This paper describes the development and implementation of laser side seam welding for the production of food and aerosol cans from 0.008″ tinplate. The project was initiated by Stoffel Welding Systems in 1974 and the first “laser bodymakers” went on line in multiple shift operation in 1983. The project required the development of new high speed welding techniques and hardware to overcome fundamental problems of weld instability. The maximum welding speed previously reported before the onset of instability was 22 m/min (866 ins/min). This figure was more than doubled as a result of our development work.
As the project progressed it became apparent that if the process was to succeed in production an ultra-reliable, CO2 laser would be required. Testing of eight different lasers from five different suppliers revealed that there was no commercially available laser with the required performance or reliability.
A new laser was, therefore, designed and built specifically for this application by PRC Corporation. This laser was the first of what are now referred to as “corporate lasers”; that is, lasers built to meet the specific standards and specifications of the end user. Bodymakers incorporating this laser have been operating multiple shift since 1983.