Analysis of mechanism of plasma and spatter in CO2 laser welding of galvanized steel

In laser welding, quality, reproducibility and formability are required. That is the great problem in the automation of the laser welding process. Therefore, construction of an on-line process monitoring system of high accuracy is requested.The light which is emitted from plasma and spatter in laser welding was detected by photo-diodes. It was found that the light intensity depends on welding speed, laser power and flow rate of assist gas. The relationship between the plasma and spatter and the bead shape, and the mechanism of plasma and spatter were analyzed for on-line laser weld monitoring systems.     

Optically pumped submillimeter laser lines from CD2Cl2 using a large tunability CW CO2 laser

Twenty-five new laser lines have been obtained in the wavelength region from 155 to 830 μm by optically pumping the CD₂Cl₂ (deuterated dichloromethane) molecule with a CW CO₂ laser having a tunability range of 300 MHz. The wavelength, polarization relative to that of CO₂ pumping radiation, and offset relative to the CO₂ center frequency were determined for all of the new lines and some other already known laser emissions. For all of them we give also the relative intensity and the optimum pressure of operation. Permanent address: Depto de Física e Química da FEIS — UNESP 15.378-000 Ilha Solteira-SP, Brazil     

CO2 laser cutting of slate

Slate is a natural stone which has the characteristic that shows a well-developed defoliation plane, allowing to easily split it in plates parallel to that plane which are particularly used as tiles for roof building. At present, the manufacturing of slate is mostly manual, being noisy, powdery and unsafe for the worker. Thus, there is a need to introduce new processing methods in order to improve both the working conditions and the quality of the products made of slate.Following the previous work focused on the drilling and cutting of slate tiles using a Nd : YAG laser, we present in this paper the results of the work carried out to explore the possibilities to cut slate plates by using a CO₂ laser. A 1.5 kW CO₂ laser was used to perform different experiments in which, the influence of some processing parameters (average power, assist gas pressure) on the geometry and quality of the cut was studied. The results obtained show that the CO₂ laser is a feasible tool for a successful cutting of slate.     

Mathematical modeling of hybrid CO2 laser

A Teller–Landau six-temperature model describing the dynamic emission of single-mode TEA CO₂ laser has been adapted. This model has been also used to describe the mechanism of obtaining relatively high-power output pulses from hybrid TE-TEA or CW-TEA CO₂ laser consisting of high- and low-pressure sections. The suggested mathematical model allows to investigate the mechanism which limits the TEA oscillation to single longitudinal mode (SLM) due to the narrow gain bandwidth of low-pressure section, and also to study the effect of the laser input parameters on the smooth output laser pulse parameters. In addition, numerical solutions of non-linear rate equation system of the suggested model are quantitatively discussed. The solutions describe the radiation field intensity, the population inversion, and the energy transfer processes. The calculated values of maximum peak power, total energy in pulse, pulse width, etc. are in a very good agreement with the observed experimental values.     

Investigation of cutting of engineering ceramics with Q-switched pulse CO2 laser

In this paper, the cutting of Si₃N₄ engineering ceramics with Q-switched pulse CO₂ laser is studied. Considering the influence of the cut front shape on the absorption of the laser beam, a simplified 2D mathematic model is developed based on a pulsed laser vaporization cut process. This model is based on the conservation of energy. The experimental results show that it would realize crack-free cutting by using high-speed and multi-pass feed cutting process.     

Gas breakdown with nanosecond CO2 laser radiation

The thresholds for CO₂ laser induced breakdown and their variation with pulse width have been measured at various pressures for Ar, N₂ and an 8/1/1 laser mixture of He/CO₂/N₂ using 3–40 ns duration pulses. These measurements indicate that excited state production plays a dominant role in determining the threshold for nanosecond duration pulses. This has been confirmed by the good agreement obtained between the measured and theoretical thresholds.     

