laser technology live -...

LASER TECHNOLOGY LIVE

AKL’14 PRESENTATIONSAT FRAUNHOFER ILTAND APPLICATION CENTER

• WEDNESDAY, MAY 7, 201414:30 - 17:00 h

• THURSDAY, MAY 8, 201417:00 - 19:30 h

WWW.LASERCONGRESS .ORG

CONTENT – LASER TECHNOLOGY LIVE

Floor Plan 4

Presentations by Booth Numbers 5

Presentations by TopicsSpecial Exhibit 7Cutting 9Joining 11Surface Treatment 15Drilling 17Micro Technology (see also Additional) 18Modeling and Simulation 22System Technology 24EUV and Plasma Technology 27Laser and Laser Optics 28Nano Processing 39Additive Manufacturing 40Life Science 45Laser Components 46Generative Methods 47

Excellence Networks 48Fraunhofer ILT 48European Laser Institute ELI 49Arbeitskreis Lasertechnik e.V. 49Chamber of Commerce 50

Publishing Notes 50

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BOOTH LOCATION TOPIC SHORT DESCRIPTION PAGE

1 Entrance Central Information Fraunhofer Institute for Laser Technolgy ILT / Press Counter 48

2a Entrance Central Information AKL e.V. – Aix Laser People 49

2b Entrance Central Information ELI – European Laser Institute 49

3 Entrance Central Information RWTH Aachen Campus 48

4 Entrance Additive Manufacturing Aachen Center for 3D-Printing 40

5 Main Hall Special Exhibit Rolls-Royce BR715 Turbofan 7

6 Entrance Chamber of Commerce Chamber of Industry and Commerce Aachen (IHK Aachen) 50

8 E100.A10 Additive Manufacturing Development of a Technology Processor for Laser Metal Depositon 40 Wed

9 E100.A10 System Technology Certification of Powder Nozzles for LMD 23 Wed

10 E100.A11 Additive Manufacturing Additive Manufacturing by Laser Metal Deposition 41 Wed

11 E100.B12 Additive Manufacturing Laser Metal Deposition of Fe-Al based Alloys 41

12 E100.A14 Additive Manufacturing Additive Manufacturing of Parts for Energy and Aerospace Applications 42 Wed

13 E100.A14 Additive Manufacturing Additive Manufacturing of Microstructures with SLM 42

14 E100.A14 Additive Manufacturing Produtivity Increase by using Adaptive SLM Process Strategy 43 Wed

15 E100.A14 Additive Manufacturing High Power Selective Laser Melting (HP-SLM) 43 Wed

16 E100.A15 Laser Components Micro SLM (Selective Laser Melting) 46

17 E100.A09 Additive Manufacturing LMD of Steam Turbine Blades by using LMDCAM Software 44 Wed

18 E100.A09 Surface Treatment Micro Cladding with Dimensions below 100 µm 15

19 E100.B07 Joining Laser Beam Welding of Ultra High Strength Steels 11

20 E100.B07 System Technology Fully Integrated Quality-Control-System for Laser Brazing Applications 24

21 E100.B06 Joining / Cutting Diagnostics and Development System for High Speed Cutting and Welding 11, 7

22 E100.C03 Laser and Laser Optics Inner Processing Optics and Powder Feed Nozzles 28

23 E100.C02 Cutting Cutting of Fiber Reinforced Plastics 8

24 E160.3 Drilling Drilling with QCW Fiber Lasers by using a Scanner Optics 17 Wed

25 E160.2 Micro Technology Direct Laser Structuring of Printed Circuit Boards 18

26 E160.2 Cutting Cutting of Thin Glass 8

27 E160.2 Cutting Cutting of Glass with Ultrashort Pulsed Lasers 9

28 E160.2 Micro Technology Water guided Laser Cutting 19

29 E160.1 Micro Technology Texturing of Moulding Tool Surfaces 19

30 E100.A02 System Technology Multi-System Micro and High Speed Pyrometry 24

31 E100.A02 System Technology Polygon Scanner Applications 25 Wed

32 E100.A05 Additive Manufacturing Automated Tip Repair of Blade Tips by Laser Metal Depostition (LMD) 44 Wed

33 E100.A06 Surface TreatmentImproved Performance of Hot-Stamped Ultra-High-Strength-Steel Parts by Local Heat Treatment using a High Power Diode Laser

15

34 E100.A07 Micro Technology Glass Frit Sealing by Laser Radiation 20

35 Floor West Cutting Laser Processing Heads for Cutting and Welding 9

36 E044 EUV and Plasma Technology EUV Application Laboratory 27

37 E053 Laser and Laser Optics An Automated Setup for Measuring Laser-induced Damage Thresholds 28

38 E053 Laser and Laser Optics Modular INNOSLAB Platform 29

39 E053 Laser and Laser Optics Pulse Energy Scaled Single Frequency Laser for Optimized LIDT Measurements 29

40 E055.2 Life Science LIFTSYS – Laser-Induced-Forward-Transfer of Cells 45

41 E023 Life Science 3D-Photopolymerzation 45

42 E030 Joining Laser Transmission Welding of Polymerfilms 12

OVERV IEW

LASER TECHNOLOGY L IVE - AKL’14

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F LOORPLAN


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PRESENTATIONS

Wed Presentations also on Wednesday, May 7, 2014

FIRST FLOOR

BASEMENT

BOOTH LOCATION TOPIC SHORT DESCRIPTION PAGE

43 E030 Joining Joining of Fiber Reinforced Plastics (FRP) and Metal 12

44 E030 Joining TWIST Polymer Foil Welding with 1567 nm Erbium Fiber Laser Radiation 13

45 E055.1 Life Science Live Cell Imaging and Automated Cell Tracking 46

46 E032 Joining Laser Welding of Copper and Steel for Battery Modules 13

47 E032 Joining Laser Ribbon Bonding for Power Electronics 14

48 E034 Surface Treatment High Speed Laser Interference Patterning 16

49 Floor D Laser and Laser Optics Qualification of Opto-Mechanical Components for Applications in Harsh Environment 30

50 Floor D Laser and Laser Optics Freeform Optics for Automotive Applications 30

51 Floor D Laser and Laser Optics Tailoring of Freeform Optical Surfaces for Highly Customized Illumination Applications 31

