Laser Ablation FAQ
Here, you'll find answers to common questions about laser ablation.
Operational Capabilities and Performance
How does the laser rust removal process work?
Laser rust removal is a laser cleaning process that utilizes laser ablation. Laser ablation is achieved by using a laser cleaning unit with a high peak power and short pulse or continuous pulse frequencies; our system is a fiber laser. The laser beam is focused onto the rust and heats it to the evaporation point. Once the rust converts into gas, it evaporates and leaves behind a clean finish that conquers the problems rust once gave the part.
What types of materials can the laser effectively remove rust from?
The layer of rust is removed quickly due to intense energy, and the metal is unharmed. Laser beams can remove rust, i.e., oxides, sulfides, and hydroxides, and different layers, such as paint and oil, Lead coating with a HEPA vacuum incorporated into the system.
What is the power output of the laser?
Currently we have three system available; a Pulse Wave (PW) 100W 110V backpack laser, designed for rope access technicians, the second is a 2000W 220V Continuous Wave (CW) and a PW 1000w 220v unit. Both larger units have 30m umbilical cords.
Are there specific safety precautions or guidelines for using the laser?
Yes, see attached a copy of the Acuren Laser safety manual and the Acuren Laser safety program, each company must have an LSO (laser safety officer) to own or operate a laser system, much like a RSO for radiography. My certification is attached.
Does the laser have adjustable settings for different rust thicknesses or material types?
Yes, we can be as delicate as to remove coating from cardboard and not affect the cardboard, to creating an anchor profile on steel suitable for coating application, currently AMPP is build new standards to be released in 2024 for laser ablation for industrial coating application without the use of abrasive blasting, I am on the AMPP committee to support the development of these standards.
What is the range or working distance of the laser for effective rust removal?
We have two focal lenses, one is 300mm, 500mm and the other is 750mm, depending on the project this would be selected at the planning stages. This is from the head to the substrate measurement for optical energy and efficiency.
Can the laser be used on delicate or heat-sensitive materials without causing damage?
The pulse system is designed for delicate materials which is the 100W 110V system, we also have been working with the manufacturer to developed new software so that the 2000W 220V continuous system can be manipulated to perform like a low wattage pulse with the kick of the high wattage continuous system.
What is the beam diameter and spot size of the laser, and how does it impact precision in rust removal?
This system is very precise, spot size is from 10 microns to 50 microns, beam size we can go from a 1mm to a 300mm with the 2000W unit.
Can the laser remove rust in hard-to-reach or intricate areas, and if so, what adaptations or accessories are available for such tasks?
If you can hit the hard-to-reach areas with the focal beam, then it will remove the corrosion and contaminants. This week we have done tests on a reactor screen for a client and seen fantastic results in hard-to-reach areas, basically it is line of sight.
Can the laser be used for selective rust removal without affecting the surrounding areas or coatings?
Yes, due the precision, but it is case by case as the end user must be skilled and highly trained.
Does the temperature affect the appliance or the rust removal?
Again, case by case, I would always recommend a test prior to commitment.
Can the laser be used in a wet environment?
The beam can be used on wet surfaces but the unit is high voltage electricity so it must be kept dry for obvious reasons.
What materials can lasers remove?
Lasers are excellent options for removing coatings, paint, corrosion, film, scale, thin layers of dust and debris. In cases where there are large deposits of scale or debris mechanical methods may need to be used in addition to the laser.
Safety, Compliance, and Maintenance
What is your safety and hazard awareness plan?
We have a robust laser safety program with a designated Laser Safety Officer (LSO), work procedures and training for technicians.
What safety features are integrated into the laser system to prevent accidents or misuse?
Double action activation switch on head, 3 stage preparation on the unit prior to activation at the head, safety stop button on the unit panel, interlock switch on the unit cabinet to access the laser source. Focal range of 300mm to 750mm means the laser does not have much power outside the focal range.
What distance from the laser is protective eyewear required?
7 meters unprotected, but we use laser absorption barriers in the work location to reduce this barrier size.
Does the laser generate any harmful by-products during the rust removal process?
Depending on the substrate being cleaned it can. We use a HEPA vacuum and an 2000cfm extraction fan much like for welding to capture most of the fumes. For toxic coatings such as lead project and site-specific protocols need to be followed up to using supplied air.
Are there any regulatory or compliance requirements associated with the use of the laser system?
Yes, we follow the ANSI Z136.1 standard for safe use of class 4 laser systems.
Does the laser system integrate any automation features for enhanced efficiency and ease of use?
Currently the laser has a focal range of 300mm to 500mm which limits the range at which the laser beam can cause harm. Certain systems stop radiating laser beams when they are out of focal range.
Are there consumables or disposable parts in the laser system, and what is the replacement frequency and cost?
