High-power transverse flow CW CO2 laser for material processing applications

A transverse flow transversely excited (TFTE) CW CO₂ with a maximum output power about 15 kW has been developed. This is excited by pulser sustained DC discharge applied between a pair of multi-pins anodes and a common tubular cathode. Though the laser power in convective cooled CO₂ laser scales proportionally with the volumetric gas flow, it did not increase in this laser when the volumetric gas flow was increased by increasing the electrode separation keeping the flow velocity constant. The discharge voltage too remained almost unchanged with increase of the electrode separation. These observations are explained considering the electrical discharge being controlled by ionization instability. Laser materials processing applications often demand programming facilities for laser power modulation. A four-stage cascaded multilevel DC–DC converter-based high-frequency switch mode power supply has been developed to modulate the output power of the laser. Laser was operated up to 15 kW output power in four different modes viz. continuous wave mode, pulse periodic mode, single shot mode and processing velocity-dependent power mode with 1.2 kHz modulation bandwidth. We describe briefly the laser system, the SMPS, and the temporal behavior of laser beam.     

Design considerations and scaling laws for high power convective cooled CW CO2 lasers

Various criteria for designing high power convective cooled CO₂ lasers have been discussed. Considering the saturation intensity, optical damage threshold of the optical resonator components and the small-signal gain, the scaling laws for designing high power CW CO₂ lasers have been established. In transverse flow CO₂ lasers having discharge of square cross-section, the discharge lengthL and its widthW for a specific laser powerP (Watt) and gas flow velocityV (cm/s) can be given byL = 1.4 x 10⁴ p ^1/2 V ^-1 cms andW = 0.04P ^1/2 cms. The optimum transmitivity of the output coupler is found to be almost constant (about 60%), independent of the small signal gain and laser power. In fast axial flow CO₂ lasers the gas flow should be divided into several discharge tubes to maintain the flow velocity within sonic limit. The discharge length in this type of laser does not depend explicitly on the laser power, instead it depends on the input power density in the discharge and the gas flow velocity. Various considerations for ensuring better laser beam quality are also discussed.     

Design and operation characteristics of a high power transverse flow pulser sustained cw CO2 laser

A transverse flow, transverse discharge cw CO₂ laser in which de discharge is sustained by employing high repetition rate high voltage pulses has been developed. Pulser sustained discharge through electrodes of innovative design provided uniform excitation at electrical input power densities more than 10 W/cc. Laser output power more than 2.5 kW was obtained in a laser gas mixture consisting of 0.5 mbar of CO₂, 16 mbar of N₂ and 38.5 mbar of He. Design details and operational characteristics of this laser are presented.     

Numerical modeling of a fast-axial-flow CW–CO2 laser

A four-temperature model has been applied on a fast axial flow, longitudinal discharge CO₂ laser. Using Runge–Kutta method, a set of differential equations of the model is numericaly solved. These equations describe the operation of the laser with certain ratio 1:3:6 of the mixture CO₂:N₂: He and average output power of 550 W.The temporal behaviour of the output power and photon density was obtained. The effects of kinetic temperature, coupled mirror reflectivity, gas flow speed, and cavity loss on the output power were studied.Calculated output power was compared with its measured value taken from experiment and a good agreement was observed.     

Numerical investigation of a fast-axial-flow CW CO2 laser

This paper presents the results of the calculation of the parameters of the active medium of a fast-axial-flow CO₂ laser using numerical methods in the framework of a one-dimensional approximation of the set of continuity equations, Bernoulli equation, equation of gas state, energy equation and multi-temperature rate equations with regard to diffusion for the gas flow in the cylindrical discharge tube. The spatial distribution of the small-signal gain and gas temperature along the gas flow direction have been calculated for a given set of initial conditions, namely, gas flow velocity, gas pressure and the tube diameter. In addition, the dependence of small-signal gain, the asymmetric stretch vibrational temperature of CO₂ (T₃) and the gas temperature on the discharge current were studied.     

Thermal instability of glow discharge in the gas loop of CO2 laser with extended disk fans-heat exchangers

CO₂ lasers with transverse discharge and convective gas cooling find ever-increasing application. On strategy in making such lasers more efficient radiators is increasing the rate of the gas flow through the discharge zone with the help of diametral disk fans-heat exchangers. The application of such fans-heat exchangers, however, entails serious difficulties related to the glow discharge-gas flow interaction. In the present study, we investigate the stability problem for volume discharge in the gas loop of a CO₂ laser with diametral dis fans-heat exchangers.     