52 Floor D Laser and Laser Optics High Brightness Diode Laser Module in the Red Spectral Range 31

53 Floor D Laser and Laser Optics Laser Ultrasound Testing for Carbon-Fiber-Reinforced Polymers 32

54 Floor D Laser and Laser Optics Automated Alignment of Micro Optics for High Power Diode Lasers 32

55 Floor D Laser and Laser Optics High-Power Dense Wavelength Division Multiplexing (HP-DWDM) 33

56 Floor D Laser and Laser Optics Automated Assembly of Optical Systems 33

57 Floor D Laser and Laser Optics Novel Design Concepts for Laser Optics 34

58 E112.1 Laser and Laser Optics High Power Ultrafast Yb:Innoslab Amplifier 34

59 E112.4 Laser and Laser Optics Pick & Align – Active Alignment of Optical Components 35

60 E112.4 Laser and Laser Optics 3D-Absorption Measurements of Optics on a ppm Scale 35

61 E103.2 Laser and Laser Optics 2 µm Lasers with Holmium and Thulium Doped Laser Materials 36

62 E103.2 Laser and Laser Optics Inverse Laser Drilling: High Aspect Ratio Microstructuring of Dielectrical Materials 36

63 Main Hall Generative Methods Process Monitoring for Selective Laser Melting SLM 47

64Main Hall E100.B09

System Technology Integrated Laser Solutions 25

65 Main Hall Cutting Process Observation in CO2 Laser Beam Cutting 10

66 Hallway Laser and Laser Optics Powder Feeding Nozzles for Laser Metal Deposition 37

67 Hallway Laser and Laser Optics Tunable Lasers & Frequency Converters for Output Wavelengths from UV to MIR 37

68 Hallway Modeling and Simulation Numerical Analysis of Laser Ablation and Damage in Glass 22

69 Hallway Modeling and Simulation Simulation of Laser Cutting and Welding 23

70 Hallway System Technology System Technology for Ultrashort Pulsed Laser Material Processing 26

71 Hallway Joining / Cutting Practical Laser Solutions for Cutting and Welding in Sheet Metal Products 10

72 Hallway Laser and Laser Optics Customized Electronics and Drivers for Laser Applications 38

73 Main Hall System Technology Process Monitoring for Selective Laser Melting SLM 26 Wed

74 Main Hall System Technology Process Observation in CO2 Laser Beam Cutting 27

75 U120.1 Nano Processing Functional Layers for Electronic Applications 38

76 U120.1 Nano Processing Laser Treatment of TCO Thin Films for OLED Lighting 39

77 U120.1 Surface Treatment Laser Polishing of Metals 16

78 U120.1 Surface Treatment Manufacturing of Glass Optics by Laser Ablation and Laser Polishing 17

79 U102.1 Drilling Laser-Beam Helical Drilling of High Quality Micro Holes 18

80 U102.1 Micro Technology Parallel Processing with Multi Beam Optics 21

81 U102.1 Micro Technology Roll-to-Roll Laser Patterning of Thin Functional Films 22

82 U102.1 Micro Technology Semiconductor Dicing with Ultrashort Pulsed Lasers 20

83 U102.1 Micro Technology Precision Laser Drilling with Helical Drilling Optics 21

SPECIAL EXHIBIT

Rolls-Royce BR715 Turbofan

It is the vision of Rolls-Royce to create better power for a changing world via twomain business segments, Aerospace and Marine & Industrial Power Systems (MIPS).These business segments address markets with two strong technology platforms, gasturbines and reciprocating engines, for use on land, at sea and in the air. Rolls-Roycehas customers in more than 120 countries, comprising more than 380 airlines andleasing customers, 160 armed forces, 4,000 marine customers, including 70 navies,and 1,600 energy and nuclear customers. The BR700 engines are the first Germancivil jet engines to be internationally certified. Their distinguishing features are theirlow operating costs, high ease of maintenance and strong environmental performance.The success of the BR700 family is evidenced by the fact that these engines havecompleted more than 16 million cumulative operating hours. The 100-seat Boeing717-200 is powered by Rolls-Royce BR715 turbofans.

Contact PersonSabine GerstnerPhone +49 6171 90 [email protected] Deutschland Ltd & Co KG

BOOTH 5MAIN HALL

Diagnostics and Development System for High SpeedCutting and Welding

For the development of cutting and welding processes Fraunhofer ILT uses a dynamic2D-machine with 5 g acceleration and 300 m/min maximum speed. Due to a fixedworking head/moved work piece, the machine is predestined for versatile diagnosticsin high speed process development. High speed laser processing is a key factor in theproduction chain of light weight components based on either fiber reinforced plastics(FRP) or high strength steel. Both materials are mechanically difficult to cut. Lasercutting is an attractive alternative to blanking or milling due to the fast, wear-freeand flexible features of the laser process. When cutting and welding automotive steel,a high processing speed and flexibility improves the economic efficiency. A cuttingspeed of 100 m/min in 1 mm thick steel can be achieved with 4 kW laser power.When processing FRP material in high speed processes, the desired effect is thereduction of thermal load of the material. As in processes which employ ultrashortpulsed laser radiation, a short interaction time minimizes the heat affected zone.

Contact PersonDr. Frank SchneiderPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 21E100.B6


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OVERV IEW


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PRESENTATIONS

CUTTING / JOINING

Wed Presentations also on Wednesday, May 7, 2014

Laser Processing Heads for Cutting and Welding

Laserfact GmbH develops, produces and delivers beam tools for flexible manufacturingwith lasers. The aim of Laserfact is the provision of laser processing heads whichperform extremely reliably, efficiently and flexibly in industrial laser applications.By using sophisticated optics and nozzle design combined with solid engineeringthe products of Laserfact achieve optimum performance with striking simplicity inconstruction, operation and application. Laserfact supplies beam tools for laser cuttingand laser welding with CO2 lasers and solid-state lasers.A specialty of Laserfact are combi-heads for flexible laser cutting and laser welding ofsheet metal components without changing heads. A combi-head allows software-controlledprocess change on demand and with it significant cost savings regarding investmentand operation.

Contact PersonHarald DicklerPhone +49 241 [email protected] GmbH

BOOTH 35FLOOR WEST

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CUTTING


Cutting of Fiber Reinforced Plastics

The reduction of cycle times for the production of fiber reinforced plastic (FRP)components is one of the priority objectives to push a wide-spread use of FRP compo-nents in mass production. FRP materials with a thermoplastic matrix are one approachto reach this goal. In contrast to thermoset materials, thermoplastic reinforced materialis moldable, can be remolten for joining and allows automated process chains includingprocesses such as tape laying / tape winding or 3D fiber spraying. Laser processes areinvolved throughout the process chain for cutting precursor material, for consolidation,cutting and trimming of parts or for joining and significantly contribute to increaseautomation and flexibility. Laser cut automotive parts are presented, either cut witha CO2 laser or with a fiber laser.

Contact PersonDipl.-Ing. Norbert WolfPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 23E100.C02

Cutting of Thin Glass

Laser micro-processing of thin glass is a rising business. Especially as flat-panel displayse.g. used in modern multimedia cell phones are a still rising market new technologiesfor machining of those thin glasses are needed. Therefore in the next years and alreadynow exists a vast demand for fast, efficient and highly qualitative manufacturing pro-cesses for thin glass sheets which include for example cutting and drilling of thin glasssheets. Laser processing especially with ultra-short pulse lasers is a promising solution.The main focus on the processes is a fast and crack free ablation of the glass. To achievea deep understanding of the process of ultra-short-pulsed laser ablation of dielectrics,the whole process is investigated including modeling and process diagnostics.

