The Importance of Visual Inspection of Laser Weld Surfaces

The Importance of Visual Inspection of Laser Weld Surfaces in HDDs

Laser Welding Technology in Helium Sealed HDDs

Helium Sealed HDDs are an innovative technology developed to achieve high-density, energy-efficient, and long-lasting data storage. In these HDDs, helium gas is sealed inside, and the exterior must be completely sealed to prevent any gas leakage. High-precision laser welding is employed to achieve this.

Laser welding allows for precise and airtight welding by concentrating energy in a very narrow area. This ensures that the helium gas remains sealed for an extended period, enhancing the reliability and durability of the HDD.

The Role of Visual Inspection in Ensuring Laser Weld Surface Quality

The surface quality of laser welds is crucial because it directly affects the performance and lifespan of the HDD. If welding defects remain in the product, they can cause serious problems during use. The following types of defects may occur, and visual inspection is essential for detecting and eliminating them.

1. Cracks

   • Fine cracks can develop in the weld area. These cracks may progress into fractures during use, potentially compromising the product's strength and longevity.

2. Pits

   • Gas generated during welding can solidify in the weld pool, leaving small holes (pits) on the surface. These pits can detract from the product's appearance and may also impact its durability.
   • Foresight Stereo Observations: In the Before images taken with existing lighting, pits may be difficult to see, but by using Foresight Stereo and capturing After images with 3D Surface imaging, the pits become clearly visible.

3. Overwelding/Underwelding
   • If the welding depth is uneven, it can lead to overwelding or underwelding. Overwelding results in unnecessary material usage, causing an increase in weight and potential deformation of the product, while underwelding can reduce joint strength, leading to product malfunction.
   • Foresight Stereo Observations: In Before images taken with existing lighting, overwelding or underwelding may be hard to detect, but Foresight Stereo enables clear visualization of welding inconsistencies in After images with 3D Surface imaging.

4. Spatter
   • Spatter refers to the small particles of molten metal that scatter during welding. These particles can adhere to the surface around the weld, reducing the quality of the finish. Spatter not only poses aesthetic issues but can also affect the functionality of the product, making appropriate treatment and inspection necessary.
   • Foresight Stereo Observations: In Before images taken with existing lighting, spatter particles may be overlooked, but using Foresight Stereo for After images with 3D Surface imaging clearly reveals their presence.

The Role of Visual Inspection

TOMOMI RESEARCH's AI-powered visual inspection systems, such as "FORESIGHT STEREO" and "E3 ENGINE," play a critical role in detecting these defects with high precision, ensuring product quality.

• Automated Defect Detection

  • High-resolution scanning automatically detects micro-cracks, pits, overwelding/underwelding, and spatter, minimizing human error and significantly improving inspection accuracy and efficiency.

• Inspection of Glossy Surfaces

  • The exterior of Helium Sealed HDDs requires a smooth and glossy finish. TOMOMI RESEARCH's lighting technology ensures that even the slightest defects on glossy surfaces, which are often missed by traditional inspection methods, are reliably detected.

• Real-Time Inspection and Quality Assurance

  • Visual inspection is conducted in real-time on the production line, with immediate feedback provided if defects are detected. This process prevents defective products from being produced, ensuring the reliability of the product. Additionally, inspection data is stored in the cloud, facilitating quality control and traceability.

Conclusion

In the manufacturing of Helium Sealed HDDs, laser welding is a critical technology for achieving high airtightness and precision, but visual inspection is indispensable for ensuring its quality. TOMOMI RESEARCH guarantees high product quality through its AI and advanced lighting technology-driven visual inspection systems. Please review the Before and After image comparisons to see how Foresight Stereo clearly detects welding defects. This allows us to continue providing products that customers can trust.