In the present paper we present advances on BrightLine Weld technology addressing following three topics: A) the novel implementation of beam shaping of CW high power laser in the visible wavelength range. Due to the higher absorption in this wavelength range, applications related to welding of copper, copper alloys and gold profit from this modality. We demonstrate thereby the increase of process window in welding of copper with a 3kW laser power at wavelength of 515nm, B) the combination of BrightLine Weld with multi-spot technology for welding of casted aluminum parts. With the presented strategy gas-tight welding of the aluminum alloys for parts like casted power electronics housings, heat exchangers and extrusion profiles is enabled. C) advantages that arise by dynamically changing the split-ratio of the laser power between core and ring during the welding process while utilizing the full available power of the laser. Thereby dynamic beam shaping reduces the process time and increases the quality at the same time. We demonstrate how a fast process like welding of copper hairpin with an NIR high-power laser benefits from this modality.
Ultrashort pulse micromachining has found a rising number of applications in a variety of scientific and industrial fields. In order to address the growing field of applications, target materials and customer requirements, a high degree of pulse parameter flexibility and ease of integration is needed. The newest generation of the TruMicro Series 2000 delivers unique features such as fast tunable pulse duration, MHz- up to GHz-burst modes in combination with flexible Pulse on Demand and elevated average power of 100W for improved productivity scaling. Three available wavelengths (343nm, 515nm, 1030nm), an integrated hollow-core fiber interface, as well as a new advanced ultrashort pulse laser control, all combined into a new one box optomechanical design with identical interfaces and dimensions opens new paths for cutting-edge applications. The improved flexibility enables fast (<800ms) and controlled (without affecting beam pointing or energy stability) tuning of pulse parameters such as pulse duration, pulse energy, pulse frequency, QCW-mode and pulse spacing up to GHz-bursts (patent pending technology). Inter- as well as intra-process parameter switching offers advanced successive parameter sequences for tailored machining. Combined processes are demonstrated that optimize both productivity (ablation rate) and quality (surface roughness, color, gloss etc.) for ablation of various metals, semiconductors and ceramics by choosing suitable timescales for energy deposition. Automated parameter studies are shown to quickly generate quantitative surface quality characteristics and foster in-depth process understanding depending on pulse parameters. Furthermore, the latest benefits for ultrafast processing employing position synchronized output and the integrated hollow-core fiber delivery with TruMicro Series 2000 are demonstrated.
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