High-power high-brightness disk lasers for advanced applications

Papastathopoulos, Evangelos; Baumann, Frank; Bocksrocker, Oliver; Gottwald, Tina; Killi, Alexander; Metzger, Bernd; Schad, Sven‐Silvius; Speker, Nicolai; Ryba, Tracey; Zaske, Sebastian

doi:10.1117/12.2578436

Cited by 7 publications

(5 citation statements)

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“…A detailed methodology [1][2][3][4] for controlling welding processes by stabilizing the keyhole incorporates superimposing two laser beams. Made by TRUMPF, this method utilizes the combination of a core beam and a ring fiber beam (referred to as BrightLine Weld), resulting in a stabilizing effect on both the keyhole and the melt pool.…”

Section: Superimposed Laser Beamsmentioning

confidence: 99%

“…Given the high laser power and stringent quality requirements for welding copper hairpins, this process predominantly relies on multi-mode lasers with 2in1-fiber guidance. TRUMPF's BrightLine Weld technology offers distinct advantages over alternative high-power beam shaping technologies [4]: It ensures full utilization of laser power regardless of the split ratio. In addition, the split ratio is adjustable within a versatile range from 0% to 100%.…”

Section: Superimposed Laser Beamsmentioning

confidence: 99%

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Dynamic beam control of fiber lasers drives innovation in laser material processing for the EV industry

Bocksrocker,

Riccio,

Fiechtner

et al. 2024

Fiber Lasers XXI: Technology and Systems

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Advancements in laser material processing, particularly in EV battery production, require innovative solutions. Dynamic beam control of fiber lasers has emerged as a promising technology to meet these needs. This contribution examines the challenges in EV battery production and the solutions provided by these lasers. Through dynamic beam control, fiber guided lasers enable precise and efficient welding of copper and aluminum components. Adjustable beam parameters such as intensity, shape, and size enhance precision, productivity, and material utilization. These capabilities of dynamic beam-controlled lasers drive innovation in manufacturing processes for the EV industry and beyond.

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Section: Superimposed Laser Beamsmentioning

confidence: 99%

Section: Superimposed Laser Beamsmentioning

confidence: 99%

Dynamic beam control of fiber lasers drives innovation in laser material processing for the EV industry

Bocksrocker,

Riccio,

Fiechtner

et al. 2024

Fiber Lasers XXI: Technology and Systems

Self Cite

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“…of a laser beam and hence the temperature gradient. Several different techniques of beam shaping are possible but the most common and industrially viable use diffractive optics [6,7], refractive optics [8,9] or spatial manipulation of fibre delivery optics [10,11]. In all cases, a precisely engineered manipulation of the optical path redistributes the incoming laser beam and modifies its energy distribution in the workpiece.…”

Section: Introductionmentioning

confidence: 99%

Control of meltpool shape in laser welding

Suder,

Chen,

Sierra

et al. 2024

Weld World

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In laser welding, the achievement of high productivity and precision is a relatively easy task; however, it is not always obvious how to achieve sound welds without defects. The localised laser energy promotes narrow meltpools with steep thermal gradients, additionally agitated by the vapour plume, which can potentially lead to many instabilities and defects. In the past years, there have been many techniques demonstrated on how to improve the quality and tolerance of laser welding, such as wobble welding or hybrid processes, but to utilise the full potential of lasers, we need to understand how to tailor the laser energy to meet the process and material requirements. Understanding and controlling the melt flow is one of the most important aspects in laser welding. In this work, the outcome of an extensive research programme focused on the understanding of meltpool dynamics and control of bead shape in laser welding is discussed. The results of instrumented experimentation, supported by computational fluid dynamic modelling, give insight into the fundamental aspects of meltpool formation, flow direction, feedstock melting and the likelihood of defect formation in the material upon laser interaction. The work contributes to a better understanding of the existing processes, as well as the development of a new range of process regimes with higher process stability, improved efficiency and higher productivity than standard laser welding. Several examples including ultra-stable keyhole welding and wobble welding and a highly efficient laser wire melting are demonstrated. In addition, the authors present a new welding process, derived from a new concept of the meltpool flow and shape control by dynamic beam shaping. The new process has proven to have many potential advantages in welding, cladding and repair applications.

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“…Since the concept of the thin disk laser (TDL) was proposed by Giense [1] , there has been much research on TDLs in continuouswave (CW) operation and short pulsed operation [2,3] . The gain of TDLs is very low due to the quasi-three-level gain media and a thickness of around 200 μm.…”

Section: Introductionmentioning

confidence: 99%

Large aperture disk standing-wave unstable resonator with intra-cavity adaptive correction

Yu,

Yi,

et al. 2024

中国光学快报

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An unstable resonator with seven large aperture ceramic disks and intra-cavity adaptive correction is presented. The composite ceramic disks with absorption rings were adopted to suppress amplified spontaneous emission. An intra-cavity aberration non-conjugate correction based on round-trip wavefront and relaxation iteration was applied in the resonator. After tilt and defocus were corrected in turn, an average output power of 4.5 kW was obtained. The corresponding beam quality factor β was 19.5. After tilt, defocus, and high order aberrations were corrected, the average output power was increased to 5.4 kW, and the beam quality factor β was improved to 6.8.

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High-power high-brightness disk lasers for advanced applications

Cited by 7 publications

References 0 publications

Dynamic beam control of fiber lasers drives innovation in laser material processing for the EV industry

Dynamic beam control of fiber lasers drives innovation in laser material processing for the EV industry

Control of meltpool shape in laser welding

Large aperture disk standing-wave unstable resonator with intra-cavity adaptive correction

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