Contact PersonDipl.-Ing. (FH) Claudia HartmannPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 26E160.2


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CUTTING

CUTTING BOOTH 27E160.2

CUTTING

Cutting of Glass with Ultra Short Pulsed Lasers

Laser micro-processing of glass and sapphireis a rising business. Especially as flat-paneldisplays e.g. used in modern multimedia cell-phones are a still rising market newtechnologies for machinig of those thin glasses are needed. Therefore in the nextyears and already now exists a vast demand for fast, efficient and highly-qualitativemanufacturing processes for thin glass sheets which include for example cutting anddrilling of thin glass sheets. Laser processing especially with ultra short pulse lasers isa promising solution. The main focus on the processes is a fast and crack free ablationof the glass. To achieve a deep understanding of the process of ultra-short-pulsedlaser ablation of dielectrics, the whole process is investigated including modelling andprocess diagnostics.

Contact PersonDipl.-Ing. (FH) Claudia HartmannPhone +49 241 [email protected] für Lasertechnik ILT

Laser Beam Welding of Ultra High Strength Steels

Ultra high strength and supra-ductile steels are entering fields of new applications.Those materials are excellent candidates for modern light-weight construction andfunctional integration. As ultra high strength steels the stainless martensitic grade1.4034 and the bainitic steel UNS 53835 are investigated. For the supra-ductile steelsstand two high austenitic steels with 18 and 28 % manganese. As there are no pro-cessing windows an approach from the metallurgical base on is required. Adjusting theweld microstructure the Q+P and the QT steels require weld heat treatment. The HSDsteel is weldable without. Due to their applications the ultra high strength steels arewelded in as-rolled and strengthened condition. Also the reaction of the weld on hotstamping is reflected for the martensitic grades. The supra-ductile steels are weldedas solution annealed and work hardened by 50 %. The results show the generalsuitability for laser beam welding.

Contact PersonDipl.-Ing. Martin DahmenPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 19E100.B7

Diagnostics and Development System for High SpeedCutting and Welding

For the development of cutting and welding processes Fraunhofer ILT uses a dynamic2D-machine with 5 g acceleration and 300 m/min maximum speed. Due to a fixedworking head/moved work piece, the machine is predestined for versatile diagnosticsin high speed process development. High speed laser processing is a key factor in theproduction chain of light weight components based on either fiber reinforced plastics(FRP) or high strength steel. Both materials are mechanically difficult to cut. Laser cuttingis an attractive alternative to blanking or milling due to the fast, wear-free and flexiblefeatures of the laser process. When cutting and welding automotive steel, a highprocessing speed and flexibility improves the economic efficiency. A cutting speed of100 m/min in 1 mm thick steel can be achieved with 4 kW laser power. When processingFRP material in high speed processes, the desired effect is the reduction of thermal loadof the material. As in processes which employ ultrashort pulsed laser radiation, a shortinteraction time minimizes the heat affected zone.

Contact PersonDr. Frank SchneiderPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 21E100.B06

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JOINING

JOINING / CUTTING


Process Observation in CO2 Laser Beam Cutting

TRUMPF Trulas 5030 is one of the fastest Flat-Bed Laser Beam Cutting Machinescurrently available. As part of the Cluster of Excellence at RWTH Aachen University,ICD D2 "Technology Enablers for embedding Cognition and Self-Optimisation intoProduction Systems", this machine is equipped with an optical sensor system thatallows live observation of the process. A high-speed camera system coaxially coupledwith the processing beam monitors the 2 millimeter observation zone while the machinemoves the processing unit at max. 300 meters per minute accelerating with 1,7 g.Current works focus on strategies to analyse the acquired data in process to enableSelf-Optimisation of the machine. Together with the Fraunhofer ILT and NLD, a systemis developed that implements cognitive functions by means of a Controller Componentand a Meta-Modelled Knowledge Base.

Contact PersonsM.Sc. Dipl. Ing. B. Eng. (hon) Ulrich Thombansen / Dipl.-Phys. Stoyan StoyanovPhone +49 241 8906-320 / [email protected] / [email protected] für Lasertechnik ILT / Lehrstuhl für Lasertechnik LLT

BOOTH 65MAIN HALL

Practical Laser Solutions for Cutting and Weldingin Sheet Metal Products

Laser beam welding renders new application and new design solutions in sheet metalconstruction possible. Combined with laser beam cutting flexibility of production canbe maximized. New ways of design are approached utilizing the specific propertiesof both processes. The parts on display show a bunch of applications. Pipe fittingscan be welded using direct programming from calculation of the cylinder sections andsubsequent cutting and welding on the same track in one set-up. Production weldingof sandwich structures is facilitated by combining overlap and stake welds. A numberof material can be processed including mild steels with up to 0.35 % carbon, stainlesssteels, titanium alloys, nickel base alloys, as well as copper and bronze. Recently deve-loped are welding processes for aluminide-base alloys, martensitic stainless steels, anddissimilar materials. Sheet thickness range from small and mid section range in standardsheet metal construction to heavy sections with up to 20 mm, e.g. for parts for chemicalequipment, shipbuilding, and structural components.

Contact PersonBernd QuilitzschPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 71HALLWAY


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CUTTING

JOINING / CUTTING

TWIST Polymer Foil Welding with 1567 nm ErbiumFiber Laser Radiation

Laser polymer overlap welding is carried out in either a) contour or b) simultaneousor c) quasisimultaneous welding configuration. Since applying high-brilliance fiber laserradiation for polymer welding purposes with 1060 nm (Ytterbium fiber laser) or 1567 nm(Erbium f. l.) or 1940 nm (Thullium f. l.), another configuration called TWIST came upas a combination of contour and quasi simultaneous welding. TWIST is a superposititionof a low-speed linear and high-speed circular movement to smear out the high intensitypeak of gaussian-shaped fiber laser radiation. By this means, the heat affected zonehomogeneity can be increased compared to regular lens-shaped weld zones generatedwith diode lasers. Additionally, the seam width can be altered. Besides laser power P,welding speed v, focal diameter d, a TWIST-welded seam depends on the TWIST circlediameter D und TWIST circular speed c as well to achieve circle-to-circle overlap. This isdemonstrated with ILT's "TWISTER XL" prototype machine, welding polymer foils using1567 nm Erbium fiber laser radiation.

Contact PersonDipl.-Phys. Gerhard OttoPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 44E030

Laser Welding of Copper and Steel for Battery Modules

Lithium-Ion battery cells are currently the most promising technology for energy storagein e-mobility. The cost-efficient production of energy storage is a key technology forthis rapidly growing industry. The laser beam welding can make a major contributionfor flexible and reliable joints. Because of price and availability the so called 18650 cellscan be used, which are primarily built in notebook computers and power tools. Sincethese cells have a small capacity in comparison to large-sized cells, they must be connectedin parallel to form larger cells. In this case a copper terminal is welded to a nickel-platedlow alloy steel can of the cell in an overlap configuration. The can is the negative poleof the cell. The joint must be achieved without a full penetration of the approximately0.25 mm thick steel. This is carried out using spatial light modulation, whichenables a controlled weld depth.

