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University of Virginia - November 2010Advances in High Power Lasers
Advances in High Power LasersFiber delivered disk & direct diode lasers
University of Virginia - November 2010Advances in High Power Lasers 2
Disk / Fiber
LPSS DPSS
BPP
[mm
mra
d]
Output power [kW]
Jan 2008: not published15 kWnearly diffraction limited
TruDiskProducts 2008
TruDiskProducts 2009
5
10
15
20
25
June 2008: Boeing> 25 kWnearly diffraction limited
5 10 15 20 25 30
Advances in SSL technology
University of Virginia - November 2010Advances in High Power Lasers 3
Rod Laser Disk Laser
r
T
r
T
Pump lightQuasi frontal
- Parabolic temperature profile- Cooling and Pumping
via lateral area
- Flat temperature profile- Cooling via base area
Laser Emission
Disk Laser Concept
University of Virginia - November 2010Advances in High Power Lasers 4
TruDisk – Product portfolio
8 - 12
8
4 - 8
4 - 8
BPP(mm-mrad)
≥ 200
≥ 200
≥ 100
≥ 100
Fiber φ(μm)
3>8 - 12
4>12 - 16
2>4 - 8
12 - 4
Number of disks
Power [1]
(kW)
[1] Power guaranteed at workpiece
University of Virginia - November 2010Advances in High Power Lasers 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
University of Virginia - November 2010Advances in High Power Lasers 6
TruDisk – Compact
5
4
3
2
1 Pump unit
Cavity
Laser resonator
Power feedback sensor
Central shutter
1
2
3
4
5
University of Virginia - November 2010Advances in High Power Lasers 7
TruDisk 4002 – 4 outputs
University of Virginia - November 2010Advances in High Power Lasers 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
Output power scaling of laser with number of coupled disks
2
2.6
3.3
4
Power per disk (kW)
4
3
5
6
# of pump modules
University of Virginia - November 2010Advances in High Power Lasers 9
Laser power is constant at the work piece
Reproducible processing results
Back reflections without any influence!
No warm-up time
Power range 3% - 100%
TruDisk - Closed loop power control
University of Virginia - November 2010Advances in High Power Lasers 10
TruDisk – Industrial optical interface
Fiber exchange without any alignment
Laser safe compartment
Hot-plug capable
Field upgradeable fiber outputs
TRUMPF Laser Network
University of Virginia - November 2010Advances in High Power Lasers 11
TruDisk – Cost effective
0%
25%
50%
75%
100%
1 2HLD4002 TruDisk 4002 (4C)0%
25%
50%
75%
100%
1 2HLD4002 TruDisk 4002 (4C)
Diodes from TRUMPF Photonics, USA
Higher diode power per bar
Less components
Extremely low operating cost
Manufacturing in N.A.
University of Virginia - November 2010Advances in High Power Lasers 12
TruDisk – Cost effective
0%
20%
40%
60%
80%
100%
HLD 4002 TruDisk 4002HLD 40022006
TruDisk 40022009
Footprint
0%
20%
40%
60%
80%
100%
HLD 4002 TruDisk 40022006 2009
Running cost
HLD 40022006
TruDisk 40022009
0%
20%
40%
60%
80%
100%
HLD 4002 TruDisk 4002
Invest
HLD 40022006
TruDisk 40022009
0%
100%
200%
300%
400%
500%
HLD 4002 TruDisk 4002
Max. output power
HLD2006
TruDisk2009
0%
20%
40%
60%
80%
100%
HLD 4002 TruDisk 4002
Diode lifetime
TruDisk 40022009
HLD 40022006
HLD 4002 = 1st generation disk laser / TruDisk 4002 = 3rd generation disk laser
University of Virginia - November 2010Advances in High Power Lasers 13
Industrial applications
Remote welding
Conventional laser keyhole welding
Hybrid laser welding
Laser metal deposition
Laser cutting
Remote laser cutting
….
University of Virginia - November 2010Advances in High Power Lasers 14
Why did Trumpf choose the disk laser architecture over the fiber laser architecture for high power?
Both are solid stateBoth are diode pumped with long life diodesBoth are fiber optic deliveredBoth have excellent BPPBoth are compactBoth have excellent WPEBoth are “non-monolithic” for industrial applicationsOnly 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 mediumOnly the disk laser is insensitive to back reflections
University of Virginia - November 2010Advances in High Power Lasers 15
Rod Laser Disk Laser
r
T
r
T
Pump lightQuasi frontal
- Parabolic temperature profile- Cooling and Pumping
via lateral area
- Flat temperature profile- Cooling via base area
Laser Emission
- +
Diode Laser
Direct conversionof current to light
Diode Laser Concept
University of Virginia - November 2010Advances in High Power Lasers 16
Application fields
BPP
[mm
mra
d]
Laser power in kW
10
20
30
40
50
1 2 3 4 5
Heat treatment / brazing
Cutting / Remote welding
Welding
84
TruDiode
TruDisk
University of Virginia - November 2010Advances in High Power Lasers 17
TruDiode Series
Long diode lifetime
Highest wall plug efficiency
Compact & Modular design
Beam quality and power
TruDiodeL A S E R
Lowest running costs
University of Virginia - November 2010Advances in High Power Lasers 18
Increase of wall plug efficiency of high-powered solid-state lasers
Wal
l plu
g ef
ficie
ncy
[%]
Year1995 2000 2005 2010
10
20
30
40
HL 4006D(lamp pumped rod)
HLD 4506(diode pumped rod)
TruDisk 4002(diode pumped disk)
TruDiode 4006(direct diode)
University of Virginia - November 2010Advances in High Power Lasers 19
TruDiode Products
0.11
0.11
0.11
0.11
0.11
NA
≥ 6004TruDiode 4006 [1]
≥ 6003TruDiode 3006
≥ 6002TruDiode 2006
≥ 6001TruDiode 1006
≥ 4000.8TruDiode 804
Fiber ∅[µm]
Power[kW]
[1] Available Q2, 2011
University of Virginia - November 2010Advances in High Power Lasers 20
TRUMPF Diode Module – the building blockExtremely 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
University of Virginia - November 2010Advances in High Power Lasers 21
Power Scaling
Power scaling
P = N x Pmodule
BPP = N0,5 x BPPmodule
N = 19
d = 5 x dmodule
N = 7
d = 3 x dmodule
University of Virginia - November 2010Advances in High Power Lasers 22
Power ScalingEfficient coupling of up to 19 modules
Laser unit
University of Virginia - November 2010Advances in High Power Lasers 23
Laser unit 2Wavelength λ2Power P2 Beam quality BPP2
Laser unit 1Wavelength λ1Power P1Beam quality BPP1
Wavelength coupling
Exit laser beamWavelength λ1+ λ2Power Pges = P1 + P2 ex 600 µmBPP = BPP1 = BPP2
Efficient coupling of up to 3 laser units
Power Scaling
University of Virginia - November 2010Advances in High Power Lasers 24
Optical design of a TruDiode 3006
Integrated beam guidance
Customer benefit
Plug & Play
Power feedback control
Power scaling
University of Virginia - November 2010Advances in High Power Lasers 25
Industrial applications
Conventional laser keyhole welding
Laser brazing
Hardening
Cladding
Heat conduction welding
Heat treatment
….
University of Virginia - November 2010Advances in High Power Lasers 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.)
University of Virginia - November 2010Advances in High Power Lasers
Thank you for your attention!
David HavrillaTRUMPF Inc.