Novel multi focus optic approach for gas-tight welding of aluminum alloys in e-mobility

Optical tools for laser machining along six orders of magnitude

“…Sustaining this progress mandates the integration of highly brilliant, high-power laser sources, coupled with advanced beam shaping solutions. 12,13 Tailoring the laser beam's shape to specific process requirements enables precise control of heat input, mitigating adverse effects like thermal distortion, stress, and undesirable metallurgical transformations. This customization enhances penetration depth, minimizes spatter, and boosts overall process efficiency.…”

“…This customization enhances penetration depth, minimizes spatter, and boosts overall process efficiency. 12,13 Fiber-based beam shaping technologies, such as 2-in-1 fibers (TruDisk platform: BrightLine Weld and TruFiber platform: BrightLine Mode) or beam shaping elements within processing optics, facilitate the creation of tailored intensity distributions (e.g., multiple spots 9,12,13 or ring shapes 14 ). It is noteworthy that these beam shaping solutions impose additional criteria on the F-Theta lens design such as enhancing the focusing NA and demanding minimal distortion.…”

“…Gas-tight welding of aluminum alloys performed on a TruLaser Cell 3000 equipped with a TruDisk 8001 laser source operating at 8kW. 12,13 Stabilization of the keyhole is achieved by distributing four focal points arranged in a tailored quadratic configuration, resulting in the enlargement of the keyhole and reduction in its fluctuation (a). Pores, evident as white dots in the X-ray image resulting from single-beam welding using the 2-in-1 fiber technology BrightLine Weld (b).…”

“…3), we explore the versatility and scalability of scanning optics for remote welding applications. 12 The required F-Theta lenses focus cw radiation up to 20 kW in average power. The processing head can be equipped with beam shaping capabilities, such as multiple spots, 9,12,13 ring distributions, 14 and 2-in-1 fibers 15 to satisfy the versatility of applications.…”

“…12 The required F-Theta lenses focus cw radiation up to 20 kW in average power. The processing head can be equipped with beam shaping capabilities, such as multiple spots, 9,12,13 ring distributions, 14 and 2-in-1 fibers 15 to satisfy the versatility of applications. Finally, we discuss optical solutions for processing in the meter range for applications like thermal annealing 16 or laser-induced forward transfer (Sec.…”