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TIG Welding - Cold Weather Military Canteen
Shortly after the 911 tragedy, ProcessLogic was contracted to produce the military's first stainless steel sanitary cold weather canteen. Our dedicated staff worked 7 days a week, 2 shifts a day to produce 5000+ 'neck to lid' assemblies and 'lid to deep drawn' can assemblies.
The 'neck to lid' weld was made with our Automatic Weld Lathe (AWS-6100 System). The 'lid to deep drawn' can weld was made on our Computer Controlled Multi Axis Weld System.
Download the AWS-6100 brochure.
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Plasma Welding - Automotive Sensors
This High volume contract welding job combined 3 different alloys joined together to create a hermetically sealed sensor component for the automotive industry. 2 Plasma welds are made automatically followed by a helium leak test. The materials are Carbon Steel, Stainless Steel
and Inconel.
The Plasma welds were made with a Automatic Welding Lathe System (AWS-6100 System).
Download the AWS-6100 brochure.
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Laser Welding - Solenoid Valves
This high volume contract welding job required a High Quality - Low Cost hermetic seal.
ProcessLogic met the challenge with a Automated Laser welding system. The welds are helium leak checked & selectively pressure checked per the specification. Welds produced with high power pulsed YAG and a precision welding lathe for precise
positioning & rotation.
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Laser Welding - Medical Endoscopes
This precision contract Welding job required a total of 3 Low Distortion, Low Heat Input hermetic seal welds per assembly. The PreAligned Precision Optics required special handling and welding to insure optimum product
performance. ProcessLogic engineers developed the tooling and weld procedures to insure 100% yields. The 3 welds were produced by one of our automated laser cells in our clean room.
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Laser Welding - Aircraft Battery Cases
This contract forming & laser seam welding job required us to shear and form .015 thick - 304 SS battery case and produce a full penetration Class 1 laser seam weld edge to edge
Our engineers chose a Weldlogic U.P.S. - 12" ultra precision seam welder to precisely position the case and produce the high quality pulsed YAG Laser Welds.
View
the U.P.S. -12 seam weld system photo.
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Laser Welding – Amplifier Devices
These High Reliability devices are made from 6061 Aluminum and require a Low Heat Hermetic Seal of the lid to case weld. This is accomplished with a Controlled Vacuum bake out, X-Y Motion Controlled Laser weld in an oxygen and moisture controlled inert glove box. All sealed
devices are helium bombed, leak tested and certified to Mil-Spec 883 and
Mil- Spec 202.
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TIG Welding- Surgical Spoons
This contract welding application required a precisely aligned 17-4 S.S. spoon with the 304-S.S. handle to produce a high strength circumferential weld.
Our process specialist designed tooling and selected the AWS-150/6100 Advanced Welding System to produce these high reliability welds economically.
Download the brochure for the AWS-150/6100 Lathe
system
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Laser Welding-Vee Seals
This precision contract welding job required our engineers to select a process that would produce a full penetration weld with almost no part distortion. The VEE Seal material is inconel 718 and the ring material thickness is .006. The Pulsed yag laser process was chosen to produce
the high quality full penetration welds required.
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Laser, Plasma, TIG - Seam Welds
These tubes are sheered and rolled to print and longitudinally seam welded with the best weld process to meet your requirements. High quality seam welded tubes are made on all weldable grades of material. Thickness .003 - .187 diameter .250 - 36" length up to 10 ft.
Download the brochure for Precision Longitudinal Seamer
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TIG Welding - Flexible Metal Bellows
This contract welding application required 2 thick to thin hermetic seal welds made on these high purity 316 S.S. flexible metal bellows.
Our Process Specialist designed tooling to precisely position the weld joints for automatic Micro-Tig pulsed Tig process. The welds were made in a high purity chamber and helium leak check certified.
View the weld system selected for this precision welding application by downloading the AWS-6100 brochure .
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TIG Welding - Exotic Specialty Tube Closures
This application required High Current short time duration welds on the hastalloy tube ends. Our engineers chose the micro tig process to produce the hemispherical result required and provided a consistent high quality hermetic seal on the tubes at a rate of 120 parts per hour.
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Laser Welding -- Medical Bone Drill Guide
This High Quality Contract welding contract challenged our Process Engineers to join this 17-4 Stainless Steel Bone Carpentry Tool with Low Heat input and No Distortion.
The ProcessLogic Pulsed Yag Laser joined the 2 piece assembly with excellent strength yet maintained the critical alignment required of the 2 piece bushing.
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Plasma Welding -- Automotive Exhaust Shells
This contract required our engineers to select a High Speed - Low Cost means to shear, roll form and weld the aluminized steel custom exhaust shells.
The Plasma Weld process was chosenfor speed and consistancy and was integrated to a PLC controlled automatic seamer.
View the PLS - Seam Weld System
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Laser Welding - Burst Diaphragm
These are over-pressure relief valves used on the F-16 pilot ejection system. The valve body is 17-4ph stainless steel and the disk is made from 304 L. Consistency in weld penetration is critical so that these valves function correctly every time. ProcessLogic Engineers designed
precision tooling to precisely position the 17-4 disk in place during welding.
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Laser Welding - Medical Implants
These are temporary medical implants. This high volume circumferential weld required us to hermetically seal a magnet inside of two deep drawn pieces that form the housing. Material is 316 -L 0.010" thick. ProcessLogic engineers select the Pulsed Laser process to produce a
smooth, hermetic, distortion free weld.
