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.
The laser technology is key to the development of the e-mobility. We demonstrate how an optimal laser beam shaping enables high speed and high quality copper welding for the battery cells manufacturing.
The beam shaping parameters are explored and optimized and the optical performance is assessed. The process window is described for four sets of shape parameters as well as the comparison with an unshaped beam. The quality in each cases for different speed and average power is discussed. An optimal process at 6m/min and 8kW is obtained. At last, different welding configuration, such as transparent welding, are described.
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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