Accuracy in determination of the temperature and partial pressure of CO<Subscript>2</Subscript> in CO<Subscript>2</Subscript>:N<Subscript>2</Subscript>:H<Subscript>2</Subscript>O:NO<Subscript>2</Subscript> mixtures by multiple-frequency laser probing

We present the results of analysis of the errors introduced by hot-band transitions 11¹0-01¹1, 03¹0-01¹1, 12⁰0-12⁰1 of the CO₂ molecule and the absorption lines of the H₂O and NO₂ molecules in determination of the temperature and partial pressure of CO₂, included in the gas mixture CO₂: N₂:H₂O: NO₂ at atmospheric pressure, by multiple-frequency laser probing using a CO₂ laser tunable over the lines of the 00⁰1-[10⁰0,02⁰0]_I,II ground-state laser transitions. __________ Translated from Zhurnal Prikladnoi Spektroskopii, Vol. 74, No. 6, pp. 810–815, November–December, 2007.     

Determination of an optimal five-gas combination in a sealed-off CO<Subscript>2</Subscript> laser

For obtaining the maximal output power, five lasing gas mixtures (CO₂, N₂, He, Xe and H₂) in a sealed-off CO₂ laser are optimized by applying a genetic algorithm and solving CO₂ laser kinetics equations. A comparison of numerical simulations shows that the optimal pressures of CO₂ and N₂ are 1.15 Torr and 7.32 Torr, respectively. Accordingly, the maximum laser power of 124 W is obtained by utilizing the optimal gas combination and an optimized resonator with a length of 1.2 m. Received: 14 August 2002 / Published online: 22 January 2003 The project supported by Zhejiang Provincial Natural Science Foundation of China (No. 602098). RID="*" ID="*"Corresponding author. Fax: +86-571/8832-0369, E-mail: chengch@mail.hz.zj.cn     

Novel considerations of functions of helium and nitrogen in a fast flow CO2 laser

In a research of fast axial flow CO₂ laser sustained by 150 kHz silent discharge, we found the optimized gas mixing ratio was CO₂:N₂:He=1:22:5 or the content of helium was only about 18%. This result upset the situation of common CO₂ lasers in which the most important laser gas is helium. An explanation of our particular results and supporting experimental evidence are given.     

A computer model of a transverse discharge cw CO laser

A kinetic model has been developed for the investigation of the novel performance of a CO laser, on which efficient extraction of laser power was obtained by exciting a subsonic gas mixture of CO/N₂/He/O₂ through transverse dc discharge. Kinetic equations for direct excitation by electron impact, V-V and V-R/T energy transfer, and stimulated emission are coupled with a semi-one-dimensional flow model. Careful consideration is devoted especially to the V-V transfer process of CO–N₂ and N₂–N₂. The laser power was calculated by a constant gain method. The laser output performance, examined as a function of gas mixture ratio, temperature, flow velocity, and discharge current, was in good agreement with the experiment.     

Wide-aperture superatmospheric-pressure CO<Subscript>2</Subscript> laser amplifier pumped by a self-sustained volume discharge

Initiation of a self-sustained volume discharge in CO₂-containing gaseous mixtures kept under a pressure of up to 10 atm with the aim of amplifying picosecond IR pulses is considered. Experimental electricdischarge and optical characteristics of a wide-aperture high-pressure CO₂ amplifier are presented. The feasibility of designing terawatt laser equipment with a master oscillator and preamplifier is discussed.     

Indigenous development of a 2 kW RF-excited fast axial flow CO<Subscript>2</Subscript> laser

RF-excited fast axial flow CO₂ lasers in kilowatt regime are presently being used for various new scientific applications in addition to laser material processing because of its versatility and superior beam quality. We have indigenously developed a compact 2 kW RF-excited fast axial flow CO₂ laser with moderate beam quality. In this paper the key design features of the laser and the associated high power capacitively coupled RF excitation technique are discussed in detail. Operational characteristics of this system are described along with the experimental findings.     

Study of shock waves interacting with Ar and N<Subscript>2</Subscript> low pressure dc discharges

Acoustical shock waves (Mach number <2) generated in situ by spark gap are propagated in weakly ionized dc discharges working at low pressure (399 Pa) and containing either Ar or N₂ gas. The electrical characterization and the laser deflection technique are used to measure the characteristics of dc discharge (such as voltage, resistance and power of discharge) and the structure and velocity of shock wave, respectively. The results stress the importance of atomic and molecular nature of the gases in affecting the power deposition and the shock wave properties.     

Effects of some synthesis parameters on the structure of titania nanoparticles obtained by laser pyrolysis

The preparation of TiO₂ nanoparticles by CO₂ laser pyrolysis of TiCl₄ (vapor)-based gas mixtures was investigated as a function of laser power and influence of the oxidizer. Increased crystallinity and crystallite dimensions as well as increase of the rutile fraction are observed at moderate flow increase in the flow rate of the oxidizing agent.     

Novel long-pulse TE CO2 laser excited by pulser–sustainer discharge

A novel long-pulse TE CO₂ laser with UV-preionization is presented. With an active volume of 1.17 l and gas pressure of 30 kPa, the laser can discharge stably with low pulser energy and high sustainer energy. Various long-pulse discharges such as 12, 20 or 25 μs are demonstrated. At discharge pulse width of 23.9 μs, maximum output laser energy of 6.8 J is obtained at an efficiency of 9.0%.     