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Laser Weld - Diaphram Seal
This is an example of a high volume seal weld on the edge of an instrument diaphram. The circumferential laser weld joins two 0.010" thick 17-7 stainless steel bellows hermetically together.
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TIG Welding - Kovar Electronic Enclosure
This is an example of a high value (> $15K) kovar electronics enclosure. All of the critical assembly, tuning and testing has been performed. The last step is to seal the lid on with a hermetic TIG weld. The joint is done with an automated seam welder with weld parameters designed
for minimum heat input.
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Laser Welding - Electronic Enclosures
This application required a vacuum bake out and Hermetic Low Heat Seal Weld to meet the Mil-Spec 883 sealing procedure. Our welding engineers chose the Pulsed Yag laser Welding process combined with one of our 3-axis positioning systems in a high purity weld chamber with vacuum
oven attached. The base material is 6061 to a 4047 cover. The result is a low Heat Hermetically sealed device.
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Plasma Welding - 304 Stainless Steel tubes
This application required our production department to sheer and roll form the .065 thick S.S. materials to form a precise tube diameter of 10.25 " x 34.00 " length. The application required a full penetration X-Ray clear weld. The tubes are used in the aircraft industry.
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Micro TIG Welding - 718 Inconel 2 ply bellows tubes
This application required our Engineering Department to develop techniques to Join .005 " thick inconel 718 sheet metal to form a X-Ray clear 8.50" dia. X 24.00 " long 2 ply tube for post weld forming into a bellows. Our production department used the UPS- 24 Ultra
Precision Seamer and a Weldlogic PA-10/100-STD Micro Tig Power Supply.
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Micro TIG Welding - 304 S.S. Aircraft Battery Base Weld
This contract forming and welding application required a .015" thick standing edge base to be pressed into a .015" thick battery case.
Our engineers chose a 2-axis motion controlled Micro Tig weld to produce the required low heat hermetic seal.
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Laser Welding- Fiber Optic Flexible Cable and Sheath
This Micro Joining application required a very small .020 weld that had to be produced between the flexible hose and the fitting made of 316 S.S.
The .020 sheath tubing had to be welded to the fitting to provide additional protection for the delicate fiber optic cable inside.
Our engineers choose a Laser with a reduced spot size to produce the micro fine laser weld required.
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Laser Welding Medical Devices
This is a precision medical drill guide for performing orthopedic surgery. The material is a 400 series stainless steel ground to a precision flatness with the pins located so that they protrude a measured distance within +/-.001". A minimal amount of heat input was allowed
during laser welding so that the pins and their faying surfaces would not warp. Each pin was welded circularly with a prescribed depth of penetration verified by section, polish and etch analysis on several weld samples.
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Laser welded - TIG Welded Sensors
This precision instrument weld was performed on a device that is subjected to an environment that is both caustic and at high temperature. The main challenge was to be able to get the laser beam in between the two tubular stems and make a good seal. The other side was then welded
to the body using precision micro-TIG. So the result is a hermetic instrument probe using four welds of two different processes, with a 72 hour turn around.
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TIG Welding - Bimetallic Hermetic Connector
This application was very challenging for our welding engineers. The main connector body is machined from beryllium copper and the ceramic connector sleeve is kovar. Since the melting point of these materials is more than 800F different it was a tall order to make a hermetic joint
that measures in the 10E-9 region on our helium leak checker. Also a big factor is the difference in thermal conductivity between the two materials. Another complication is that if too much heat is added to the kovar sleeve then the joint between it and the ceramic pin mounting
will fail. As if that isn't enough, the parts are worth over $700 per assembly prior to welding!! Oh, and they need them right away, say tomorrow?
Using a Weldlogic AWS-150 micro-TIG power supply with a standard welding lathe, the autogeneous weld joint was developed and verified to be hermetic. Sections were made to verify a uniform profile. The parts then underwent an 8000 psi pressure test and another helium leak test
at the customers facility and passed with flying colors. And yes, they were on time.
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Micro Laser Welding - Constant Pressure Orthodontic Devices
This assembly is an example of micro laser welding. The laser weld replaces a brazing operation that was failing because of the high acidity inside of its environment, the human mouth. Used in the orthodontics industry, this spring loaded component is under constant stress cycling.
The weld is applied directly to the interface between the .048" shaft and yoke. No significant flexure is allowed between the two weldments so the chance for cyclic failure is minimized. Also galvanic corrosion is eliminated since both parts are the same alloy.
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TIG Welded/Formed Wire Shapes
There are many applications that call for a round ball on the end of a wire, shaft or tube. This is one that is used for a ball and socket joint for a small dental device. The .031 diameter wire is 304 stainless steel and makes a repeatable .065" +/- .003" sphere when
micro-tig welded correctly. The resulting temper of the material is in the annealed state so there is no work hardening. The area near the base of the ball is therefore not prone to cracking or fatigue failure.
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Laser Welding - A Reliable Supply Chain Link in Repetitive High Value Assemblies
This is an example of some very high value brazed assemblies that need a small amount of laser welding done near the last stage of manufacturing. The two feedthroughs are inserted and then hermetically welded into the much larger flange. The assembly is then helium leak tested
to the E-10 ccHe/sec range then forwarded for further processing.
This processing is done on a monthly basis where Processlogic is a small but very important part of the supply chain. On time delivery every time these parts arrive is as important as getting a consistantly good weld.
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