CO2 laser assisted removal of UO2 and ThO2 particulates from metal surface

Pulsed laser assisted removal of uranium dioxide and thorium dioxide particulates from stainless steel surface have been studied using a TEA CO₂ laser. Decontamination efficiency is measured as a function of laser fluence and number of pulses. Threshold fluence for the removal of UO₂ particulates has been found to be lower than that required for the removal ThO₂ particulates. Usage of a ZnSe substrate, that is transparent to the laser wavelength used here, enabled us to decouple the cleaning effect arising out of absorption in the particulates from that in the substrate and has contributed towards understanding the mechanism responsible for cleaning. The experimental observations are also corroborated by simple theoretical calculations.     

Thermal and efficiency analysis of the CO2 laser cutting process

In CO₂ laser gas-assisted cutting process, modeling of the interaction mechanism is important. Consequently, the present study treats the complete problem of the interaction of the melting surface with the boundary layer and describes the behavior of the melting layer. In the analysis, gas–liquid interface parameters are developed and relationships between the parameters influencing the cutting action are identified theoretically. To achieve this, effects of momentum and gas–liquid interface shear stress, due to the assisting gas jet, are considered. The approximate magnitude of the heat absorbed is estimated and melting layer thickness is predicted. An experiment is carried out and the theoretical predictions are compared with the experimental findings. First and second law efficiencies of the cutting process are predicted, which may, then, be used to improve the process. It is found that the assisting jet velocity increases the first and second law efficiencies of the CO₂ laser cutting process.     

AC-chopper application for CW CO2 laser

A microprocessor-based algorithm was developed to control the power supply to a CO₂ laser using an AC-chopper method. This system was connected directly to a CO₂ laser tube without the need for a dc-dc converter or the storage capacitance of a multilevel circuit. The typical CO₂ laser power supply system had a full-bridge series resonant inverter or voltage multiplier. AC-to-AC converter schemes using zero voltage switching (ZVS) can be used efficiently and economically for low and medium power applications.This paper reports the performance characteristics of a symmetrical AC-chopper technology that can maintain the quality of the ac output of a CO₂ laser tube, regardless of the amount of switching loss. The laser was operated to an output power, maximum system efficiency total gas mixture of 37.2 W, 92%, and CO₂:N₂:He=1:9:15, respectively. The laser system, AC-chopper power supply and its operation were examined.     

High-power multibeam CO2 laser for industrial applications

Multibeam CO₂ lasers consist of a large number of closely packed parallel glass discharge tubes, all sharing a common plane parallel resonator. This paper describes construction and operation of a CW multibeam CO₂ laser consisting 20 discharge tubes and cooled length of 1500 mm, delivering 1 kW power. A high-frequency pulser is used for producing preionization in all discharge sections for initiating the main DC discharge simultaneously in all discharge tubes. Plane parallel resonator consists of a plane ZnSe mirror of 90 mm diameter having 60% reflectivity and a gold-coated copper mirror of same diameter. This laser operates in waveguide regime and laser power is not critically sensitive to mirror misalignment.     

Short single-mode CO2 laser pulse generation by pulsed Q-switching

A simple method for the generation of short, single-mode CO₂ laser pulses produced by applying two voltage gates (of amplitude 3U_λ/4 and U_λ/4) to an electro-optic Q-switch placed in a three-mirror cavity is proposed. Single, single-mode, well-synchronizable pulses of 3 ns duration and of 3 mJ energy have been experimentally achieved from a TEA CO₂ laser with an intracavity Pockels cell with 3 ns switching time. Using a numerical simulation it is shown that with shorter switching time (≈1 ns) the method enables one to obtain, from such a laser, a single, megawatt pulse of 1 ns duration.     

Phase-locking of a multi-channel radial array CO2 laser

A theoretical analysis of phase-locking in a multi-channel radial array CO₂ laser is presented. The concepts are based on the theories of injection phase-locking and matrix optics. The mutual optical coupling occurring within the central region is demonstrated by theoretical deduction. Interrelated graphs of the coupling coefficient and the distance between the coupling position and the cavity mirror are calculated by numerical simulation. The results of the analysis are in accord with experimental results.     

