Effect of electric field on plasma control during CO2 laser welding

Experimental results showed that an applied electric field can affect the shielding behavior of the laser-produced plasma during laser welding. It was found that at optimum field strength, the penetration depth can be increased by about 8% and the width of bead can also be reduced. In other words, the electric field can be used for enhancing the efficiency of the laser energy coupling to the workpiece. In addition, the influences of the electric field strength, field direction and laser power on the penetration depth and the bead width are reported.     

CO2 laser beam modulating for surface texturing machining

Laser texturing is a novel technique that may be used to texture a cold roller in the process of manufacturing high quality steel sheets. With the aim of improving the quality of the textured roller by using a CO₂ laser, a new laser beam modulating device is proposed. An optical beam expander with a fast rotating chopper system is designed. The laser pulse is split into two parts by the chopper blades; one is the preheating pulse that is reflected onto optical loop mirrors; the other is the directly transmitted pulse that creates the craters at the preheated spots. The preheating beam focus spot size and position can be adjusted. The focusing characteristics and optical parameter compensation for the flying optics are investigated. The heat transfer and melt process of laser texturing are numerically simulated. The effects of the double pulses on the texturing are analyzed. The effect of preheating the sample ahead of the laser texturing pulse is examined. The surface profile and bump hardness show improvements by using this approach.     

Effect of magnetic field on plasma control during CO2 laser welding

During high power CO₂ laser beam welding, the plasma above the keyhole has a shielding effect that it not only absorbs part of the laser energy but also defocuses the laser beam. As a result, the welding efficiency and the aspect ratio of the welds are influenced. In order to reduce the effect of plasma, helium as a plasma control gas has been used successfully and effectively. However, the cost of helium in Southeast Asia is extremely high and therefore the production cost is significantly increased when helium is used as a continuous bleeding plasma control gas. To search for an alternative plasma control technique, feasibility in using magnetic effect as a control tool is explored in this paper. The influences of the magnetic field strength, laser power, welding speed, field direction and shielding gas (e.g. helium and argon) on the penetration depth and the width of bead were also investigated. Experimental results indicated that the magnetic field can influence the shielding effect of the plasma without using plasma control gas. It was found that at a suitable magnetic field strength the penetration depth was increased by about 7%, but no significant difference on the width of bead was found. Moreover, it was shown that the plasma control effect can be achieved at low magnetic field strength and the penetration depth can be increased significantly under argon atmosphere.     

Effect of electric and magnetic fields on plasma control during CO2 laser welding

Feasibility in using electric and magnetic fields as a plasma control tool during high-power laser welding is explored in this paper. Preliminary results indicated that both fields can influence the shielding effect of the plasma above the keyhole. It was found that at suitable field parameters the penetration depth can be increased by more than 13%. Moreover, under the effect of both fields, the interrelation between the penetration depth and the width of bead was found. In addition, the influence of both electric and magnetic fields strength, field direction and laser power on the penetration depth and the width of bead were also investigated.     

Investigation of CO2 laser beam modulation by rotating polygon

A beam-modulating system based on the rotating polygon has been proposed in a previous experimental work [14]. The aim was to improve the quality and efficiency of CO₂ laser surface texturing. Based on the generalized ABCD law, the focusing characteristics of a real beam through the modulating system are investigated in this paper. By introducing a precise defocusing, the velocity synchronization between the focal spot and the workpiece can be realized. Micro-dimples of nearly circular shape can be achieved on the surface. Surface texturing of mill roll has been performed. The experimental and theoretical results are in good agreement.     

Use of a beam expanding telescope in a grating-tuned waveguide CO2 laser

A Galilean telescope is used as a beam expander in a grating tuned CO₂ waveguide laser to improve line selection while minimizing cavity length to maximise the frequency tuning range. The laser has been used in optoacoustic measurements of saturation of absorption on the transition pumping the 891 m CH₂CF₂ laser.     