Contact PersonDipl.-Ing. Benjamin MehlmannPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 46E032

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JOINING

JOINING


Laser Transmission Welding of Polymerfilms

Due to the requirements in the packaging industry to a more individual packagingdesign, to smaller lot sizes and greater format flexibility innovative solutions for thesealing process are required. The conventional sealing method uses tools with a fixedsealing contour and also requires special sealing layers on the films. The flexibility inchoice of material and packing geometry is thereby very small. Hence a new generationof high-power diode laser sources is used for sealing foil packaging. With a wavelengthrange from 1.5 to 1.9 microns, where many commercially available plastics in packagingtechnology have an absorption peak, it is possible to seal plastics directly without theneed of additional absorbers. In addition, by using a freely position able laser beam assealing tool any desired contour is feasible and fast format changes are possible. Lasertransmission welding is also suitable for the welding of high-barrier-layer multi-filmssuch as those be used for encapsulation of flexible solar cells or OLEDs.

Contact PersonM.Eng. Maximilian BrosdaPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 42E030


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JOINING

Joining of Fiber Reinforced Plastics (FRP) and Metal

Joining of lightweight components is gaining more and more importance especially inthe automotive industry. The latest international initiatives concerning the average fleetCO2-emissions like the agenda 2020 in Germany force the OEMs to reduce the fuelconsumption and the exhaust gas. New methods for weight optimization are enabledby the combination of fiber reinforced plastics and metals. These hybrid componentscombine their unique characteristics and thus can lead to advantageous constructionparts properties. As a result, light and simultaneously stiff components are realized.The need for joining these dissimilar materials without using additional materials likeadhesives or primers is the central challenge. An approach to overcome the problemsof state-of-the-art technologies is using laser radiation to ablate the metal surface inorder to create microstructures with undercut grooves. By melting the above placedplastic with laser radiation, the material expands into these structures and forms aftersetting a joint based on mechanical interlocking.

Contact PersonDipl. Wirt.-Ing. Christoph EngelmannPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 43E030

JOINING

Micro Cladding with Dimensions below 100 µm

Due to the need for an economical and ecological use of natural resources, there isan increasing market demand for processes which allow the selective contacting ofmicro parts with noble metals and alloys. Laser micro cladding is such a process. A finepowder is fed into the interaction zone of laserbeam and substrate and is completelymelted leaving a small contact dot or line with dimensions below 100 µm and an excellentbonding to the substrate. The heat input into the substrate is minimized due to thehigh precision of the process. A modified process is the dispensing of a paste containingthe noble metal and a subsequent laser melting which provides 100 % materialefficiency. A potential application are snapdomes which are nowadays completelygalvanizing. With micro laser cladding five small gold spots with a diameter of 100 µmare deposited saving a singifiant amount of gold. The functionality has been proven intests and the snapdomes also passed a lifecyle test of more than 500.000 actuations.

Contact PersonDipl.-Phys. Matthias BeltingPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 18E100.A09

Improved Performance of Hot-StampedUltra-High-Strength Steel Parts by Local Heat Treatmentusing a High Power Diode Lasers

Ultra-high-strength steels are widely used in the automotive industry. They allow areduction of weight and improve crash-behavior. A state of the art process for ultra-high-strength steel parts is hot-stamping of boron alloyed steels, producing fully mar-tensitic microstructures in the final part. Although hot-stamped parts offer fair ultimatestrain, higher ultimate strain may be required in critical zones to improve crash behaviorand joining. A way to increase ultimate strain in a desired zone is local softening by laserheat treatment. Non-treated areas retain their strength. The process is temperaturecontrolled, using a fiber-coupled high-power diode laser with a maximum laser powerof 12 kW and a zoom-optics with a rectangular beam profile and top hat intensitydistribution.

Contact PersonDipl.-Ing Sabrina VogtPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 33E100.A06

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SURFACE TREATMENT

SURFACE TREATMENT


Laser Ribbon Bonding for Power Electronics

Laser ribbon bonding is a new field of application for laser micro welding in theelectronics industry especially in the area of power electronics. Traditional ribbon bondingis conducted by using ultrasonic welding to create the bond between the aluminum orcopper ribbon and a conductive surface. By adapting an ultrasonic ribbon bonder andequipping it with a fiber laser, a galvanometric scanner and a beam focusing and deliverysystem, a new technology for ribbon bonding is created. Results will be displayed incudingaluminum and copper ribbon bonds with a thickness of about 250 to 300 µm to DCB-substrates. For the laser welding of the ribbons spatial power modulation is being usedand the effect of this approach on the welded ribbons is presented. At the booth themachine itself will not be presenten since it will be displayed at SMT Hybrid Packaging2014 at the same time.

Contact PersonDipl.-Ing. Benjamin MehlmannPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 47E032

Practical Laser Solutions for Cutting and Weldingin Sheet Metal Products

Laser beam welding renders new application and new design solutions in sheet metalconstruction possible. Combined with laser beam cutting flexibility of production canbe maximized. New ways of design are approach utilizing the specific properties of bothprocesses. The parts on display show a bunch of applications. Pipe fittings can be wel-ded using direct programming from calculation of the cylinder sections and subsequentcutting and welding on the same track in one set-up. Production welding of sandwichstructures is facilitated by combining overlap and stake welds. A number of materialcan be processed including mild steels with up to 0.35 % carbon, stainless steels,titanium alloys, nickel base alloys, as well as copper and bronze. Recently developed arewelding processes for aluminide-base alloys, martensitic stainless steels, and dissimilarmaterials. Sheet thickness range from small and mid section range in standard sheetmetal construction to heavy sections with up to 20 mm, e.g. for parts for chemicalequipment, shipbuilding, and structural components.

Contact PersonBernd QuilitzschPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 71HALLWAY


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JOINING

CUTTING / JOINING

Manufacturing of Glass Optics by Laser Ablationand Laser Polishing

The current state of the development of a laser based process chain for manufacturingfused silica optics is presented. This process chain is currently under developmentand focuses on the fabrication of highly individualized, non-spherical optics, sinceconventional manufacturing methods tend to be comparatively slow and expensive inthis field. In a first step fused silica is ablated with laser radiation to produce the geo-metry of the optics. A subsequent laser polishing step reduces the surface roughnessand a third step uses micro ablation to remove the last remaining redundant material.Although the process chain is still under development, the ablation of fused silica alreadyreaches ablation rates above 20 mm³/s. The second step, the laser polishing, reducesthe roughness significantly. The micro-roughness is already suitable for optics but theform accuracy is still insufficient. Therefore the third processing step is under develop-ment to optimize the form accuracy.

Contact PersonDipl.-Ing. Sebastian HeidrichPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 78U120.1

Drilling with QCW Fiber Lasers by using a Scanner Optics

Laser drilling enables the machining of different materials such as steel, high-strengthmaterials, multi layer systems or ceramics with high reproducibility and productivity.It offers an alternative manufacturing method to mechanical drilling, electric dischargemachining (EDM), electro chemical machining as well as electron beam drilling. Laserdrilling is applicable for many manufacturing demands in industry due to the smallachievable hole diameters, high flexibility (e. g. different diameters and inclinationangles) and the large attainable aspect ratios. By using new diode-pumped lasers suchas QCW fiber lasers, it is possible to increase quality and productivity on the same time.In order to increase the productivity for holes with large diameters of e.g. 600 µm, suchas cooling holes in turbo machinery parts, a scanner optics is used to quickly deflect thelaser radiation. In comparison to trepanning with a relative movement between thedrilling optic and the work piece, the drilling time can be decreased to a few 100 ms.