Simplified power supply for long pulse CO2 laser using zero cross switching technique

We propose a simple power supply for a longitudinally pulsed CO₂ laser with long pulse duration by the switching control of AC line (60 Hz) on HV leakage transformer primary, which can generate long pulse of about 3 ms compared to a typical pulsed power supply. In this power supply, a low voltage open loop control for high voltage discharge circuit is employed to avoid the HV sampling or switching, and AC line voltage switched directly by a SCR is applied to the leakage transformer primary. Thus, there is no need of a rectified bridge and an energy-storage capacitor in the discharge circuit, and the leakage transformer allows one to omit a current-limiting resistor. In order to control the laser output power, the pulse repetition rate is adjusted up to 60 Hz. A ZCS circuit and a PIC one-chip microprocessor are used to control the gate signal of SCR precisely.     

Thermal processes taking place in the bone during CO2 laser irradiation

The present study examines the drilling and heating of a bone due to pulsed CO₂ laser irradiation. To obtain temperature profiles inside and at the surface of the bone, electron-kinetic and Fourier theories are used. The study is extended to include an experimental investigation into the measurement of the penetration speed. This is achieved using a fibre-optic system. In order to reduce the degree of burning around the hole side, helium was used as the assisting gas during drilling. It is found that the penetration speeds predicted from the theory are in good agreement with the experimentally obtained values.     

An injection-locked single-mode tea CO2 laser for SMM laser pumping

A D₂O laser has been developed for collective Thomson scattering measurements of ion temperature in high temperature plasmas. A pulse duration and a spectral width of a high power D₂O laser has been successfully controlled for this purpose, by using a TEA CO₂ laser injection-locked by an etalon-tuned TEA CO₂ laser as a pump source.     

Active long pulse shaping technique of pulsed CO2 laser using multi-pulse discharge control

We describe the pulse forming of pulsed CO₂ laser using multi-pulse superposition technique. Various pulse shapes, high duty cycle pulse forming network (PFN) are constructed by time sequence. This study shows a technology that makes it possible to make various long pulse shapes by activating SCRs of three PFN modules consecutively at a desirable delay time with the aid of a PIC one-chip microprocessor. The power supply for this experiment consists of three PFN modules. Each PFN module uses a capacitor, a pulse forming inductor, a SCR, a high voltage pulse transformer, and a bridge rectifier on each transformer secondary. The PFN modules operate at low voltage by driving the primary of HV pulse transformer. The secondary of the transformer has a full-wave rectifier, which passes the pulse energy to the load in a continuous sequence.We investigated various long pulse shapes as different trigger time intervals of SCRs among three PFN modules. As a result, we could obtain laser beam with various pulse shapes and durations from about 250 to 1000 μs.     

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.     

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.     

Optimization of three gas compositions in a CO2 laser

Three pressures of gases (CO₂, N₂ and He) added into CO₂ laser tube are optimized for obtaining maximal laser output power by applying a genetic algorithm and solving the CO₂ laser kinetics equations. After the optimization, the laser power is increased by 96% as compared with a non-optimal case.     

Optoacoustic Laser Stark spectroscopy and FIR laser action on CH3Br using a waveguide CO2 laser

The optoacoustic spectrum of CH₃Br around 10 m band lines of a tunable cw waveguide CO₂ laser is investigated. Several new infrared absorptions are observed and most of the correspond ing molecular transitions are assigned. Far infra red laser action is reported by pumping with the same CO₂ laser: pump offsets are given using the Transferred Lambs dip (TLD) technique. A new FIR laser emission is obtained and assigned. An optoacoustic Laser Stark spectroscopy technique is used to investigate off resonance infrared tran sitions.