time (and Money) — Industrial Laser Service Case Study

Most people understand that regular, routine laser maintenance saves money over the long haul. The math supports this, just from an industrial laser service perspective. Servicing industrial lasers – inspecting the optics and mirrors, fine-tuning calibrations, and even doing essential training — lets those CO2 Cincinnati lasers keep humming along.

Laser Maintenance Group (LMG) isn’t just about laser maintenance. We understand the costs in time and money that a struggling laser center can cause in the productivity and quality aspects as well. The indirect cost of sending out poor quality parts or even good parts that are consistently late is hard to quantify. We all agree: Poor quality and late delivery is worse than direct maintenance costs.

What many companies don’t remember is that these complex laser centers eventually require rebuilds. While more costly than routine industrial laser service calls, these rebuilds are essential to keeping these CO2 lasers running at peak efficiency.

Industrial laser service case study scenario — Laser System: Cincinnati CL-7A with a 2KW Rofin-Sinar resonator

High-Level Laser Problem: Instability at High Power

Several factors can cause instability at high power. Based on LMG’s experience, if your laser has over 12,000 hours since the last rebuild, chances are it’s a ‘White Powder Contamination’ issue. That is, your resonator optics are being coated with tungsten dust. That disrupts the laser in the beam path as it gets circulated through the gas system. Pictured are two affected internal optics (The silver one is a rear mirror. The yellow one is an output coupler).

Laser Geek-Out: Explanation

CO2 laser white powder contamination is an eventual and normal condition for DC-excited lasers. Laser maintenance won’t prevent this; the material science doesn’t yet exist to avoid this issue.

On all CO2 lasers, the tungsten cathode pins oxidize over time. The problem can be accelerated by vacuum leaks and poor quality laser gas. Both factors contribute to the moisture content inside the system. This allows for the oxidation of the pins. This oxidation then gets distributed throughout the system. Some lands on the internal laser optics and mirrors. As the optics are coated with this dust, laser beam quality and power drop off quickly.

Root Cause Problem:

The tungsten oxide (white powder) contamination has a root cause: The resonator is way past the 12,000 hours where a white powder rebuild should be done. As a result, the tungsten oxide dust coats the optics, deforming the beam shape and lowering the laser’s power.

Short-term routine laser center maintenance solution:

Laser service: White powder contamination can be prevented by laser system rebuilds. — Laser Service Guy Kiser tunes a Rofin-Sinar resonator

Because of this problem, the optics need to be changed at every maintenance interval. Mere cleaning won’t help, since it is usually burned in. The crystal structure of the optic is stressed from absorbing too much laser energy rather than passing it through to the beam delivery. After any of the optics are replaced, we at LMG have to realign them to form a symmetrically-shaped laser beam. (In this photo Laser Service Guy Kiser tunes a Rofin-Sinar resonator.)

Only changing the optics creates what we call a performance spike. The laser runs great for a week or maybe even a month and then starts to slowly fall back to where it was. How fast the laser degrades depends on how severe the contamination is.

Long-term preventative industrial laser service solution:

The Rofin-Sinar resonators on these CO2 Cincinnati lasers should have a white powder rebuild after approximately 12,000 hours of operating time. That may be longer or shorter, as the operating condition of the resonator dictates.

Don’t let anyone tell you your laser is old, and it won’t ever make rated power again. Quite frankly, hearing that upsets me. Why? It means that person either doesn’t know about Cincinnati CO2 lasers and Rofin-Sinar resonators, or doesn’t care. If your 2000 watt resonator cannot make and hold at least 2200 watts, your tech should be embarrassed.

How laser service impacts your manufacturing and your business

At LMG, we’ve seen how the laser’s performance affects the entire plant. If a laser is not performing well, the result can wreak havoc with production schedules. When this happens, the quality of the parts you make is in jeopardy. We also know that corporate accountants are going to complain every time any manufacturing division asks for money, whether it’s to fix the roof or fix a laser.

At LMG we work with our customers to help them prepare for this expense. (In fact, right now we are working with customers to see how the Covid-19 stimulus package funds can be used for this type of industrial laser service and production improvement.) We can usually tell in advance that the performance will degrade to the point something needs to be done in order to keep up with production and quality.

