Laser Assisted Dry Ice Blasting - SBB Sonderabfallgesellschaft

Transcription

Effizient und schonend reinigen
Laser Assisted Dry Ice Blasting
A Hybrid Machine Tool Concept for Cleaning and Recycling
Innovative Verfahren zur Reinigung, Entschichtung und
Vorbehandlung von Oberflächen
´
Informationsveranstaltung 13.11.2008
Sonderabfallgesellschaft Brandenburg/Berlin mbH (SBB), Potsdam
Prof. Dr. h. c. Dr.-Ing. Eckart Uhlmann
Dipl.-Ing. Robert Hollan
Kontakt: Hollan@iwf.tu-berlin.de, Tel. 030 / 314 – 22 413
SBB mbH, Potsdam
Institute for
Machine Tools
and Factory Management
Prof. Dr.-Ing. Eckart Uhlmann
Technical
University
Berlin
Production Technology Center Berlin
Prof. Dr. h. c. Dr.-Ing. Eckart Uhlmann
Institute for Machine Tools and Factory Management
Technical University Berlin
Fraunhofer Institute for Production Systems and
Design Technology
1986 IWF and IPK moved into PTZ
450 employees (scientists, service and students)
More than 70 test areas and 7 special
laboratories on approx. 7 100 m²
Budget of 24 Mio. Euro
Spin-offs and start-ups by 12 % of former
staff members
SBB mbH, Potsdam
Institute for
Machine Tools
Technical
University
Berlin
Overview Structure of Presentation
Introduction
Stand-alone-Technologies
Dry Ice Blasting, Laser Processing
Metrology
Optimization of Stand-alone-Technology
Hybrid Machine Tool Concept
Hybrid Cleaning Strategy
Results of Hybrid Tests
Surface Quality
Summary and Outlook
SBB mbH, Potsdam
Institute for
Machine Tools
Technical
University
Berlin
Introduction
Introduction
Metrology
Optimization
Results of Hybrid Tests
Surface Quality
Summary and Outlook
Collaborative research center SFB 281 “Disassembly Factories”
for the development of recycling technologies
funded by the German Research Foundation DFG
TFB:
Components, systems, methods and information
technology tools for practical product and material
cycles
1
Development of the hybrid cleaning technology
with dry ice blasting and laser (E7)
Motivation:
Recycling requires a de-coating and a cleaning
process as well as a pre-treatment.
2
1
Environmental friendly technologies dry ice
blasting and laser
Removal of highly adhering or hard contaminants, protective or functional coatings
SBB mbH, Potsdam
Institute for
Machine Tools
3
2
Technical
University
Berlin
4
Dry Ice Blasting I
One-way blasting medium:
Solid carbon dioxide pellets
TP = -78,3 °C
ρP = 1100 kg/m³
lP
dP
dP
lP
SBB mbH, Potsdam
Institute for
Machine Tools
Technical
University
Berlin
= 5 - 15 mm
= 3,0 mm
Dry Ice Blasting II
Removal Mechanisms:
Impact
Thermal Effect
Sublimation
tS
SBB mbH, Potsdam
Institute for
Machine Tools
Technical
University
Berlin
Dry Ice Blasting III
Dry ice blasting equipment:
Artimpex device “Cryonomic Cab52”, based on the injection
principle, blasting nozzle “G 5000” (venturi injector)
Blasting pressure:
Up to 16 bar
4
1
3
5
2
6
7
SBB mbH, Potsdam
Principle:
Because of independent adjustable blasting pressure (2)
and transport pressure (3)
capable of injection principle
as well as compressed air
blasting
Dry ice mass flow:
Up to 20 - 105 kg/h
Institute for
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Technical
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Dry Ice Blasting III
ICETECH device “ICEBLAST KG 30”, based on the
compressed air blasting principle
Blasting pressure:
Up to 16 bar
3
Principle:
Compressed air blasting
1 2
Dry ice mass flow:
Up to 30 - 100 kg/h
4
5
SBB mbH, Potsdam
Blasting nozzles:
asdf
Institute for
Machine Tools
Technical
University
Berlin
Dry Ice Blasting IV
KIPP device for carbon dioxide snow blasting
Blasting pressure: From 4,5 to 16 bar of compressed air
Liquid carbon dioxide pressure: High pressure liquid carbon dioxide bottle, 57 bar
Liquid carbon dioxide mass flow: From 20 up to 45 kg/h
1
2
3
4
SBB mbH, Potsdam
Compressed air
Liquid CO2
Agglomeration chamber
Blasting nozzle
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University
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Interaction Laser-Material:
•
Reflection
•
Transmission
•
Absorption
Material removal process:
Absorption
Sublimation, ionisation
Melting
Isothermal plasma
Adiabatic expansion
absorptance A [%]
Laser Processing I
wavelength λ [µm]
SBB mbH, Potsdam
Institute for
Machine Tools
Technical
University
Berlin
Laser Processing II
Equipment for Laser processing:
Dilas Diodenlaser device “Dilas Diodenlaser 1500 W”
Wavelength:
940 nm ± 5 nm
Laser power:
Up to 1500 W
Laser frequency:
In cw-modus* applied
Pulse duration:
In cw-modus* applied
Diameter of focus:
3,8 mm x 8 mm
*cw-modus: continuous-wave modus
SBB mbH, Potsdam
Institute for
Machine Tools
Technical
University
Berlin
Laser Processing III
Equipment for Laser processing:
Bauer+Mück Nd:YAG solid state laser device “SV10”
Wavelength:
1064 nm
cw-laser power:
18 W (TEM-mode), 100 W (multi mode)
Laser frequency:
0 kHz up to 10 (250) kHz
6
4
2
5
1
Scanner frequency:
0 Hz up to 300 Hz
7
Pulse duration:
90 ns
Diameter of focus:
20 µm (direct), 200 µm (fibre)
SBB mbH, Potsdam
3
Institute for
Machine Tools
Technical
University
Berlin
Metrology
Standard of comparison and measurement device I
Material removal rate:
•
Defined standard of PUR-2 component
varnish
•
Detection of surface profile transversal
to the robot’s movement
•
Software based calculation of
cross sectional area (CSA)
•
Information of material removal
transversal to robot’s movement
(estimation of necessary overlapping)
A
B
C
D
E
2 cm
Taylor Hobson contact instrument for measurement
of surface finish, form and contour “Talysurf-120L”:
•
Diameter of the contact device: 2 µm
•
Angle of the contact device: 60°
Surface qualitiy:
•
Error of measurement: < 0,15 µm
•
•
Measuring range: 2 mm
•
Measurement length: orthogonal
collinear
Measurement of the surface
roughness according to
DIN EN ISO 4287
SBB mbH, Potsdam
Institute for
Machine Tools
Technical
University
Berlin
20 mm
5 mm
Metrology
Standard of comparison and measurement device II
Material volume removal rate or
cross sectional area (CSA):
•
Surface profile transversal to
the robot’s movement
•
Software based calculation
(Talymap Univ.) of cross
sectional area (CSA) of
removed material
•
Calculation of volume
removal rate in case of
different feed speeds
•
Gravimetric analysis in case
of too rough surface for
calculation of CSA
•
Tests with Rusted specimen
and thermal sprayed
coatings
SBB mbH, Potsdam
A
B
C
D
E
2 cm
Surface profile
CSA
Maximum depth:
CSA:
Institute for
Machine Tools
163 µm
1,21 mm²
Technical
University
Berlin
Optimization of Stand-alone-Technologies
Dry Ice Blasting I
2.4
mm²
1.6
1.2
0.8
0.4
0.0
2
4
6
8
10
Trockeneisstrahldruck p
Blasting Pressure
SBB mbH, Potsdam
bar
14
Querschnittsfläche
CSAdes Abtrags aq
Querschnittsfläche
CSA des Abtrags aq
Optimization of dry ice blasting pressure and blasting angle
2.4
mm²
Institute for
Machine Tools
1.6
1.2
0.8
0.4
0.0
40
50
60
70
°
Trockeneisstrahlwinkel a
Blasting Angle
Technical
University
Berlin
90
Dry Ice Blasting II
4.0
mm²
3.0
2.5
2.0
1.5
1.0
0.5
0.0
0
20
40
60
kg/Std
Trockeneismassenstrom
m
Dry
Ice Mass Flow
SBB mbH, Potsdam
100
Querschnittsfläche
CSA des Abtrags aq
Querschnittsfläche
CSAdes Abtrags aq
Optimization of dry ice mass flow and blasting distance
1.8
mm²
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
Institute for
Machine Tools
0
2
4
6
8
10
12
14 cm 18
Trockeneisstrahlabstand
as
Blasting Distance
Technical
University
Berlin
Laser Processing I
1.0
mm²
0.6
0.4
0.2
0.0
-40
-20
0
20
40
mm
80
Abstand Oberfläche-Fokusebene
des Lasers aFok
Focus
SBB mbH, Potsdam
Querschnittsfläche
CSAdes Abtrags aq
Querschnittsfläche
CSAdes Abtrags aq
Optimization of laser focus and distance of laser pulses on the workpeace
1.4
mm²
1.0
0.8
0.6
0.4
0.2
0.0
Institute for
Machine Tools
0
100
200
300
400
500
Laserpulsabstand
ap
Distance
of Laser Pulses
Technical
University
Berlin
µm
700
Laser Processing II
1.4
mm²
1.0
0.8
0.6
0.4
0.2
0.0
0
2
4
6
kHz
Laserpulsfrequenz fp
Frequency of Laser Pulses
SBB mbH, Potsdam
10
Querschnittsfläche
CSA des Abtrags aq
Querschnittsfläche
CSA des Abtrags aq
Optimization of laser frequency and holding time between laser pulses
1.4
mm²
1.0
0.8
0.6
0.4
0.2
0.0
0.0
Institute for
Machine Tools
0.1
0.2
0.3
0.4
ms
Wartezeit pro Laserpuls tw
Time between Laser Pulses
Technical
University
Berlin
0.6
Increased thermal effect of dry ice blasting, final laser cleaning
Laser-heating to increase
the thermal effect of dry ice
blasting:
Final laser cleaning after
preliminary purification by
dry ice blasting:
•
Energy addition by
controlled power output of
the laser
•
Preliminary cleaning by dry
ice blasting removes most of
contaminant or coating
•
Thermal camera to observe
surface temperature, to
control increased thermal
effect and to avoid thermal
stress
•
Final camera assisted laser
cleaning process removes
residues of contaminant or
coating
•
Possibility of a pre-treatment
by laser processing (e. g.
