Laser no. 7 is 1000 watts!!
 -  New 6 axis robot!!

Carrs’ latest push into the technical unknown involves a large Trumpf CW Nd yag laser. It welds too fast to be hand operated and suits high precision production welding. 

The Trumpf 1006D is a big laser system and delivers a 1000 watts average power at the work-piece. This can penetrate 3 mm stainless steel adequately leaving a neat keyhole weld. The robot works to 0.1 mm accuracy and repeatability, so the manual aspect of the laser welding is removed, thus ensuring the angle of attack and the distance from the work piece to the laser head is kept constant. The combination of the repeatable welding parameters and the repeatable physical location gives Carr’s a set up that is accepted across many quality conscious industries like, medical, automotive and aerospace. The Continuous Wave (or CW) characteristic of this laser gives the machine the ability to open the keyhole weld and then push a neat “nail” style weld through the joint. The ability to weld at such heat densities allows Carr’s to weld components that could only be electron beam welded in the past. A 21st century answer to EB welding, with the repeatability and accuracy, without the cost.

Welding Porosity

Castings, whether gravity fed, or low pressure die-cast, can come up with defects sometimes and it is quite often that, these defects do not arise until the component is finished. Carr’s weld casting defects in aluminium, cast iron and stainless alloys, from engine blocks to cast iron tools for die casters. Large SG iron blocks to LM24 automotive engines, (as pictured) are all welded, with no distortion.

Application Story.
- Sheet metal spot welding.

These precision made front panel assemblies are part of a batch that Carr’s welded together using their Yag lasers. A simple spot weld around 0.8 mm every 20 mm leaves a sturdy structure and no distortion. Unlike resistance welding, 30 small spots can be done, neatly and quickly.

Quality is King

Carr’s have taken the quality gauntlet and pushed it further to achieve the highly recognised UKAS standard of ISO9001. This covers all our work here at Carr’s from aerospace components to mould cavity or casting repairs.

Welding guns at Carr’s

Carr’s have perfected the art of welding through the side of a barrel to weld up corrosion on the inside, for the Gunsmiths to machine flat again. This technique involves laser welding a well positioned hole drilled from the outside to coincide with the rust spot on the inside. Welding materials can be matched to the barrel to give good re-bluing properties. Another first for Carr’s!!!

Welding copper alloys

Clamcleats Ltd. in Welwyn Garden City mould their own product and had a cracked cavity, which happened to be a 30 year old tool. The aluminium bronze was around 2mm thick at the crack site, and so after annealing, Carr’s laser welded the crack from both sides. No data for the shape of the cavity existed, so the weld was hand finished to size. The tool is running again now!