Laser failure bottom line and industrial laser service solution:

What happens if your laser operators have to keep slowing down to cut decent parts? The quality folks are angry. The production leads are frustrated. Your laser operators are stressed out from being gunned down from both sides.

Solution? Let LMG take a look at your laser center and get it back to normal. We know how to make things right, from the various laser parts, to the programming, to the operations. You don’t have to live under this type of pressure, with good laser systems that aren’t functioning at their potential. Learn more about LMG’s Industrial Laser Services, then call us! We will work with you to get your laser back up to where it needs to be, and your team back to normal.

Use the Right Fire Extinguisher Around Laser Systems

To avoid laser system and optics contamination, it’s vital to have the right type of fire extinguishers in your factory. AND you should know which extinguishers to use, when, and why.

Did you know that, although CO2 fire extinquishers cost many times more than typical Class D extinguishers, they are well worth the extra cost? In this video, part of Laser Maintenance Group / Innovative Laser & Design’s Laser Safety series, Scott Kiser explains why he is a firm believer in having several CO2 extinguishers in his shop.

Another way to avoid lens contamination is to use the right kind of fire extinguisher around your laser systems.

CONTACT LMG:
To discuss how LMG can help your business, call 423-593-7206 or email lasersolutions@comcast.net

Laser Service Tip: Preparing For The End (of the Coronavirus Pandemic)

Posted on March 25, 2020June 29, 2020 by Scott Kiser

Laser service — or any type of machine maintenance — can often be overlooked. During the Covid-19 Coronavirus pandemic, businesses slowed throughout the world. A lot of my laser service and maintenance customers wondered what to do during the slowdown. I wrote a couple of LinkedIn articles on what companies — especially manufacturing firms — can do during any sort of economic or business slowdown.

This article deals specifically with maintenance and service. It can be found here on LinkedIn (and, while you’re on LinkedIn, why don’t you connect with me, if you haven’t already!)

Does the Stimulus Package impact you? It might! It seems that the Federal Government’s Stimulus Package (including $10,000 in Small Business grants, as well as other low interest loans) can be used to bring in contractors, consultants and other W2 workers to perform essential services (such as maintenance). Are you experiencing a factory slowdown because of the Covid-19 pandemic? If so, it would be a great time to call LMG to come take care of your machines.)

After reading the article and checking out the Pandemic loan and grant information at SBA.gov, you’ll know what to do. Then you can stop twiddling your thumbs and get busy! (And if you still don’t know what to do, please give me a call or send me an email at lasersolutions@comcast.net — I’m certain that, together, we can think of something!)

With nearly 3 decades of laser service experience, I’ve seen a boat load of industrial laser situations. Some good, some … not so great. (I’d rather do laser maintenance than laser repair!) Here are some more case studies about those laser service experiences.

Regular Laser Maintenance Visits Prevent Costly Repairs

Posted on December 12, 2019June 29, 2020 by Scott Kiser

You wouldn’t drive your high-performance car thousands of miles without scheduled maintenance and checking. Yet many industrial laser owners do just that: Put off regular laser service or maintenance visits until something breaks. They claim they “forget”, or it’s “something we’ll get around to.” But they don’t. And repairing CO2 laser systems are much more costly and time intensive than regular laser maintenance.

Laser Service Guy Scott Kiser tuning a Rofin-Sinar resonator on a Cincinnati laser — Laser Service Guy Scott Kiser tunes a Rofin Sinar resonator on a Cincinnati laser

LMG Laser Maintenance Visit Packages

We at LMG would rather maintain your laser systems, not repair or replace them. That’s why we offer scheduled laser maintenance visit packages. Pricing for these packages varies based on the type of machines you have, and the amount of hours you run your machine.

Rules of Thumb for Laser Maintenance Visits

Just like high-performance vehicles, CO2 laser systems best operate if they are serviced every 800 to 1,000 hours. If you are like most companies, you’ll run your industrial laser systems between 40 and 60 hours a week. In this scenario, LMG recommends scheduling us for a laser maintenance visit every three months. If you operate more than one system at your facility, it’s beneficial to schedule all the CO2 laser systems for maintenance at the same time. This video with LMG owner Scott Kiser gives more detail.