Numerical solution of Boltzmann tranport equation for TEA CO2 laser having nitrogen-lean gas mixtures to predict laser characteristics and gas lifetime

Selective laser isotope separation by TEA CO₂ laser often needs short tail-free pulses. Using laser mixtures having very little nitrogen almost tail free laser pulses can be generated. The laser pulse characteristics and its gas lifetime is an important issue for long-term laser operation. Boltzmann transport equation is therefore solved numerically for TEA CO₂ laser gas mixtures having very little nitrogen to predict electron energy distribution function (EEDF). The distribution function is used to calculate various excitation and dissociation rate of CO₂ to predict laser pulse characteristics and laser gas lifetime, respectively.Laser rate equations have been solved with the calculated excitation rates for numerically evaluated discharge current and voltage profiles to calculate laser pulse shape. The calculated laser pulse shape and duration are in good agreement with the measured laser characteristics. The gas lifetime is estimated by integrating the equation governing the dissociation of CO₂. An experimental study of gas lifetime was carried out using quadrapole mass analyzer for such mixtures to estimate the O₂ being produced due to dissociation of CO₂ in the pulse discharge. The theoretically calculated O₂ concentration in the laser gas mixture matches with experimentally observed value. In the present TEA CO₂ laser system, for stable discharge the O₂ concentration should be below 0.2%.     

Supersonic CO2 laser excited by RF discharge in closed cycle

A supersonic gas flow having a Mach number of 2 has been realized in a closed-cycle radio-frequency (RF)-discharge-excited supersonic CO₂ laser system. Stable RF discharge at a high CO₂ gas concentration has become possible using supersonic gas flow and RF discharge generated between dielectric electrodes. As a result, high RF input power density has been obtained. In addition, a high small-signal gain has been obtained in the supersonic section through decreases in gas pressure and gas temperature due to supersonic gas flow.This revised version was published online in August 2005 with a corrected cover date.     

Theoretical and experimental study of V–I characteristics of UV pre-ionized TEA CO2 laser for variety of laser gas mixtures

Experimental and theoretical study of V–I characteristics of UV pre-ionized TEA CO₂ laser has been carried out for a variety of gas mixtures emitting different optical pulse shapes suitable for various applications. Coupled differential equations have been solved to model the pulse excitation circuit using the numerically calculated values of ionization coefficient (α), attachment coefficient (β) and drift velocity (U_d) as functions of E/N (i.e. electric field to neutral particle density ratio) for chosen gas mixture. Calculated and experimental V–I characteristics for gas mixtures (CO₂:N₂:He::1:2:3, 1:1:4, 1:1:5 and 1:0:4.7) show a good agreement. It has been shown that gas mixture has a dominant effect on the delay between pre-ionization and main discharge; thus, determining the long-term stability of discharge. The excitation pulse duration increases with increase in molecular content of gas mixture (i.e. amount of CO₂ and N₂ in gas mixture).     

Ion flux's pressure dependence in an asymmetric capacitively coupled rf discharge in NF<Subscript>3</Subscript>

Starting from an analytical macroscopic/phenomenological model yielding the self-bias voltage as a function of the absorbed radio-frequency (rf) power of an asymmetric capacitively coupled discharge in NF₃ this paper studies the dependence of the ion flux onto the powered electrode on the gas pressure. An essential feature of the model is the assumption that the ions' drift velocity in the sheath near the powered electrode is proportional to E ^α, where E=−ΔU (U being the self-bias potential), and α is a coefficient depending on the gas pressure and cross section of elastic ion-neutral collisions. The model also considers the role of γ-electrons, stochastic heating as well as the contribution of the active electron current to the global discharge power balance. Numerically solving the model's basic equations one can extract the magnitude of the ion flux (at three different gas pressures) in a technological etching device (Alcatel GIR 220) by using easily measurable quantities, notably the self-bias voltage and absorbed rf power.     

Scaling and performance of CO2 lasers at supra-atmospheric pressure

The performance of a compact uv photo-preionized TE laser is studied in the pressure range 1–5 bar. As the pressure is increased, the laser pulse shape is little altered, but both the peak power and the total output pulse energy increase significantly with pressure, even for constant input electrical energy. For various gas mixtures and excitation source capacitors the measurements suggest approximate output energy scaling with the product of the source charge per unit electrode area [C.m^–2] and the molecular partial pressure [CO₂+N₂+CO]. This is explained in terms of the pressure-dependent discharge impedance. An input-energy-related discharge instability limits the optimum laser pressure to 1.5–2.5 bar, and we show that, at constant input energy, the instability boundary depends on the molecular partial pressure alone. The pre-ionization photo-electron yield varies negligibly with pressure, but the discharge tolerance to added oxygen decreases asp ^–3 top ^–4, dependent on gas mixture. Nevertheless sealed operation for >10⁵ shots has been obtained with a 5% CO₂5% CO3% N₂2% H₂85% He gas mixture at a total pressure of 5 bar.