4/2000 - RSL - 1
High Power Diode Laser
ROFIN DL Series
ROFIN DL x75 750 W
ROFIN DL 010 1000 W
ROFIN DL 015 1500 W
ROFIN DL 020 2000 W
ROFIN DL 025 2500 W
ROFIN DL 030 3000 W
4/2000 - RSL - 2
ROFIN DL x75 S 750 W
ROFIN DL 010 S 1000 W
ROFIN DL 015 S 1500 W
ROFIN DL 020 S 2000 W
ROFIN DL 025 S 2500 W
ROFIN DL 030 S 3000 W
High Power Diode Laser
ROFIN DL-S Series
4/2000 - RSL - 3
High Power Diode Laser
ROFIN DF Series (high power)
Fiber coupled diode laser:
ROFIN DF 010 1000 W
ROFIN DF 018 1800 W
ROFIN DF 022 2200 W
4/2000 - RSL - 4
High Power Diode Laser
ROFIN DF Series (low power)
Fiber coupled diode laser:
ROFIN DF x03 30 W
ROFIN DF x06 60 W
4/2000 - RSL - 5
The way from the diode chip to the diode stack
ca,10 mm
115 μm
600 μm
ca,70° x 15°
2,Laser-bar (ca,3W) ("fast-" and "slow"-axis)
4,Beam forming using microchannel lenses
Setup of a diode laser stack
- electrically in series
- water cooling in parallel
5,Stacking of microchannel coolers (diodes) --> 1 kW
3,Mounting onto a micro channel cooler ca,30 W
P opt
PQ
Solder
6,Diode stack!
p-dotiert
pn-übergang
n-dotiert
- - -- -
- - -
-
1,Light from the pn-Transition
Source,E.Lerner,Laser FocusWorld Jan,1998
4/2000 - RSL - 6
Comparison of diode lasers with conventional lasers
High power diode laser
(example 2 kW)
State-of-the-art CO2 laser
(example 2 kW)
large (1 - 3 m3)
heavy 1000-3000 kg
high energy consumption (efficiency 3 - 10 %)
high running costs
G compact (0,02 m3)
G light (10 kg + 75 kg + 150 kg)
G efficient (30 - 50 %)
G 1/10 of running costs possible
Hbeam quality too low
4/2000 - RSL - 7
Welding with HPDL,Comparison with Conventional Lasers
0
0,5
1
1,5
2
2,5
3
3,5
4
4,5
5
0
0,25 0,5 0,75
1
1,25 1,5 1,75
2
2,25 2,5 2,75
3
Dicke im mm
Schwei?geschwindigkeit in m/min
NdYAG,700 W
cw
I = 2 x 106 W/cm2HLDL,700 W cwI = 2 x 104 W/cm2
welding speed for
Nd:YAG and HPDL
4/2000 - RSL - 8
Diode Lasers in Comparison with Conventional Lasers
(today)
10.0001 10 100 1.000
0.1
1
10
100
1.000
CO2 lasers
Solid state lasers
Diode lasers
Diode pumped Nd:YAG lasers
Disc lasers
Lamp pumped Nd:YAG lasers
Laser power [W]
Beam parameter product
[mm x
mrad
]
Fiber coupled diode lasers
Diode lasers
Industrial available
Values based on 1/e2 (86% criterion)
4/2000 - RSL - 9
Parameter field for the Materials Processing with Lasers
By P.Loosen,Fraunhofer-Institut für Lasertechnik
1 10 100 1.000 10.000
Laser power [W]
0.1
1
10
100
1.000
Beam parameter product
[mm x
mrad
]
Drilling
Marking
Printing
Technology
PolymerWelding
Soldering
Cutting
non-metals
Brazing
Hardening
Remelting
Cladding
Limit of todays
diode lasers
Deep Penetration
Welding
Cutting
Welding
Sintering
For F-number = 4
4/2000 - RSL - 10
Examples for Diode Laser Welding:
Welding of thin (150 μm) stainless steel sheets
Diode laser power,500 W
Spot size,ca,3.8 x 1.8 mm2
Power density,ca,7 x 103 W / cm2
Welding Speed,6000 mm/min
Material,X5CrNi18 10
Application,Tube welding