Contact PersonDipl.-Ing. Hermann UchtmannPhone +49 241 [email protected] für Lasertechnik LLT

BOOTH 24E160.3

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SURFACE TREATMENT

DRILLING


High Speed Laser Interference Patterning

Functionalization of surfaces with Nanostructures for Selectively Influencing its propertiesdeliver many possible applications in a wide field of different markets. While StochasticNanostructures can be created by various rather inexpensive methods and even on largeareas, is the creation of Deterministic Nanostructures expensive and often limited tosmall areas. Multi-Beam-Interference (MBI) allows to directly enhance surfaces withperiodical structures with a size from 100 to 5000 nm in one process step. It is relativematerial independent and can be applied on most polymers and metals. Normally a"spot-by-spot"-approach is used to structure areas larger than diameter of the over-lapping laser beams which has the disadvantage of a high process time. To overcomethis handicap we like to present you a new approach with a continuous movementalong a symmetry axis of interference intensity distribution. It allows a huge decreasein process time and more homogenous structuring of large areas.

Contact PersonDipl. Phys. Michael StegerPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 48E034

Laser Polishing of Metals

The latest results on laser polishing of metals will be shown:

• Machine tool for Laser Polishing• CAM-NC Data Chain for easy Programming of the Polishingof Complex Dhaped 3D Parts

• Simultaneous and Synchronized Movement of 5 Mechanical Axesand 3 Scanner Axes together with a Measuring Probe for easy Work Piece Alignment

• Additive Manufactured SLM parts Polished with Lasers• 2-Gloss-Effects on Tools• Further Laser Polished Samples (e.g. Titanium, Inconel 718,Aluminium, Tool Steel 1.2343, GGG40, …)

Contact PersonDipl.-Ing. Ingo RossPhone+49 241 [email protected] für Lasertechnik ILT

BOOTH 77U120.1


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SURFACE TREATMENT

SURFACE TREATMENT

Water guided Laser Cutting

In conventional laser processes the laser beam is focused with a lens onto the work-piece. The resulting beam caustic limits the applicable working distance to the Rayleighlength – typical in the range of few hundred microns. By using a micro water jet asoptical guide – similar to an optical fibre used in telecommunication – it is possibleto extend the applicable working distance to several millimeter up to centimeters.The waterjet is created with a special sapphire nozzle with diameters in the range from30 - 100 µm. The guidance inside the water jet generates a tophat intensity distributionwhich enables even material ablation across the diameter. The main advantage comparedto all other technologies is the possible big aspect ratio and the high quality of thecutting kerf. Furthermore this process creates cutting geometries with parallel walls.The main applications for this technology are the cutting of metal, mechanical compo-nents and precision drilling with high aspect ratios.

Contact PersonDipl.-Phys. Patrick GretzkiPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 28E160.2

Texturing of Moulding Tool Surfaces

Micro- and nano-structured surfaces in plastics are now found in many areas ofeveryday life. Many of these structures are inserted during the injection moldingprocess with a structured tool inserts. These tool inserts can be made by usinglasers with ultrashort pulses. The use of ultrafast lasers offers the advantage oflarge independency from the chosen material, so that e.g. hardened steel toolscan be edited. Likewise, the geometry influencing melting deposits, which areobtained through the use of nanosecond lasers can be avoided to a large extent.In another application, the melt-free structuring of mechanically stressed surfaces,offers a way of minimizing friction for example on components of internal combustionengines.

Contact PersonDipl.-Ing. Andreas DohrnPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 29E160.1

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MICRO TECHNOLOGY

MICRO TECHNOLOGY


Laser-Beam Helical Drilling of High Quality Micro Holes

A large variety of modern components and products such as fuel injectors and spinningnozzles require holes drilled to very high standards with regard to roundness, diameterand aspect ratio. Laser-beam helical drilling has shown great promise to produce thesehigh quality micro holes.In helical drilling the laser beam is moved in rotation relative to the work piece. In thiscase, the rotational movement is produced using a Dove Prism, mounted in a highspeed, hollow shaft motor. If the beam is shifted parallel to the optical axis, the out-going beam moves on a circular path; if, however, it is tilted in front of the prism, theoutgoing beam traces the shape a cone. Helical drilling allows the production of exactcylindrical and round holes in the range of 50 µm as well as negatively tapered holes.

Contact PersonDipl.-Ing. Dipl.-Wirt.-Ing. Christian FornaroliPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 79U102.1

Direct Laser Structuring of printed Circuit Boards

High integration in electronics manufacturing requires on the one hand highlyfunctional active electronics components and on the other hand technologies to gene-rate high density printed circuit boards. Moreover electronics are used with increasingapplications as distributed systems where often sensors and data handling have to beintegrated into three dimensional structural components such as casings of the specificproduct. In both cases conventional lithographic and etching patterning technologies ofthe conducting layers do not provide the necessary flexibility for small series productionand prototyping. Using laser ablation with ultra-short pulsed lasers these restrictionscan be resolved. Even patterned circuit boards with structure size of < 20 µm can begenerated on complex 3D-parts.

Contact PersonDipl.-Phys. Patrick GretzkiPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 25E160.2


18

DRILLING

MICRO TECHNOLOGY

Precision Laser Drilling with Helical Drilling Optics

A large variety of modern components and products such as fuel injectors and spinningnozzles require holes drilled to very high standards with regard to roundness, diameterand aspect ratio. Laser beam helical drilling has shown great promise to produce thesehigh quality micro holes. In helical drilling the laser beam is moved in rotation relativeto the work piece. In this case, the rotational movement is produced using a Doveprism, mounted in a high speed, hollow shaft motor. If the beam is shifted parallel tothe optical axis, the outgoing beam moves on a circular path; if, however, it is tilted infront of the prism, the outgoing beam traces the shape a cone. Helical drilling allowsthe production of exact cylindrical and round holes in the range of 50 µm as well asnegatively tapered holes.

Contact PersonDipl.-Ing. Dipl.-Wirt.-Ing Christian FornaroliPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 83U102.1

Parallel Processing with Multi Beam Optics

Laser patterning of functional thin films is an important industrial process for applicationslike thin film solar modules, organic LEDs and flexible electronics. The lateral patterngeometry often consists of line segments that are created by moving the workpiece(e.g. large glass panes for thin film PV or continuous film web for roll-to-roll processingof flexible electronics) below a comb of laser beams, or by galvanometer scanners.A combination of both can help to increase the throughput of laser patterning processesdrastically. The exhibit shows an optical system consisting of a diffractive optical element,imaging optics a galvanometer scanner and a plane field objective, which creates acomb of four foci that can be moved at high speeds using the scanner. Applicationsin silicon PV and thin films electronics are illustrated.