What Happens During LMG’s Maintenance Visits?

Your CO2 laser is a highly complex system, but LMG’s experts — with decades of experience — have laser maintenance visits down to an exact science and process. We will:

Almost a catastrophic breakdown: The bolt on the laser shroud was loose. It caught the laser, which sent particles into the lens and cut a water hose. The beam super-heated the copper tip, fusing it shut. Fortunately, the laser operator did the smart thing: Shut Down Prevents Catastrophic Breakdown — Video: Why Routine Laser Maintenance?

Change the oil
Check fluid levels
Perform compression tests (check for gas leaks)
Check hoses (did you know: Hoses often change color just before they fail!)
Check all moveable parts
Run diagnostic tests
Clean your laser system
Adjust and realign Rofin Sinar resonators
Check critical alignment points
… and more!

If there are potential trouble spots, if your laser system needs consumable parts, or if a standard part is wearing down, LMG will give you a fast and fair estimate. Often, these types of repairs can be done during the same visit, thus preventing dangerous laser failure situations, expensive part replacement, and costly down time.

With nearly 3 decades of industrial laser experience, LMG’s motto is simple:
“The Performance of Your Laser System is a Reflection of the Work We Do!“

Contact Laser Maintenance Group For a Quote

Don’t wait until your high-performance industrial laser system fails. Schedule your laser maintenance visits now with LMG Founder and Chief Technology Consultant Scott Kiser (aka “The Laser Service Guy”) directly at 423-593-7206, or email: LaserSolutions@Comcast.net.

Laser Repair — When Industrial Lasers Fail, RUN!

Posted on December 10, 2019March 24, 2020 by Scott Kiser

I’ve been involved in laser repair and maintenance for decades. Just when I think I’ve seen almost every industrial laser situation and scenario, I’ll hear about something new. Some situations just leave me shaking my head. Take these photos — and the video of the burning laser bellows, at the bottom of this post — I received recently.

The first one shows a CO2 Cincinnati laser during arc out. The next one shows the result of the arc out.

A CO2 laser during arc out. Don't take pictures of this! Turn the power off and RUN! When I saw these photos, my jaw literally dropped. Later, I told a friend:

“That laser arc out picture was amazing to see for sure. The polymer block has a super high dielectric strength so it’s stunning to see it go all that way across it like that. The block had to be replaced.

If they had reached 20,000Vdc, it would have gone through them instead (since people are conductive.)

It’s a good way to be killed or at the very least burned inside and out.”

The aftermath of a near disaster with a laser-cutting machine

Most importantly, and the lesson I want to impress on your mind, is this: Industrial laser machines are powerful. Treat them right, and they will work hard and do good work for you. But they can be extremely dangerous. In a situation like this, the people who took the photo of this industrial laser arc-out were VERY lucky!

They could have died.

Be Safe Around Industrial Laser Machines

Don’t die just for the sake of taking a cool photo or a selfie. Be aware of your surroundings. Treat your laser machines with care. If something like this starts to happen, if something doesn’t look, sound, smell or feel right, TURN OFF THE POWER!

If you can’t find something wrong, contact a qualified laser tech who can run a thorough check on your machine and repair or replace what’s needed. (In other words, call me BEFORE something like this happens!)

Perform Regular Laser Maintenance Before You Need Laser Repair

Even more important: Maintain your machines. Laser repair costs much more than routine, expert laser service and maintenance. Don’t let your machines get in a bad way, where your safety is compromised. I recommend having a routine laser service and maintenance plan, such as the laser services that we at LMG offer.
An ounce of prevention ….

Take care!

Scott, the Laser Service Guy
LaserSolutions@Comcast.net
423-593-7206

Here’s another example of what NOT to do: The laser was still cutting, but much more slowly than normal. The laser was off track and cutting through the laser machine’s bellows. DON’T VIDEO A DISASTER! It is dangerous (and makes laser repair much more difficult.) Shut down the laser machine!