Welding of foils
by courtesy of Cross Section of welded sheet metal,Colour etch
100 μm
4/2000 - RSL - 11
Cosmetic Welding to Avoid Crevice Corrosion
Diode laser power,1.45 kW
Spot size,ca,3.8 x 1.8 mm2
Power density,ca,2 x 104 W / cm2
Shield gas,Nitrogen
Welding Speed,2000 mm/min
Material,X5CrNi18 10
--> - Gas tight
- Edge smoothened
- Cosmetic weld
before
welding
after
welding
500 μm
500 μm
4/2000 - RSL - 12
Welding of Aluminum with High Power Diode Laser
Diode laser power,2.0 kW
Spot size,ca,3.8 x 1.8 mm2
Power density,ca,2 x 104 W / cm2
Shield gas,Nitrogen
Welding Speed,1100 mm/min
Material,AlMgSi1
4/2000 - RSL - 13
Welding of Aluminum with High Power Diode Laser
Diode laser power,2.0 kW
Spot size,ca,3.8 x 1.8 mm2
Power density,ca,2 x 104 W / cm2
Shield gas,Nitrogen
Welding Speed,1100 mm/min
Material,AlMgSi1
4/2000 - RSL - 14
Typical Weld with a ROFIN DL 020 High Power Diode Laser
Laser Power 2 kW
Focal Length 50 mm
Focal Position ±0 mm
Working Distance 38 mm
Material 1.4301
Thickness 1,0/1,0 mm
Welding Speed 0,5 m/min
Weld Depth 2,0 mm
Seam Type Fillet weld at lap
joint
Seam Width (top) 3,7 mm
Seam Width (bottom) 1,7 mm
Protection Gas Argon
Gas Flow (top) 30 l/min
Gas Flow (bottom) 10 l/min
Aesthetic Fillet Weld at Lap Joint
(Cross Section)
4/2000 - RSL - 15
Welding of Stainless Steel Kitchen Sink
Beam-Positioning by Robot
Cosmetic Weld Seam
4/2000 - RSL - 16
Brazing with High Power Diode Laser
Diode laser power,1.7 kW
Spot size,ca,7.6 x 3.6 mm2
Power density,ca,6 x 103 W / cm2
Shield gas,Argon
Brazing Speed,0.4 m/min
Material,Zn coated steel
Thickness,0.8 mm
Brazing Material,Cu Si 3
Flux material,none
Gap,0.2 mm
800 μm
4/2000 - RSL - 17
Brazing with High Power Diode Lasers
Laser,ROFIN DL025 Material,Zink coated steel Sheet thickness,0,9 mm
Laser power,2,5 kW Solder,CuSi Wire diameter,1 mm
Speed,2 - 4 m / min
4/2000 - RSL - 18
Hardening of Piston Rings
0,0 0,5 1,0 1,5 2,0
400
500
600
700
800
900
H?rte-Tiefen-Verlauf
v=2115 mm/min
P=1.37 kW
H?rte [HV 0.05]
Tiefe [mm]
hardness
[HV0.05]
hardness distribution
depth [mm]
Diode laser power,1.37 kW
Spot size,ca,4.4 x 9.1 mm2
Power density,ca,3 x 103 W / cm2
Shield gas,Argon
Hardening Speed,2115 mm/min
Material,55SC6
--> minimal heat load
minimal distortion
high hardness (820 HV 0,05)
adjusutable hardening depth (0.1-0.5 mm)
by courtesy of
4/2000 - RSL - 19
Hardening of Side Cutting Pliers
A-B 1 mm
C
D
10 mmC-D
B 10 mm
A
Diode laser power,600 W
Spot size,ca,4 x 2 mm2
Power density,ca,1.5 x 104 W / cm2
Shield gas,Nitrogen
Hardening Speed,120 mm/min
Material,Ck45
--> no distortion
simultaneous welding of both wedges
by courtesy of
4/2000 - RSL - 20
Distortion Free Hardening of Guiding Rails
Laser power,2 x 500 W hardening depth,0.9 mm
Spot size,4 x 5 mm2 hardness,700HV0.05
Speed,270 mm/min hardening width,4 mm
Material,58CrV4)
4/2000 - RSL - 21
Scheme of hardening setup
Hardness > 800HV0,1
0,2...0,4mm
