Laser Beam Welding (LBW) finds widespread use in industries like naval and automotive. To meet the demands of complex welding processes, higher power lasers have been developed. However, conventional refractive optics limit power utilization, affecting robustness. Multi-Plane Light Conversion (MPLC), a fully reflective technology, enables complex beam shaping with 16kW lasers. A MPLC-based laser head with an 800µm annular shape at 1µm wavelength has been developed. LBW of 304L stainless steel (6mm thick) at 7kW and HLAW of steel (16kW) with 23mm penetration depth are successfully demonstrated. MPLC's extended depth of field improves welding efficacy, showcasing its potential in advancing laser welding applications.
Laser welding is crucial for manufacturing e-mobility components, particularly copper and aluminum parts. However, their high reflectivity and thermal conductivity present challenges, leading to inadequate penetration and weaker welds. Beam shaping offers a promising solution by modifying the laser beam's intensity distribution. In this study, we demonstrate successful welding of aluminum battery cases, copper busbars, and hairpins using Multi-Plane Light Conversion for beam shaping. Results show improved weld quality, reduced defects, and enhanced mechanical properties. The technique provides a higher depth of field and an extra degree of freedom for optimizing weld quality, promising efficient and reliable manufacturing of e-mobility components.
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.
Access to the requested content is limited to institutions that have purchased or subscribe to SPIE eBooks.
You are receiving this notice because your organization may not have SPIE eBooks access.*
*Shibboleth/Open Athens users─please
sign in
to access your institution's subscriptions.
To obtain this item, you may purchase the complete book in print or electronic format on
SPIE.org.
INSTITUTIONAL Select your institution to access the SPIE Digital Library.
PERSONAL Sign in with your SPIE account to access your personal subscriptions or to use specific features such as save to my library, sign up for alerts, save searches, etc.