1、Activating / Surface preparation
Surfaces have to be clean and free from grease or other depositions for adhesions, paintings or even welding preparations. Only well prepared surfaces fulfil the requirements for a good and permanent adhesion.
In focus are:
• To achieve high adhesive forces by removal of disturbing contaminations and modification of surfaces
• Automation, good process control and simple integration into production processes
• Low costs
• High environmental compatibility, no VOC or other auxiliary materials
• No secondary pollution and easy to collect waste
That is the reason why laser surface treatment is increasingly applied in many different industries. In using pulsed Usiland laser surfaces of various materials can be cleaned and roughened gently if required, to achieve optimal conditions for ongoing processes. With only a few laser pulses dirt, grease and release agent residues can be removed as well as oxide layers and corrosions.
Following tasks can be fulfilled with the Usiland laser process:
• Painting-preparation of plastic surfaces or metals on aircrafts, helicopters, automobiles or attachment parts
• Gluing-preparation of metals or plastic surfaces in aviation, automobile or medical industry
• Preparation of welding seams or pretreatment of bonding surfaces prior to welding process
Preparation for paintings on aircraft surfaces made of composites (activation)
Even sensitive materials for example composite materials can be treated gently. The laser evaporates the disturbing release agents and removes contaminations. In this process he can roughen the surface selectively, without damaging the fibres. Thus an optimal area for further processing is created.
Preparation of welding seams and joints at automobile parts, pipes or other metallic structures
To achieve a good and stable welding seam the weld joints must be cleaned. In many cases a removal of oxide layers is required. The Usiland laser is able to achieve this in automated applications that can be directly upstream of the welding process.
Preparation for gluing of automobile windows
Today automobile windows are glued in most cases. It is important to create a clean and adhesive area. The laser treated surface is perfectly prepared for the ongoing gluing process without any reworks.
Surface preparation of helicopter rotor blades
To receive a quick result and clean surface characteristics for ongoing paintings, the surface of rotor blades will be treated gently by our laser process. The treatment is the first working step after the curing process. After that the coating system is applied.
2、De-painting / De-coating
Whether repair or production, often you have the task: PAINT OFF!
In some cases you have an incorrect or a bad painting on parts and then you have to de-paint it, WITHOUT DAMAGING THE PART.
Perhaps the part has to stay free of paint in certain areas. For this very time-consuming masking method is needed, for being free of paint during the production process.
We deliver the solution!
On the one hand organic protective layers can be removed completely (down to the substrate). On the other hand they can be removed selectively (up to the primer). With our pulsed lasers it is possible to remove material layer by layer, even on smallest areas. The part which is to be treated will not be damaged. The masking for local de-paintings is no longer needed due to the precision of the laser process.
In many applications of different industries the laser is already used for de-painting or de-coating tasks as for example:
• De-painting of cooling tubes and brake lines
• Stripping of flat cables
• De-coating of Bond pads
• De-painting of rim calottes
• De-painting of composite materials
• De-coating of visible areas
De-painting of cooling tubes and brake lines
For the subsequent production process, the coating at the end of tubes has to be removed without any residues. Brushes or peeling processes quickly reach their limits at precision, wear and damaging of the part itself. The Usiland process is able to remove different organic layers completely without any problems. Metallic protective coatings will not be damaged.
Stripping of flat cables
Because of its compact building method with minimum employment of material and fully automatic manufacturing, flat cables (FFC, exFC, FLC) are applied in many industries. For the attachment of plug connections, active and passive components it is important to remove the isolation in certain areas. With USILAND laser it is possible to free these contact points, even on miniature flat cables! Due to the laser treatment a precise positioning and a clean de-coating takes place. The connection can be made without mechanical reworks. The flat cable itself will not be damaged.
De-coating of Bond pads
To protect electronic components to aggressive atmospheres, circuit boards are coated with a parylene or other protective paints for example. The problem is that even contact points – like bond pads – are coated. A masking of these certain areas is very difficult and has an extremely effort. With just less laser pulses, the coating will be removed in this minimal area. The metallic surface is clean and can directly be adhered in the following step.