10mm
170°
Hardening of torsion springs
Torsion Springs Process Photograph
Hardening requirements
Process setup
Cross Section10mm
2mm
-90° +90°
0°
8mm
in cooperation
with:
4/2000 - RSL - 22
Cladding with CO2 Laser and High Power Diode Laser
Stellit 21 onto steel
Processing speed,900 mm/min 900 mm/min
Laser Spot,4,5 x 4 mm2 4,7 mm diameter
Deposit cross section,1,8 mm2 2,1 mm2
Laser Power,1400 W 3900 W
Diode Laser CO2 Laser
4/2000 - RSL - 23
Diode Laser Cladding
Diode laser power,1,4 kW
Spot size,ca,4 x 2 mm2
Power density,ca,1.5 x 104 W / cm2
Shield / feed gas,Argon
Speed,400 mm/min
Material,Stellite F Powder
X2CrNi 19.1
--> - wear resistant layer deposition
- repair
by courtesy of
1 mm
1 mm
single
track
multiple
track
interface
50 μm
4/2000 - RSL - 24
Laser Assisted Machining
Diode laser power,600 W
integrated into a high
precision turning machine
Machined material,Si3N4
---> Turning of hard and brittle materials
possible
CNC-controlled
Complex contours
by courtesy of
4/2000 - RSL - 25
Polymer - Welding,Seam Geometries
2) Overlap welding at the interface:
Transparent / strong absorbing
Local heating,heat transfer to the transparent layer
complete use of the energy,high pressure --> best setup
2a) Welding at the interface,Transparent / strong absorbing,other seam geometries
1),Volume”-Welding,Butt - Joint
same absorption in both parts and 1/a ~ d!
Low heat conduction in polymers; critical on absorption &
energy,poor efficiency of energy --> not very well suited
Courtesy of
Scarf joint spline and pivotstepped overlap
4/2000 - RSL - 26
Examples of Polymer-Welding with Diode Lasers
IR Diode Housing Lid with push buttons
Welding of an electronic key
Diode Power 20 - 60 W
Welding speed 3 - 10 m/min
Focal diameter 1 mm
Oil Tank Tank Lid
Welding of an oil tank (GFK)
Diode power ca,60 W
Welding speed 1 - 2 m/min
Focal diameter 2 mmCourtesy of
High Power Diode Laser
ROFIN DL Series
ROFIN DL x75 750 W
ROFIN DL 010 1000 W
ROFIN DL 015 1500 W
ROFIN DL 020 2000 W
ROFIN DL 025 2500 W
ROFIN DL 030 3000 W
4/2000 - RSL - 2
ROFIN DL x75 S 750 W
ROFIN DL 010 S 1000 W
ROFIN DL 015 S 1500 W
ROFIN DL 020 S 2000 W
ROFIN DL 025 S 2500 W
ROFIN DL 030 S 3000 W
High Power Diode Laser
ROFIN DL-S Series
4/2000 - RSL - 3
High Power Diode Laser
ROFIN DF Series (high power)
Fiber coupled diode laser:
ROFIN DF 010 1000 W
ROFIN DF 018 1800 W
ROFIN DF 022 2200 W
4/2000 - RSL - 4
High Power Diode Laser
ROFIN DF Series (low power)
Fiber coupled diode laser:
ROFIN DF x03 30 W
ROFIN DF x06 60 W
4/2000 - RSL - 5
The way from the diode chip to the diode stack
ca,10 mm
115 μm
600 μm
ca,70° x 15°
2,Laser-bar (ca,3W) ("fast-" and "slow"-axis)
4,Beam forming using microchannel lenses
Setup of a diode laser stack
- electrically in series
- water cooling in parallel
5,Stacking of microchannel coolers (diodes) --> 1 kW
3,Mounting onto a micro channel cooler ca,30 W
P opt
PQ
Solder
6,Diode stack!
