Advances in High Power Lasers. Fiber delivered disk & direct diode lasers

Transcription

1 Advances in High Power Lasers Fiber delivered disk & direct diode lasers Advances in High Power Lasers University of Virginia - November 2010

2 Advances in SSL technology 25 LPSS DPSS BPP [mm mrad] TruDisk Products 2008 TruDisk Products 2009 Disk / Fiber Jan 2008: June not 2008: published Boeing 15 kw > 25 kw nearly diffraction nearly diffraction limited limited Output power [kw] 2

3 Disk Laser Concept Rod Laser Disk Laser Laser Emission T Pump light Quasi frontal r T r - Parabolic temperature profile - Cooling and Pumping via lateral area - Flat temperature profile - Cooling via base area 3

4 TruDisk Product portfolio Power [1] (kw) BPP (mm-mrad) Fiber φ (μm) Number of disks > > > [1] Power guaranteed at workpiece 4

5 TruDisk Extremely long diode life Passively cooled diodes Cooled with non-di water Life expectancy commensurate with single emitter diodes Modular, non-spliced architecture 5

6 TruDisk Compact 1 1 Pump unit Cavity Laser resonator Power feedback sensor Central shutter 4 6

7 TruDisk outputs 7

8 TruDisk Power scaling / field upgradeability 6 pump modules per disk w/ 4 kw laser power per disk Power scaling per disk by number of pump modules Output power scaling of laser with number of coupled disks 6 pump modules per disk w/ 4 kw laser power per disk Power scaling per disk by number of pump modules # of pump modules Power per disk (kw) Output power scaling of laser with number of coupled disks 8

9 TruDisk - Closed loop power control Laser power is constant at the work piece Reproducible processing results Back reflections without any influence! No warm-up time Power range 3% - 100% 9

10 TruDisk Industrial optical interface Fiber exchange without any alignment Laser safe compartment Hot-plug capable Field upgradeable fiber outputs TRUMPF Laser Network 10

11 TruDisk Cost effective Diodes from TRUMPF Photonics, USA 100% 75% 50% 25% Higher diode power per bar Less components Extremely low operating cost 0% HLD4002 TruDisk 4002 (4C) 1 2 Manufacturing in N.A. 11

12 TruDisk Cost effective 100% Invest 100% Running cost 100% Footprint 80% 80% 80% 60% 60% 60% 40% 20% 0% HLD TruDisk HLD 4002 TruDisk % 20% 0% HLD 4002 TruDisk % 20% 0% HLD TruDisk HLD 4002 TruDisk % Max. output power 100% Diode lifetime 400% 80% 300% 60% 200% 40% 100% 20% 0% HLD 2006 TruDisk 2009 HLD 4002 TruDisk % HLD TruDisk HLD 4002 TruDisk 4002 HLD 4002 = 1st generation disk laser / TruDisk 4002 = 3rd generation disk laser 12

13 Industrial applications Remote welding Conventional laser keyhole welding Hybrid laser welding Laser metal deposition Laser cutting Remote laser cutting. 13

14 Why did Trumpf choose the disk laser architecture over the fiber laser architecture for high power? Both are solid state Both are diode pumped with long life diodes Both are fiber optic delivered Both have excellent BPP Both are compact Both have excellent WPE Both are non-monolithic for industrial applications Only the disk laser is truly modular: - Field upgradability of power with no splicing required - The disk laser yields the minimum risk & downtime - There are no potential failure modes that require factory repair - Therefore, no need for the laser itself to be a spare part - Diode replacement without splicing Only the disk laser has uncritical power densities on the active medium Only the disk laser is insensitive to back reflections 14

15 Diode Laser Concept Rod Laser Disk Laser Laser Emission Diode Laser T Pump light Quasi frontal r T r - Parabolic temperature profile - Cooling and Pumping via lateral area - Flat temperature profile - Cooling via base area - + Direct conversion of current to light 15

16 Application fields BPP [mm mrad] Heat treatment / brazing Welding TruDisk TruDiode Cutting / Remote welding Laser power in kw 16

17 TruDiode Series Long diode lifetime Highest wall plug efficiency Lowest running costs Compact & Modular design Beam quality and power L A S E R TruDiode 17

18 Increase of wall plug efficiency of high-powered solid-state lasers 40 TruDiode 4006 (direct diode) Wall plug efficiency [%] HL 4006D (lamp pumped rod) HLD 4506 (diode pumped rod) TruDisk 4002 (diode pumped disk) Year 18

19 TruDiode Products Power [kw] Fiber [µm] NA TruDiode TruDiode TruDiode TruDiode TruDiode 4006 [1] [1] Available Q2,

20 TRUMPF Diode Module the building block Extremely long life due to Passive Cooling - Simple macro-channel heat sinks remove all issues with water chemistry and erosion - No voltage present in the heat sink channels removing all electro-corrosion issues Hard solder - No soft solders used removing all solder migration and thermal fatigue issues CTE matched heat sinks - Expansion matched packaging allows high current thermal cycling and minimizes thermal fatigue issues 20

21 Power Scaling N = 19 Power scaling d = 5 x d module P = N x P module BPP = N 0,5 x BPP module N = 7 d = 3 x d module 21

22 Power Scaling Efficient coupling of up to 19 modules Laser unit 22

23 Power Scaling Efficient coupling of up to 3 laser units Laser unit 1 Wavelength λ 1 Power P 1 Beam quality BPP 1 Wavelength coupling Laser unit 2 Wavelength λ 2 Power P2 Beam quality BPP 2 Exit laser beam Wavelength λ 1 + λ 2 Power P ges = P 1 + P 2 ex 600 µm BPP = BPP 1 = BPP 2 23

24 Optical design of a TruDiode 3006 Integrated beam guidance Customer benefit Plug & Play Power feedback control Power scaling 24

25 Industrial applications Conventional laser keyhole welding Laser brazing Hardening Cladding Heat conduction welding Heat treatment. 25

26 Why will the direct diode laser be the disruptive laser technology of the not too distant future? Eliminates the middle-man Highest WPE of all solid state lasers Extremely compact Lowest cost high power laser architecture Good BPP, and getting better & better! When BPP s & power levels of the direct diode match the high power disk & fiber lasers, the direct diode laser will take over those associated applications (i.e. remote welding, high speed cutting, hybrid welding, etc.) 26

27 Thank you for your attention! David Havrilla TRUMPF Inc. Advances in High Power Lasers University of Virginia - November 2010