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.     

Methodology of generic modeling as applied to energy coupling of CO2 laser material interaction

Energy coupling is a key phenomenon in material processing techniques that use lasers. It is a complex physical process, which involves numerous parameters, such as material's refractive index, laser wavelength, angle of incidence, polarization, temperature, power, power intensity, surface roughness and surface coating. Although there are some empirical and theoretical models of the dependence of the energy coupling efficiency, also termed absorptivity on individual and/or blocks of parameters, to date, there is no comprehensive model that addresses the wide array of parameters that affect energy coupling for laser material interaction. To address this need, several of the available models are examined, and a generic methodology is introduced and used to de-couple, classify and re-categorize the parameters. The process of creating a general model that combines the influences of the selected crucial parameters is presented. Current limitation and restrictions of the model are addressed.     

First-order layout of a two-lens varifocal objective focusing a CO2 laser beam in a post-objective three-axis scanner

In this paper we describe a procedure to work out the first-order layout of a two-lens varifocal objective for a post-objective three-axis scanner. In particular, the two lenses are considered thin, the laser beam is propagated paraxially (ABCD law) and the focal lengths of the two lenses and the maximum value of the distance between them are worked out in accordance with the specifications of the objective. Finally, the plots of the dimension and the position of the focused light spot versus the distance between the two lenses are evaluated.     

Processing of concretes with a high power CO2 laser

Laser material processing, being a non-contact process, minimizes many of the complexities involved in the decontamination and decommissioning of nuclear facilities. A high power laser beam incident on a concrete surface can produce spalling, glazing or vaporization, depending upon the laser power density and scan speed. This paper presents effect of various laser processing parameters on the efficiency of material removal by surface spalling and glazing. The size of laser beam at constant fluence or energy density had significantly different effect on the spalling process. In thick concrete block cutting the flow or removal of molten material limits the cutting depth. By employing repeated laser glazing followed by mechanical scrubbing process cutting of 150 mm thick concrete block was carried out. Gravitation force was utilized for molten materials to flow out while drilling holes on vertical concrete walls. The dependence of the incident laser beam angle on drilling time was experimentally studied.     

Modelling of CO2 laser welding of magnesium alloys

Laser welding is an important joining process for magnesium alloys. These materials are being increasingly used in different applications such as in aerospace, aircraft, automotive, electronics, etc. To date, carbon dioxide (CO₂) neodymium-doped yttrium aluminum garnet (Nd:YAG) and the high power diode laser have been extensively used to investigate the weldability of magnesium alloys. The present work describes an analytical thermal model for the weldability of magnesium alloys (WE43) using an industrial (CO₂) laser source. The main target of the project is to present to the industrial community a simple and rapid tool for the determination of the penetration depth and the bead width as a function of both the incident laser power and welding speed. The proposed model is based on the Davis thermal approach, largely considered for the characterization of the average radius of the liquid zone, aiming at predicting the joint shape. Moreover, since during the welding process considered in this study, a protecting gas is used to avoid joint oxidation, both thermal convection and radiation phenomena in the welding area have been estimated and introduced in our model for a better characterization of the welding process. The obtained results have been compared to the experimental ones and a satisfactory correlation has been observed, indicating the reliability of the model developed in this study.     

Case hardening of steel by a CO2 laser beam

Case hardening of a carbon steel, Armco Iron, an alloyed steel and a high-speed steel was carried out with a CO₂ laser beam. The indispensibility of an absorptive coating in the laser heat treatment was established. Four coatings capable of absorbing CO₂ laser radiation of a 10.6 μm wave length were examined. The influence of spot size, power and scanning speed on the depth of hardening were studied. Processing at optimal conditions yielded a hardening depth of up to 0.7 mm and a surface hardness of up to 220 H_v.     