p-dotiert
pn-übergang
n-dotiert
- - -- -
- - -
-
1,Light from the pn-Transition
Source,E.Lerner,Laser FocusWorld Jan,1998
4/2000 - RSL - 6
Comparison of diode lasers with conventional lasers
High power diode laser
(example 2 kW)
State-of-the-art CO2 laser
(example 2 kW)
large (1 - 3 m3)
heavy 1000-3000 kg
high energy consumption (efficiency 3 - 10 %)
high running costs
G compact (0,02 m3)
G light (10 kg + 75 kg + 150 kg)
G efficient (30 - 50 %)
G 1/10 of running costs possible
Hbeam quality too low
4/2000 - RSL - 7
Welding with HPDL,Comparison with Conventional Lasers
0
0,5
1
1,5
2
2,5
3
3,5
4
4,5
5
0
0,25 0,5 0,75
1
1,25 1,5 1,75
2
2,25 2,5 2,75
3
Dicke im mm
Schwei?geschwindigkeit in m/min
NdYAG,700 W
cw
I = 2 x 106 W/cm2HLDL,700 W cwI = 2 x 104 W/cm2
welding speed for
Nd:YAG and HPDL
4/2000 - RSL - 8
Diode Lasers in Comparison with Conventional Lasers
(today)
10.0001 10 100 1.000
0.1
1
10
100
1.000
CO2 lasers
Solid state lasers
Diode lasers
Diode pumped Nd:YAG lasers
Disc lasers
Lamp pumped Nd:YAG lasers
Laser power [W]
Beam parameter product
[mm x
mrad
]
Fiber coupled diode lasers
Diode lasers
Industrial available
Values based on 1/e2 (86% criterion)
4/2000 - RSL - 9
Parameter field for the Materials Processing with Lasers
By P.Loosen,Fraunhofer-Institut für Lasertechnik
1 10 100 1.000 10.000
Laser power [W]
0.1
1
10
100
1.000
Beam parameter product
[mm x
mrad
]
Drilling
Marking
Printing
Technology
PolymerWelding
Soldering
Cutting
non-metals
Brazing
Hardening
Remelting
Cladding
Limit of todays
diode lasers
Deep Penetration
Welding
Cutting
Welding
Sintering
For F-number = 4
4/2000 - RSL - 10
Examples for Diode Laser Welding:
Welding of thin (150 μm) stainless steel sheets
Diode laser power,500 W
Spot size,ca,3.8 x 1.8 mm2
Power density,ca,7 x 103 W / cm2
Welding Speed,6000 mm/min
Material,X5CrNi18 10
Application,Tube welding
Welding of foils
by courtesy of Cross Section of welded sheet metal,Colour etch
100 μm
4/2000 - RSL - 11
Cosmetic Welding to Avoid Crevice Corrosion
Diode laser power,1.45 kW
Spot size,ca,3.8 x 1.8 mm2
Power density,ca,2 x 104 W / cm2
Shield gas,Nitrogen
Welding Speed,2000 mm/min
Material,X5CrNi18 10
--> - Gas tight
- Edge smoothened
- Cosmetic weld
before
welding
after
welding
500 μm
500 μm
4/2000 - RSL - 12
Welding of Aluminum with High Power Diode Laser
Diode laser power,2.0 kW
Spot size,ca,3.8 x 1.8 mm2
Power density,ca,2 x 104 W / cm2
Shield gas,Nitrogen
Welding Speed,1100 mm/min
Material,AlMgSi1
4/2000 - RSL - 13
Welding of Aluminum with High Power Diode Laser
Diode laser power,2.0 kW
Spot size,ca,3.8 x 1.8 mm2
Power density,ca,2 x 104 W / cm2
Shield gas,Nitrogen
Welding Speed,1100 mm/min
Material,AlMgSi1
4/2000 - RSL - 14
Typical Weld with a ROFIN DL 020 High Power Diode Laser
Laser Power 2 kW
Focal Length 50 mm
Focal Position ±0 mm
Working Distance 38 mm
Material 1.4301
Thickness 1,0/1,0 mm
Welding Speed 0,5 m/min
Weld Depth 2,0 mm
Seam Type Fillet weld at lap
joint
Seam Width (top) 3,7 mm
Seam Width (bottom) 1,7 mm
Protection Gas Argon
Gas Flow (top) 30 l/min
Gas Flow (bottom) 10 l/min
Aesthetic Fillet Weld at Lap Joint
(Cross Section)
4/2000 - RSL - 15
Welding of Stainless Steel Kitchen Sink
Beam-Positioning by Robot
Cosmetic Weld Seam
4/2000 - RSL - 16
Brazing with High Power Diode Laser
Diode laser power,1.7 kW
