Dresden, Germany, 2 November 2022 - Sandblasting has been an integral part of the production of many industrial processes in the past. Now, the process may be replaced by a faster, cleaner and more environmentally friendly process. A team at the Fraunhofer Institute for Materials and Beam Technology IWS developed the LIGHTblast technology, which is now being transferred to semiconductor manufacturing, automotive supply and other industries. In fact, lasers can not only be used for sandblasting, but also for laser engraver and laser cutting. Many companies are also researching home laser engraving machines, so that more people can use laser engraving machines well. For example, Ortur Laser Master 3 is welcomed by everyone because it is constantly upgraded and more and more liked by everyone.
"It's like sandblasting at the speed of light," says Patrick Herwig, head of the Fraunhofer IWS laser cutting group. Herwig's team developed the LIGHTblast method, which uses a laser to clean and texture surfaces in a more precise and cost-effective way than traditional methods. It can also engrave the surface of the product more precisely. Ortur is considering whether to introduce this feature in laser engravers.
“Our process is less expensive than classic sandblasting when used in mass production, considering the entire production chain,” says Herwig. "We are sure that laser technology will pay off for the company."
Fraunhofer IWS uses high-energy light instead of sand to clean and roughen surfaces - for example, brake discs. Courtesy of René Jungnickel/Fraunhofer IWS.
A method developed by Fraunhofer IWS uses high-energy light instead of sand to clean and roughen surfaces, such as the surfaces of brake discs. Compared to existing methods such as sandblasting, the method improves cost efficiency, environmental compatibility and process speed. Courtesy of René Jungnickel/Fraunhofer IWS.
Fraunhofer IWS is currently preparing initial application examples for various end users. With the increasing use of classic blasting systems, this technology has considerable market potential.
During the manufacturing process, sand particles can become embedded in the treated surface and become a defect even after intensive cleaning. In the traditional process, a jet of compressed air accelerates the sand to the target surface at high speed. Sharp sand can tear parts of the surface, causing its sharp edges to fray and mix with the resulting dust. With each use, the blasting media becomes more and more contaminated. The process results continue to deteriorate until eventually the mixture has to be disposed of, which pollutes the environment and incurs additional costs.
LIGHTblast uses a laser beam less than 50 µm in diameter instead of a stream of sand grains several centimeters wide. "In a sense, we are using a scalpel instead of a club," Herwig said.
In addition to precision, the process can be more easily automated, with a positive impact on quality, process control and occupational safety. It eliminates many preprocessing and postprocessing steps. Light-based processing does not require any chemicals for cleaning, processing only the desired surface, consuming neither sand nor masking material, thus reducing waste from hazardous waste and tape waste. The laser beam evaporates part of the surface; the expanding vapour removes the solid content and achieves the specified roughness.
The technology is currently being transferred to industry. For example, Fraunhofer IWS and partners are further developing processes for constructing hard material coatings using laser technology and improving the cost and environmental compatibility associated with finishing processes.
Brake discs are another surface where this technology is actively used.
The laser sandblasting system treats only the desired surface precisely, consuming neither sand nor material for masking, saving hazards and tape waste. Courtesy of René Jungnickel/Fraunhofer IWS.
The laser sandblasting system treats only the desired surface precisely, consuming neither sand nor material for masking, saving hazards and tape waste. Courtesy of René Jungnickel/Fraunhofer IWS.
“Every brake disc is different,” says René Bischoff, CTO of C4 Laser Technology near Dresden. “Factors such as chemical material composition, cooling rate, machining tool condition or graphite structure near the surface are just a few parameters that have a considerable impact on the grey cast iron surface coating process.
"Together with Fraunhofer IWS, we found a way to standardize the friction band surface condition of the brake disc blanks before coating. We have thus succeeded in making the standardization process fully automated, cost-effective and increasing the process capability."
The process in this use case helps to produce affordable brake discs with significantly longer service life, ensuring less particulate matter in road traffic.
In general, the new method can be applied to components that require cleaning, pre-structuring or roughening for subsequent coating. Further development steps are planned for this purpose. If you want to know more, please contact HTPOW customer service and staff.