De-painting of rim calottes
In the field of rim production or rim painting it is necessary that the calotte is clean and stays from paint. The mostly used method for keeping this area free of paint is the so called masking. Balls or plugs are put inside the holes to protect them from the coating. Due to the USILAND method of de-painting rim calottes there is no need to cover the holes any longer! The masking and de-masking process is eliminated and the calotte is de-painted without any residues. Even the surrounded areas where the paint should stay will not be affected. The change from paint free to paint offers a much better quality than using the ordinary masking method.
De-painting of composite materials
In using chemical stripping or mechanical abrasive blasting processes you always have a huge amount of hazardous waste which is very expensive to dispose. The Usiland process, with its especially developed Usiland-diagnostics, offers a totally new user friendly and environmentally friendly alternative for the automated removal of paint systems from composite surfaces, regardless of the colour and structure. With the Airbus, Boeing, Eurocopter and other approved Usiland process, layers can be removed for the first time either selectively – just to the primer - or completely – down to the substrate - without material damaging.
3、Cleaning / De-greasing
The USILAND method for cleaning and de-greasing of various surfaces replaces chemical or mechanical processes in many industries.
Wear-free cleaning of moulds and tools is possible with the USILAND laser method. Even very restructured or curved surfaces will be cleaned fast, gentle and without any additives or auxiliaries.
In following applications the USILAND method is used for cleaning successfully:
• moulds, e.g. vulcanization, casting or injection moulds
• welding seams, cleaning of joint areas for welding or welding seams for ongoing paitings
• baking plates in the food industry
• moulds or tools for the processing of composite materials
Cleaning of moulds in the automotive industry
Within the automobile industry, high demands on optics and product quality of the interior, require high-quality casting tools for the production of door panel leatherette, instrument panels and other surfaces for car interior. To receive a constant product quality, it is necessary to have a regular cleaning. In the mould cleaning of small and huge areas – no matter whether 2D or 3D geometries – the laser removes the parts residue-free, which don’t belong to the tool or mould. In addition to that the laser is able to work quickly and completely. The mould cleaning can also be used in hot moulds.
Cleaning of welding seams
The production of high quality welding seams needs a clean preparation and an optimal protection for a long lasting corrosion resistance. At that point the USILAND process helps in the matter of preparation by cleaning of weldings seams from oil and grease or the removal of oxide layers. After the welding process the laser procedure can be used for the cleaning of those welding seams to guarantee a long lasting corrosion resistance.
Cleaning of baking plates in the food industry
During the baking process, residues remain on the plates which have to be removed to guarantee a continuous production process. Without this cleaning the bakery products will stick in the mould and the whole baking machine has to be stopped. Various moulds can be cleaned with pulsed USILAND lasers, to receive a clean surface without residues and a constant baking quality. Due to the high flexibility of these systems it is possible to perform a cleaning inside and outside the baking line. Thus a continuous cleaning in the hot mould in flow and a cleaning in defined time intervals is possible.
Cleaning of moulds or tools for the processing of composite materials
Not only e.g. for vulcanization moulds, as well as for moulds which are used for the treatment of composite materials the pulsed USILAND laser systems can be used to achieve a clean surface. Completely cured composite materials can only be cut with special tools. Diamond-staffed cutters are used for this task. Over the time parts of composite materials are fixed between the diamonds. They have to be removed for a constant cutting quality. With the help of the pulsed USILAND lasers it is possible to clean the tools completely without damaging the diamonds.
4、Selective laser material processing
In many cases it is not only necessary to clean or de-coat surfaces, moreover the substrate itself has to be changed or removed. For this task the Usiland laser systems offer special characteristics to change or remove this surface areas locally (that means only on the surface) as well as in the depth of the material.
Changed laser configurations and parameters will be applied differently for cleaning or de-painting tasks. Depending on the material we can choose the characteristics of the laser, so that we specifically
• remove very thin layers of the surface, only little µm
• structuring surfaces to achieve an exact harshness
• change the surface conditions, e.g. to smooth rough surfaces
• Basically we distinguish between the treatments of metallic material and composite material.