Consumables are minimum, outer lenses are ~$11 each and may need to be replaced every few hours of operation. Focal lenses are $300 each, depending on hours of use and application depends on the consumables, very project specific.
What safety certifications does the laser system have, and does it comply with industry standards?
Yes, ours is the only one that has the EN60825-1 laser source certification paired with the SPE1000, other suppliers will say they are certified but only to the FDA not the EN60825-1 or SPE 1000.
Is there a minimum or maximum temperature range for effective rust removal with the laser?
Range is -30 degrees Celsius to +40 degrees Celsius.
Does the laser produce any noise or vibration during operation that might impact the working environment?
Yes, it produces some noise <85Db. Single hearing protection is more than adequate. The Hepa Vac generates more noise than the laser.
Does the laser system require any specific ventilation or exhaust systems to manage fumes or by-products? (for example we have lead paint here, what does the fumes from the removal pose as far as toxic exposures)
110V HEPA vacuum with the nozzle at the substrate and an 2000cfm extraction fan much like for welding. To ensure there is no air contamination during removal of toxic materials negative air systems could be used and technicians may be required to use supplied air systems such as PAPR powered masks.
What is the expected downtime or cooldown period between consecutive uses of the laser?
Zero, it has a built-in cooler/chiller for hot environments which can also acts as a heater for cold temperatures, the system has a 100% duty cycle unlike a welding unit. There is a warmup period however prior to beginning work of 10 to 20 minutes depending on the ambient temperature.
Is there harmful residue left behind from the laser?
No
How would you manage the hazard/safety zone?
We install laser light absorbing barriers around the work front, and an exclusion area a further 2 meters from the barriers with the required signage.
Compatibility and Integration
Is the laser portable, or is it designed for stationary use?
Both, with the two options of units we can select the correct tool for the job.
Are there any restrictions on using the laser in certain industries or applications?
Consider it like welding, it is hot work with spark potential.
Can the laser be integrated into existing manufacturing or maintenance processes easily?
With the support from the manufacturer in Edmonton I feel this this could be achievable.
Is the laser system compatible with different rust types, such as surface rust, pitting rust, or deep rust layers?
Yes, with the software being variable we can change the settings to achieve most requirements. We just carried out testing on HEP (high energy piping, with thick scale, this can have varied success and would recommend testing prior to commitment).
What is the expected lifespan of the laser, and is there a warranty or support provided?
Yes, 100,000 hours for the laser source, manufacturer give two years parts warranty, full technical support.
Can the laser be used for other applications besides rust removal?
Yes, because it is a non-contact solution it can be use on steel, industrial coatings, high build epoxies, galvanising, wood, rubber mold, mold, graffiti, lead abatement, powder coating, liquid nitride, anodizing etc. Polyeurethane coatings and other very thick coatings can be removed but may not be the most time efficient compared to media blasting.
Does the laser system have built-in diagnostics or monitoring features for performance analysis?
To some degree yes, we can monitor run times, operating temperatures, and trouble shoot error codes, heat monitoring, laser output performance.
Can the laser remove rust from painted surfaces without damaging the paint layer?
The laser will remove whatever it touches. However, the focal area can be as small as 1mm for precision targeting. Therefore, it should be possible to target areas of rust without impacting the adjacent coatings.
What is the energy efficiency of the laser, and are there any considerations for sustainable operation?
We have run the unit with an 8000W generator @ 80% efficiency.
What is the power source for the laser, and does it have any specific requirements?
Yes, either 110V for the 100W or 220V for the 2000W.
Is the laser system compatible with different power supplies or voltages?
No, either 110V for the 100W or 220V for the 2000W, single phase 30A.
User Training and Experience
Is training available for users to operate the laser safely and efficiently?
Yes, as the corporate LSO I do the training, I can also delegate a DLSO (deputy laser safety officer) under the ANSI Z136.1 regulations/standards.
Are there user reviews or case studies available to demonstrate the effectiveness of the laser for rust removal?
We have done our own in-house testing and can provide results.
Can the laser be used for delicate or heat-sensitive materials without causing damage?
Yes, but testing prior is recommended.
What is the expected downtime or cooldown period between consecutive uses of the laser?
Zero, Lasers have built in cooling system and can run continuously with no issues.
Does the laser system come with a user manual or documentation for reference?
Yes.
Can the laser be used on delicate or heat-sensitive materials without causing damage?
Yes, but testing prior is recommended.
Is technical support available, and what is the response time in case of issues or questions?
Yes, the manufacturer in Edmonton is offers top class support in both technical issues and support to the end users.
What is the expected downtime or cooldown period between consecutive uses of the laser?
Zero, I know a company that runs there’s 13 hours per day continuously with no issues.
Can the laser be used for delicate or heat-sensitive materials without causing damage?
Yes, but testing prior is recommended.