Naval Undersea Warfare Center (NUWC) Keyport PERFORMANCE SPECIFICATION

COLD WIRE-FEED LASER PROCESSING HEADPESK 6676Rev - (June 23, 2008)

Prepared By:NAVAL UNDERSEA WARFARE CENTERDIVISION KEYPORT

TABLE OF CONTENTS



1.0 SCOPE 31.1 Purpose 31.2 Intended Use 31.3 General Description 32.0 APPLICABLE DOCUMENTS 33.0 REQUIREMENTS 33.1 Operating Environment 33.2 Cable Receiver Requirements 43.3 Optics Geometry and Beam Shape & Size Requirements 43.4 Camera System Requirements 53.5 Visible Laser Optics Requirements 53.6 Software/User Manual Requirements 53.7 Spares 54.0 QUALITY ASSURANCE 54.1 Verification Test 54.2 Final Acceptance 54.3 Warranty 54.4 Delivery Schedule 5



Revision Changes:

1.0 SCOPE1.1 Purpose: The purpose of this document is to provide performance specifications for the competitive procurement of a Cold Wire-Feed Laser Processing Head for use in laser cladding operations. It is the intent of this procurement to use commercial off the shelf (COTS) products that have already being designed and used in industrial environments.

1.2 Intended Use: The Cold Wire-Feed Laser Processing Head will be utilized at the Naval Undersea Warfare Center (Division Keyport) by the Rapid Prototyping and Fabrication Department (Code 32). The equipment shall be used primarily for cold wire-feed cladding for corrosion repair processes.

1.3 General Description: Industrial laser processing operations require a laser processing head to properly focus, shape, monitor, and control the laser beam with respect to the work-piece during the specific operation. This specification outlines the performance requirements of a laser processing head to perform cold wire-feed laser cladding at NUWC-Keyport. The process of cold wire-feed cladding involves a wire metal filler material positioned into a focused laser beam and controlled with automated robotic positioning with respect to the work-piece. Cold wire-feeding specifically refers to the fact that the wire is not provided any electrical current to assist in the melt process. The only heat input is from the industrial laser source which is provided via fiber-optic delivery to the laser processing head. The laser processing head consists of a cable receiver compatible with the specified industrial laser, working laser focusing and bending optics, mounting plate, visible laser focusing and bending optics for set-up. This specification does not cover the automated robotic positioning system, the industrial laser, or the wire-feeding system.

2.0 APPLICABLE DOCUMENTS ANSI Z136.1-1993 American National Standard for the Safe Use of Lasers

3.0 REQUIREMENTSThe Cold Wire-Feed Laser Processing Head shall meet or exceed the following requirements:

3.1 Operating Environment:The system will be used in an industrial environment at Keyport, WA. Typical operation will be for short clads of less than 5 minutes in duration. If needed it is acceptable for the vendor to integrate water cooling for the optics to handle the heat dissipation, however it is not a requirement.

3.2 Cable Receiver Requirements:

3.2.1 Compatibility: The cable receiver shall be compatible with an IPG YLR-5000 Continuous Wave (CW) 4kW Fiber laser with fiber-optic delivery. The IPG laser operates at a wavelength of 1070-1080nm. The cable receiver shall be compatible with a 600micron fiber-optic cable with QBH style connector. The fiber-optic laser-beam half-angle divergence is approximately 0.1rad. The optics shall provide a fixed focus laser standoff in accordance with the geometry specifications outlined in section 3.3.

3.3 Optics Geometry and Beam Shape & Size Requirements:

3.3.1 Geometry: The optics shall provide the working focused spot at 90 degrees from the incoming fiber-optic cable. The overall maximum envelope dimensions of the unit are given in Figure 1. The cold wire feed processing head shall fit within a 17.5 inch (444 mm) diameter cylinder when the spot size is at 4mm in the divergent zone of the beam. Note the 15 degree off center angle of the optics when positioned inside the cylinder. FIGURE 1: LASER PROCESSING HEAD ENVELOPE

3.3.2 Dimensional Data: The vendor shall supply NUWC-Keyport with either a dimensional drawing of the entire cold wire feed processing assembly or part piece drawings of each item with the solicitation. Drawings shall identify interface points (mechanical, fiber, etc). In addition, the vendor can supply a CAD model, but it is not a requirement.

3.3.3 Optical Parameters: The optic components shall consist of approximately 50mm diameter optics with a focal length of approximately 150mm. Working spot size is approximately 4mm in the divergent region of the beam.

3.4 Visible Laser Optics Requirements: The Cold Wire-Feed Laser Processing Head shall permit the transmission of the visible wavelength laser pointer (640-680nm wavelength) for positioning setup. 3.5 (Option) Camera System Requirements: As an option the vendor shall provide a price for the inclusion on the Cold Wire-Feed Laser Processing Head a camera system that allows the operator to view the working area in-line with the optical path. The camera system shall include a cross-hair generator for positioning the working focal spot with respect to the work-piece. A price for this optional system is preferred, however it is acceptable for the vendor to no-bid this item. If selected, the camera system shall come fully integrated on the cold wire feed processing head with applicable external viewing system included.

3.6 Software/User Manual Requirements: All necessary software shall be supplied to operate the system. The software shall operate on MS Windows 2000 OS or MS Windows XP OS on a PC. All necessary maintenance and operational manuals shall be provided.

3.7 Spares: The vendor shall quote the following spare parts as an option: Quantity 20 spare cover slides

4.0 Quality Assurance The Cold Wire-feed Laser Processing Head equipment shall meet the following quality assurance requirements:

4.1 Installation & Verification Test: A Verification Test shall be performed by NUWC technical representatives, which shall include the following:

4.1.1 Installation: NUWC-Keyport personal will install the Cold Wire Feed Processing Head on NUWC-Keyports system (i.e. laser, fiber, chiller).

4.1.2 Dimensional Envelope: NUWC-Keyport personal will verify optics fit within the dimensional envelope as shown in Figure 1.

4.1.3 (Option) Camera: The camera system shall be evaluated for clear picture and stable and accurate cross-hair generator.

4.2 Final Acceptance: A NUWC representative shall take final acceptance of the equipment after installation and verification testing has been completed. Final acceptance shall not be made until the NUWC representative verifies that all testing performed in Section 4.1 meets all performance requirements in this specification.

4.3 Warranty: The Cold Wire-Feed Laser Processing Head shall have a minimum of a 1 year warranty.

4.4 Delivery Schedule: All components shall be delivered to NUWC-Keyport no later than 6 weeks from contract award.