Reflectivity measurements of a CO2 laser produced plasma

Reflectivity measurements on a CO₂ laser produced plasma are presented and results are compared with the conflicting results of other recent papers. The results presented here show strong anomalous absorption above an irradiance level of ～4 × 10¹⁰W cm^-2 which is a factor of two lower than is predicted from the theory of the parametric instability.     

CO2 laser cutting of MDF: 2. Estimation of power distribution

Part 2 of this paper details an experimentally-based method to evaluate the power distribution for both CW and PM cutting. Variations in power distribution with different cutting speeds, material thickness and pulse ratios are presented. The paper also provides information on both the cutting efficiency and absorptivity index for MDF, and comments on the beam dispersion characteristics after the cutting process.     

Detection of small N2O concentrations using a frequency doubled CO2 laser

A reliable procedure for remote high-accuracy laser detection of N₂O as one of the principal destroyers of the protective ozone layer of the Earth has been developed. The procedure is based on using a CO₂-laser system emitting efficiently in the 4.5 μm range. In this case lasing from isotopic modification ¹²C¹⁸O₂ of carbon dioxide with its subsequent frequency doubling by a nonlinear crystal is used. With the object of reducing the price the composition of the active medium (both for TEA laser and low-pressure longitudinal-discharge-excitation laser) has been optimized. New high-efficiency intracavity frequency doubling schemes based on nonlinear AgGaSe₂ crystals have been developed for CO₂-lasers of both types. Low concentrations of N₂O and concentrations of the principal background gases CO and H₂O have been measured under real atmosphere conditions with the aid of the lidar complex built around these lasers.     

Emission properties of laser ablation of SnO2: Sb transparent conducting film and KTiOPO4 crystal

Optical emission spectra of Nd:YAG laser ablation of KTiOPO₄ (KTP) crystal and SnO₂:Sb transparent conducting thin film were recorded and analyzed in vacuum and in air. The integral intensities of spectral lines from laser-ablated KTP crystal were obtained as functions of distance from the target surface and laser power density in vacuum and in air. The ambient gas effects on pulsed laser ablation of target were discussed. We also performed laser ablation of SnO₂:Sb transparent conducting thin film in air and the electron temperature and full-width at half-maximum (FWHM) of atomic and ionic spectral lines in the plasma were quantified using Boltzmann plot method and Lorentzian fit, respectively. Integral intensities of atomic and ionic Sn spectral lines were also obtained as functions of distance from the target surface and laser irradiance. The intensity ratio of ionic and atomic Sn spectral lines as a function of laser power density was got which gives some information about the variation of ionization ratio with laser irradiance in the plasma produced by high-power laser.     

In-process high power CO2 laser beam position sensing

The case for in-process sensing is one of the strengths of laser materials processing, both in the variety of signals obtainable from the process and the range of techniques for beam guidance. It is known that beam/nozzle alignment is of importance for high quality laser cutting. Thus, an in-process beam position sensing system was devised in this study as one of the potential tools for automation of the cutting process. Further, if the beam could be stabilized at a given location automatically this would be equivalent to relocating the laser beam. Laser beam position sensing is the first step towards this goal. The aim of this study is to create a beam position sensing system. This work presents a new approach using a rotating slit, a focusing lens and a photodetector. An automatic alignment procedure is also investigated.     

Collimation testing of a CO2 laser beam with a shearing interferometer

A shearing interferometer based on a Michelson interferometer is proposed for collimation testing of a CO₂ laser beam. The shear and tilt between the interfering wavefronts is obtained by replacing one or both mirrors of the Michelson interferometer with double mirrors arranged to act as 90 ° or near 90 ° prisms in retroreflecting mode. Detailed analysis for two experimental configurations of this system are presented.     

Reflectivity measurements from a nanosecond CO2 laser produced plasma

The back-scattered light from a laser produced plasma has been studied using a nanosecond gigawatt CO₂ laser. The spectral shift and width of the reflected light have been determined as a function of the incident laser energy.