Contact PersonDr. Malte Schulz-RuhtenbergPhone +49 241 8906-604malte.schulz-ruhtenberg@ilt.fraunhofer.deFraunhofer-Institut für Lasertechnik ILT

BOOTH 80U102.1

21

MICRO TECHNOLOGY

MICRO TECHNOLOGY


Glass Frit Sealing by Laser Radiation

In industrial manufacturing glass solders are mainly applied in electro technology andelectronics especially for the closure of electrode feedthrough and housing. The dura-bility and the mechanical load of a glass solder joint depends on the mechanical stresses.Because of the problems with mechanical stresses the most joining processes requirea temperature-time-profile which causes a thermal impact for the whole componentry.Often the required temperature sequence damages sensible components inside thehousing by diffusion processes. Thus a soldering technology which works with reducedtemperature input and a local heating is needed. Glass soldering by laser radiation isan alternative to reduce the thermal input because of the localised energy absorption.The absorption of the laser radiation by the glass solder is an essential condition for asuccessful soldering process. By absorption the laser radiation the necessary temperaturefor a constant heating, melting and crack free soldering is achieved.

Contact PersonDipl.-Ing. Heidrun KindPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 34E100.A07

Semiconductor Dicing with Ultrashort Pulsed Lasers

In semiconductor manufacturing, the active components are generally produced withthin film technologies on large scale silicon semiconductor wafers. At the last processingstep the single components have to be cut out of the wafer , which is done by diamondcutting, which requires cutting width areas of more than 50 µm. To achive a maximumyield of components out of a large wafer, the width of the cutting streets have to beminimized. Numerous laser processes are used for dicing wafers, but they fail at wafersfor LEDs with metallization layers. Based on high precision polygon scanning mirrors anew approach has been developed using high repetition rate ultra fast lasers. With thisapproach cutting with of less than 20 µm has been achieved and the influence of thecutting process on the functionality of the semiconductor device has been minimized.The new dicing system consists of ultrafast scanning with speeds > 100 m/s and anultrashort pulsed laser.

Contact PersonDipl.-Ing. Dipl.-Wirt.-Ing Christian FornaroliPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 82U102.1


20

MICRO TECHNOLOGY

MICRO TECHNOLOGY

Simulation of Laser Cutting and Welding

Laser cutting and welding are well established production technologies, which in theindustrial application are rated by productivity and product quality. Nevertheless, thereseems to be still a certain potential for a design optimization based on physical modelingand numerical simulation. For laser cutting an interactive metamodel based on anapproximative model has been developed, which helps to optimise the process itself.For laser welding one important quality characteristic is the component distortion.The simulation of the heat distribution inside the component makes it possible to opti-mise the distortion. A substitute heat source is formulated to determine the temperaturefields. The automation and the acceleration of the determination simplifies the applicationof simulation tools and raises the efficiency. Quick numerical methods and optimisationalgorithms which automatically find the model parameters on the basis of the experimentaldata were implemented.

Contact PersonDr. Markus NießenPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 69HALLWAY

Certification of Powder Nozzles for LMD

The Laser Metal Deposition (LMD) has established as a technology for functionalizationof surfaces, repair and modification of components as well as generation of new parts.The most important field of application is the manufacturing of tools and combustionengines, stationary gas turbines and aero engines. At the LMD process a filler materialin form of a powder is melted using the laser beam and fused with the base material.Therefore the powder feeding into the melt pool is an important influencing variablefor the result of the process. The powder efficiency, the oxidation by the ambientatmosphere and the roughness of the cladded layer are influenced by this parameter.For this reason there is a need for a characterization of the powder-gas-flow to assurethe quality of the processing result. As a solution a measurement method has beendeveloped that allows to scan the powder density distribution of the entire powder-gas-flow. This method is used to certificate powder nozzles by standardized parameters.

Contact PersonDipl.-Ing. Stefan MannPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 09E100.A10

23

MODELING AND SIMULATION

SYSTEM TECHNOLOGY


Roll-to-Roll Laser Patterning of Thin Functional Films

Organic electronics is promising to be one of the groundbreaking technologies torevolutionize our everyday lives by including new functionalities into nearly any item.Cost is the most significant barrier, since new functionalities should not increase theprice of the product dramatically. Roll-to-roll production is the solution to overcomethe price barrier. In combination with integrated laser processes new possibilities areopened up for cost-efficient, versatile and high throughput manufacturing lines. Laserpatterning – the selective removal of layers without impact on the surrounding material– plays a key role in establishing thin film technologies in production. The exhibit showsa modular lab system for roll-to-roll film printing, drying and laser patterning. The lasermodule consists of a 1 to 11 beam splitter for parallelization and a galvo scanner forflexbility.

Contact PersonDr. Malte Schulz-RuhtenbergPhone +49 241 8906-604malte.schulz-ruhtenberg@ilt.fraunhofer.deFraunhofer-Institut für Lasertechnik ILT

BOOTH 81U102.1

Numerical Analysis of Laser Ablation and Damage in Glass

Display manufacturers are striving to thinner and harder display out of glass pushingconventional cutting processes to their limits. Milling as well as laser ablation withps-pulse duration became recognized as promising solutions. However, there are gapsin understanding the mechanisms involved in laser ablation, especially issues related tocut quality and maximum ablation depth. A theoretical model describing laser ablationas well as laser damage in glass was developed showing well agreement with experimentalresults. The spatial distribution and the density of free electrons result from two dominantmechanisms, namely, radiation propagation in the ablated cavity as well as in the glassand nonlinear absorption of ultra-short laser pulses. The model gives insight how cratershape, morphology of the ablation front and damage within the glass evolve andpredicts three different kinds of spatially distributed damage mechanisms dependingon shape and morphology of the ablation front.

Contact PersonDipl.-Phys. Urs EppeltPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 68HALLWAY


22

MICRO TECHNOLOGY

MODELING AND SIMULATION

Polygon Scanner Applications

Latest developments in high power ps-lasers achieve new records regarding averagelaser power and pulse rate. Due to the high scanning speed of polygon scanners a lowpulse overlap can be achieved for an optimal result in full utilization of the laser power.The new developed prototype of a polygon scanner based micro structuring machinehas a scan field of 100 mm and a maximum scan speed of 360 m/s using optics with160 mm focal length. Biggest challenges to be solved are the modulation of the laserbeam with several megahertz synchronously to the laser pulses and the correspondinglyadapted positioning of the laser beam on the work piece. Areas of application includethe large-scale structuring or laser treatment of different materials with high powerps-lasers. In addition to current applications of the system with ps-lasers, high-speedprocesses with cw-lasers, such as the quasi simultaneous soldering of solar cells ordicing of semiconductor wafers, are possible.

Contact PersonDipl.-Ing. Oliver NottrodtPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 31E100.A02

Integrated Laser Solutions

LUNOVU develops and manufactures integrated laser machine systems for industryand R&D. Based on an exceptional expertise in mechanical design, automation and laserprocesses, LUNOVU provides system solutions for various applications, such as lasercladding, laser welding, laser polishing, laser micro joining, laser functionalization andothers. Being part of a large R&D network, LUNOVU continuously integrates latestlaser technology into its products. As product development is strictly driven by marketrequirements, the machine solutions provide significant added value to customers.LUNOVU laser machine systems provide innovative technology, combined with maximumoperational efficiency and reliability.