roughening of the surface)
•
Possibility of reduced
mechanical effect due to
increased thermal effect of
dry ice blasting
SBB mbH, Potsdam
Institute for
Machine Tools
Combination of both
strategies:
•
Preliminary cleaning by
laser assisted dry ice
blasting removes most of
contaminant or coating
•
Final laser cleaning
process removes
residues of contaminant
or coating
Technical
University
Berlin
Laser assisted dry ice blasting, combination of laser assisted dry ice blasting
and final laser cleaning process
A
E
C
C
A
D
B
SBB mbH, Potsdam
B
Institute for
Machine Tools
Technical
University
Berlin
Results of Hybrid Tests I
Laser assisted Dry Ice Blasting
Improvement of the material removal rate of
up to 500 % compared with dry ice blasting.
DIB
Hybrid
4,0
A
B
C
2 cm
Volume removal rate
mm³/s
3,0
2,5
2,0
1,5
1,0
0,5
A
B
C
0,0
2 cm
SBB mbH, Potsdam
A
B
C
D
E
Comparison dry ice blasting vs. hybrid
Institute for
Machine Tools
Technical
University
Berlin
Results of Further Investigations
Percentage of Removal Effects
100
15 %
34 %
51 %
%
80
Thermal
Effect
60
40
Mechanical
Effect
20
100 %
85 %
66 %
49 %
-78,5
20
200
500
0
Starting Temperature of Gas Turbine Parts [°C]
SBB mbH, Potsdam
Institute for
Machine Tools
Technical
University
Berlin
Results of Hybrid Tests II
Final Laser Cleaning
Improvement of the cross sectional area (material removal rate)
between 28 % and 49 % compared with dry ice blasting.
Problem of comparing the improvements of final laser cleaning and laser assisted dry ice blasting:
•
•
Disadvantage of CSA/mass based
comparison:
Any removed material is weighted
equal
Removing the highly adhering residues of preliminary cleaning by
dry ice blasting can’t be compared
with the first percentage that can
easily be removed
Due to inhomogeneity highly adhering residues of contaminants or
coatings remain only partial, have to
be removed selective.
SBB mbH, Potsdam
DIB
Hybrid
mm²
1,6
1,4
1,2
CSA
•
2,0
1,0
0,8
0,6
0,4
0,2
0,0
A
B
C
D
Comparison of DIB vs. hybrid
Institute for
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Technical
University
Berlin
E
Surface Quality
Measurement of the surface roughness according to DIN EN ISO 4287
• Average roughness Ra
• Mean total roughness Rtm*
• Total roughness Rt
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
A
B
C
D
E
F
SBB mbH, Potsdam
6
µm
4
3
2
1
0
A
B
C
D
E
Institute for
Machine Tools
F
Gesamthöhe
des ProfilsR
Rt
Total
Roughness
t
2.0
µm
Mean
Roughness
Rtm
MittlereTotal
Höhe der
Profilelemente Rc
Arithmetischer Mittelwert
Average
Roughness
der Profilordinaten
Ra Ra
*Rc according to DIN EN ISO 4287
12
µm
8
6
4
2
0
A
B
Technical
University
Berlin
C
D
E
F
Summary
Stand-alone technologies: Dry ice blasting and laser processing are ecological alternatives of
conventional cleaning and de-coating methods. Both technologies are not suitable to remove highly
adhering, hard or thick contaminants / coatings.
Laser assisted dry ice blasting: Improvement of the removal rate of up to 500 % compared with dry
ice blasting.
Final laser cleaning after preliminary dry ice blasting: Improvement of the removal rate between 28 %
and 49 % compared with dry ice blasting.
Outlook
Combination of preliminary laser assisted dry ice blasting and final laser cleaning and optimization of
parameters
Automation: Thermal camera to control the laser power according to the surface temperature and
image recognition to identify residues for a selective final laser cleaning process
Economical evaluation tool to determine the break-even point for specific cleaning / de-coating tasks
SBB mbH, Potsdam
Institute for
Machine Tools
Technical
University
Berlin

Laser Assisted Dry Ice Blasting - SBB Sonderabfallgesellschaft

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