The development of LBW processes is driven by more complex laser-based welding processes made possible with the development of lasers of higher available power. Nevertheless, most laser-heads are based on refractive optics, limiting the capability to fully use this power. Multi-Plane Light Conversion (MPLC) is a fully reflective technology enabling complex beam shaping through a succession of phase plates. A MPLC-based laser head has been developed providing an annular shape. It presents a less than a 1mm focus shift. LBW as well as HLAW of steal up to 16kW is demonstrated with improved butt-joint configuration gap welds.
Multi-kilowatt Laser Beam Welding (LBW) processes must take up three challenges to keep improving its performance: handling high power, shaping the output beam and reducing focus shift. This will lead to a higher quality and speed as well as the capability to weld thicker parts.
We describe here a beam shaper compatible with industry standard equipment (collimation and focusing modules, arm robot and laser) handling up to 16kW average power delivering a mm-wide annular shape and reducing the focus shift. The LBW processes improvements on different materials are described.
Multi-kilowatt Laser Beam Welding processes are facing new challenges: reducing the final parts weight and improving reliability to decrease the amount of discarded parts. Appropriate beam shaping enables those improvements by decreasing the process defects and by allowing welding of new types of materials and of thinner parts.
We describe here the design and the process test results of a fully reflective beam shaper laser head compatible with high-power lasers demands integrated on a robot. The high efficiency cooling permitted by a reflective design reduces focus shift. A mm-wide annular shape onto the processed part enables melt pool size control.
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