Contact PersonDr. Rainer BeccardPhone +49 241 [email protected] Integrated Laser Solutions GmbH

BOOTH 64MAIN HALL

25

SYSTEM TECHNOLOGY

SYSTEM TECHNOLOGY


Fully integrated Quality-Control-Systemfor Laser Brazing Applications

In Cooperation with Scansonic MI GmbH the Fraunhofer ILT presents a quality controlsystem for laser brazing. A high-speed camera is fully integrated into the brazing opticsAlO3 without affecting the accessibility of the optics for joining 3D-parts. The observati-on system is completed by an innovative illumination modul that is also fully integratedinto the brazing head. With this system the full brazing process is documented in anon-line configuration; machine parameters are monitrred as well as the product quality.The actual movement of the handling system is measured at the tool-center-point.Additionally the system aims the monitoring of seam imperfections like pores andwetting behaviour of the process. As algorithms are implemented on FPGA-technologythe system is capable for real-time monitorring which opens up the possibility forclose-loop applications and will reduce set-up times. A live presentation on contactlessvelocity measurement at tool-centre-point ist given and results on quality monitorringduring the laser brazing process are presented.

Contact PersonDipl.-Phys. Michael UngersPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 20E100.B07

Multi-System Micro and High Speed Pyrometry

In photovoltaic laser soldering is an established process to bond elongated interconnectorsto metallized silicon wafers. A main advantage of the laser soldering process is thespatial and temporal controllability of laser beam power. This enables a specific energydeposition for each individual solar cell. New on-line process control techniques havebeen investigated that uses multi-system micro-pyrometry and high-speed pyrometry.As a controller platform a new developed controller system of the Amtron Companyhas been adapted to the present task for quasi continuous laser soldering. As a beamguiding system a scanning unit is applied. Thermal radiation emitted by the process ismeasured by multi-system micro-pyrometric devices located laterally to the processingarea. An additional pyrometric device is coaxially integrated into the laser beam path.All signals are processed within a single controller unit which also enables the close-loop control of the process.

Contact PersonDipl.-Ing. (FH) M.Sc. SFI (IWE) Wolfgang FiedlerPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 30E100.A02


24

SYSTEM TECHNOLOGY

SYSTEM TECHNOLOGY

Process Observation in CO2 Laser Beam Cutting

TRUMPF Trulas 5030 is one of the fastest Flat-Bed Laser Beam Cutting Machinescurrently available. As part of the Cluster of Excellence at RWTH Aachen University,ICD D2 "Technology Enablers for embedding Cognition and Self-Optimisation into Pro-duction Systems", this machine is equipped with an optical sensor system that allowslive observation of the process. A high-speed camera system coaxially coupled with theprocessing beam monitors the 2 millimeter interaction zone while the machine movesthe processing unit at 200 meter per minute accelerating with 2 g. Current works focuson strategies to analyse the acquired data in process to enable Self-Optimisation ofthe machine. Together with the Fraunhofer ILT and Chair NLD, a system is developedthat implements cognitive functions by means of a Controller Component and aMeta-Modelled Knowledge Base.

Contact PersonM.Sc. Dipl. Ing. (FH) B. Eng. (hon) Ulrich ThombansenPhone +49 241 [email protected] für Lasertechnik LLT

BOOTH 74MAIN HALL

EUV Application Laboratory

Technological application of Extreme Ultraviolet (EUV) radiation is at the forefront of themodern science and is gaining more and more industrial relevance as the semiconductorindustry is making a switch from structuring with 193 nm (DUV) to 13.5 nm (EUV)wavelength. In the EUV Application Laboratory at Fraunhofer ILT/RWTH Aachen varioushighly promising applications are being explored and evaluated. The setup for ultra-high resolution EUV interference lithography suited for large area nanoscale structuringwill be demonstrated, as well as a novel dark-field EUV defect inspection system forEUV Mask blanks with sub-100 nm defect size sensitivity. Additionally, the uniquelaboratory-based multi-angle EUV reflectometer will be shown, which allows to deter-mine not only a thickness of thin films with sub-nm precision but also their chemicalcomposition. All setups are built in-house and are using efficient and compact radiationsources based on the Fraunhofer ILT developed technology.

Contact PersonDr. Serhiy DanylyukPhone +49 241 [email protected] für Technologie Optischer Systeme TOS

BOOTH 36E044

27

SYSTEM TECHNOLOGY

EUV AND PLASMA TECHNOLOGY


System Technology for Ultrashort-PulsedLaser Material Processing

Pulsar Photonics presents a tool system that stands out by its integrated inspectionroutines and workflow management – all consistently dedicated to ultra-short pulse lasermaterial processing. Embedded sensors and networked actuators offer the industry4.0 capability of machine data acquisition with benefits of an improved reliability. Theadvantages of inline measuring capabilities become particularly visible in the single-partand small batch production, e.g. by shortening process development cycles and usingfree machine capacity for lean component qualification. For competitive series applicationsPulsar Photonics focuses on the increased efficiency by multiple beam processing. In anencapsulated multi-beam module, the laser beam is divided into up to 100 parallelizedpartial beams, thus enabling the efficient production of periodic structures, large-scaledablation or the parallel processing of multiple components.

Contact PersonDipl.-Ing. Joachim RyllPhone +49 241 [email protected] Photonics GmbH

BOOTH 70HALLWAY

Process Monitoring for Selective Laser Melting SLM

Process control for Selective Laser Melting is seen as one of the key enablers for futureseries production of SLM built parts. The Fraunhofer ILT shows a manufacturing systemat lab-level which makes a vital step towards this goal. As a laboratory system, the opticaltrain is specifically designed and optimised for process control. It uses a pre-focus systemin combination with a fast closed loop scanning system and interfaces to a set of coaxiallycoupled sensors to observe the melting process. Pyrometric sensors detect radiationfrom the melt pool at 100 kHz and a camera system provides a visual image of theprocessing zone while the beam position is recorded synchronously. The signals arevisualized as a so called emission map which provides a spatial resolution of 100 microneven at scanning speeds of 10 m/s. As such, the monitoring system allows the detectionof deviations in the thermal emission during the SLM process indicating potentialprocess instabilities or defects in the SLM built parts.

Contact PersonM.Sc. Dipl. Ing. (FH) B. Eng. (hon) Ulrich ThombansenPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 73MAIN HALL


26

SYSTEM TECHNOLOGY

SYSTEM TECHNOLOGY

Modular INNOSLAB Platform

Over the past decade the Innoslab has proven that it is a flexible and efficient platformfor high power laser oscillators and amplifiers with a wide parameter range. Companieslike Edgewave and AMPHOS successfully take the design as a basis for their laser systems.Especially Innoslab amplifiers have proven that they can scale the power and energyof small or medium power oscillators while maintaining the specific properties of theoscillator. Lasers with pulse lengths from ps to ns and cw lasers have been amplifiedthis way. The presented modular platform is the basis of several custom-designed lasersystems that were delivered by Fraunhofer ILT in the past years. Due to its flexible layoutit can be adapted to provide a solution for a large variety of customer requests. Theplatform supports applications where Nd based lasers are the right choice. Actuallyadaptations of the platform to host materials like Tm and Ho for applications at wave-lengths around 2 µm are under development.