Spot size,ca,7.6 x 3.6 mm2
Power density,ca,6 x 103 W / cm2
Shield gas,Argon
Brazing Speed,0.4 m/min
Material,Zn coated steel
Thickness,0.8 mm
Brazing Material,Cu Si 3
Flux material,none
Gap,0.2 mm
800 μm
4/2000 - RSL - 17
Brazing with High Power Diode Lasers
Laser,ROFIN DL025 Material,Zink coated steel Sheet thickness,0,9 mm
Laser power,2,5 kW Solder,CuSi Wire diameter,1 mm
Speed,2 - 4 m / min
4/2000 - RSL - 18
Hardening of Piston Rings
0,0 0,5 1,0 1,5 2,0
400
500
600
700
800
900
H?rte-Tiefen-Verlauf
v=2115 mm/min
P=1.37 kW
H?rte [HV 0.05]
Tiefe [mm]
hardness
[HV0.05]
hardness distribution
depth [mm]
Diode laser power,1.37 kW
Spot size,ca,4.4 x 9.1 mm2
Power density,ca,3 x 103 W / cm2
Shield gas,Argon
Hardening Speed,2115 mm/min
Material,55SC6
--> minimal heat load
minimal distortion
high hardness (820 HV 0,05)
adjusutable hardening depth (0.1-0.5 mm)
by courtesy of
4/2000 - RSL - 19
Hardening of Side Cutting Pliers
A-B 1 mm
C
D
10 mmC-D
B 10 mm
A
Diode laser power,600 W
Spot size,ca,4 x 2 mm2
Power density,ca,1.5 x 104 W / cm2
Shield gas,Nitrogen
Hardening Speed,120 mm/min
Material,Ck45
--> no distortion
simultaneous welding of both wedges
by courtesy of
4/2000 - RSL - 20
Distortion Free Hardening of Guiding Rails
Laser power,2 x 500 W hardening depth,0.9 mm
Spot size,4 x 5 mm2 hardness,700HV0.05
Speed,270 mm/min hardening width,4 mm
Material,58CrV4)
4/2000 - RSL - 21
Scheme of hardening setup
Hardness > 800HV0,1
0,2...0,4mm
10mm
170°
Hardening of torsion springs
Torsion Springs Process Photograph
Hardening requirements
Process setup
Cross Section10mm
2mm
-90° +90°
0°
8mm
in cooperation
with:
4/2000 - RSL - 22
Cladding with CO2 Laser and High Power Diode Laser
Stellit 21 onto steel
Processing speed,900 mm/min 900 mm/min
Laser Spot,4,5 x 4 mm2 4,7 mm diameter
Deposit cross section,1,8 mm2 2,1 mm2
Laser Power,1400 W 3900 W
Diode Laser CO2 Laser
4/2000 - RSL - 23
Diode Laser Cladding
Diode laser power,1,4 kW
Spot size,ca,4 x 2 mm2
Power density,ca,1.5 x 104 W / cm2
Shield / feed gas,Argon
Speed,400 mm/min
Material,Stellite F Powder
X2CrNi 19.1
--> - wear resistant layer deposition
- repair
by courtesy of
1 mm
1 mm
single
track
multiple
track
interface
50 μm
4/2000 - RSL - 24
Laser Assisted Machining
Diode laser power,600 W
integrated into a high
precision turning machine
Machined material,Si3N4
---> Turning of hard and brittle materials
possible
CNC-controlled
Complex contours
by courtesy of
4/2000 - RSL - 25
Polymer - Welding,Seam Geometries
2) Overlap welding at the interface:
Transparent / strong absorbing
Local heating,heat transfer to the transparent layer
complete use of the energy,high pressure --> best setup
2a) Welding at the interface,Transparent / strong absorbing,other seam geometries
1),Volume”-Welding,Butt - Joint
same absorption in both parts and 1/a ~ d!
Low heat conduction in polymers; critical on absorption &
energy,poor efficiency of energy --> not very well suited
Courtesy of
Scarf joint spline and pivotstepped overlap
4/2000 - RSL - 26
Examples of Polymer-Welding with Diode Lasers
IR Diode Housing Lid with push buttons
Welding of an electronic key
Diode Power 20 - 60 W
Welding speed 3 - 10 m/min
Focal diameter 1 mm
Oil Tank Tank Lid
Welding of an oil tank (GFK)
Diode power ca,60 W
Welding speed 1 - 2 m/min
Focal diameter 2 mmCourtesy of