Contact PersonDipl.-Phys. Marco HöferPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 38E053

Pulse Energy Scaled Single Frequency Laserfor Optimized LIDT Measurements

For LIDT measurements of optical components usually high pulse energies and stabletemporal profiles are required to ensure realistic and representative test beam conditions.To provide that for the Fraunhofer ILT LIDT measurement setup and to demonstrateenergy scaling properties of the Innoslab concept the energy scaling of a 80 mJ MOPAsystem to the 500 mJ level in a single 5-pass Innoslab-based amplifier stage is currentlybeing developed. The technology of the 80 mJ stage was already demonstratedsuccessfully in different setups also for airborne LIDAR systems. It consists of a stableQ-switched and injection seeded single frequency oscillator with Pulse Energies below10 mJ and a subsequent 7-pass Innoslab amplifier. These systems are operated at arepetition rate of 100 Hz with pulse durations in the x*10 ns regime. For the 80 mJMOPA the compact setup was inherited from the airborne systems. The whole setupis currently under construction.

Contact PersonDr. Jens LöhringPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 39E053

29

LASER AND LASER OPTICS



Inner Processing Optics and Powder Feed Nozzles

IXUN Lasertechnik GmbH develops and delivers customised laser optics (in particular,inner processing optics) as well as powder and protective gas nozzles for all laser beamsources for processing (laser hardening, alloying, joining and laser cladding/coating)of outer and inner contours. With know-how and long-term experience in the sectorof surface processing with laser radiation, IXUN Lasertechnik GmbH offers individualsolutions for processing of single parts and mass production components. Range ofservices:Laser Cladding, Laser Hardening, Processing of individual and series parts, Pre- andpost-processing for delivery of pre-finished, laser-processed components, Feasibilitystudies, Consultation for the development of custom laser plant concepts, Supportand consultation for production ramp-up and problematic cases.

Contact PersonDr. Khudaverdi KarimovPhone +49 241 [email protected] Lasertechnik GmbH

BOOTH 22E100.C03

An Automated Setup for Measuring Laser-inducedDamage Thresholds

The Laser-induced Damage Thresholds (LIDT) of optical components are major designissues for the laser engineer as they limit efficiency and lifetime of many laser systems.Not only does the LIDT of an optical component depend on the laser parameters suchas pulse duration, wavelength, beam profile, etc.; it is also closely linked to the productionprocess and thus difficult to estimate. This setup allows testing of optical componentswith respect to LIDT and qualification of batches of them for usage in volatile lasersystems. It is conform with ISO 11254-2 and can be adapted to a large variety of laserparameters. A monitoring system detects damage of a test spot online and stopsits irradiation. In this way, contamination of the test sample is prevented and moretest spots can be placed on the test sample. Environmental conditions can be defined(vacuum with p < 1e-5 mbar or vented with process gas).

Contact PersonDipl.-Phys. Ansgar MeissnerPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 37E053


28



Tailoring of Freeform Optical Surfaces for HighlyCustomized Illumination Applications

LEDs are becoming a light source of great importance, allowing very flexible beamshaping due to their limited spatial extent. Here, the techniques of classical opticsdesign can no longer be applied as demands on target intensity distributions andoptical efficiency are particularly high. It is thus required that new concepts are developedfor the design of efficient and flexible optics. Instead of classical lens geometries, generalrefracting or reflecting surfaces (freeform surfaces) are used in the optical design.Their shape is established using complex mathematical algorithms which are developedat Fraunhofer ILT. LED systems for the uniform illumination of square and rectangularareas were designed. Additionally, the flexibility of this approach was demonstratedby creating arbitrary irradiance distributions in the target plane.

Contact PersonDipl.-Phys. Michael BerensPhone +49 241 [email protected] für Technologie Optischer Systeme TOS

BOOTH 51FLOOR D

High Brightness Diode Laser Modulein the Red Spectral Range

High brightness beam sources with emission in the red spectral range are required fordirect materials processing, medical technology or pumping solid-state lasers, e.g. analexandrite laser for climate research. An optomechanical concept for the tight overlayof the radiation using a minimal number of optical components for collimation andfocusing is presented. The concept can be quickly tailored to individual customer require-ments for the entire spectral range from UV through to IR. The optics were designedusing commercial ray-tracing software for optimum intensity distribution of the pumpradiation in the crystal. Diffraction at the FAC is taken into account by use of a proprietarysoftware library for wave optical simulation (OPT). In order to ensure a homogeneoustemperature of the diodes and hence a spectral width that is as small as possible, theshape of the heat sinks was modified accordingly. An optical output power of 15.5 W(35 Hz, 100 µs) was realized. The beam quality is measured to M² = 25 and M² = 41in the FA and the SA respectively.

Contact PersonDipl.-Phys. Ulrich WittePhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 52FLOOR D

31




Qualification of Opto-Mechanical Componentsfor Applications in Harsh Environment

Laser resonators and complex sequential amplifier and frequency converting setupsrequire a high mechanical stability of the optical components. For example, typical tiltstability requirements of oscillator mirrors are in the range of a few µrad. For scientificapplications the environmental laboratory conditions are quite stable regarding tem-perature, humidity, pressure, etc. and usually offer low vibrational loads. In industrialor scientific fields though, many laser applications demand stable laser operation inunstable environments. This is particularly the case in airborne or spaceborne LIDAR-lasers where frequency, pointing and power output stabilities have to be maintainedat different environmental conditions and with inevitable vibrational noise and mechanicalshocks (e.g. during handling). During development and qualification of opto-mechanicalcomponents and sub-assemblies, these are subjected to thermal tests, mechanicaltests (vibration and shock) and experimental modal analysis (to determine resonancefrequencies).

Contact PersonDipl.-Ing. Erik LiermannPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 49FLOOR D

Freeform Optics for Automotive Applications

Traditional illumination optics based on apertures and imaging optical components arelimited in terms of efficiency and compactness. These approaches depend on numerousoptical components which make the alignment process complicated. By using freeformoptics, all optical functions can be integrated into one component. The freeform opticstransform the input intensity distribution (e.g. given by an LED) into a desired outputintensity distribution. At Fraunhofer ILT and Chair TOS, efficient algorithms have beendeveloped to calculate the shape of freeform optics by the input and output intensitydistributions. Within the BMBF funded project AUTOLIGHT, segmented freeform opticshave been developed which generate a fog light and a daytime running light intensitydistribution with one integrated optical component. By segmenting the surfaces ofthe freeform optics, the thickness of the optics can be limited, and the replication ofpolymer freeform optics is simplified. The freeform lens as well as other freeform opticsare displayed.

Contact PersonDipl.-Ing. Dipl.-Wirt.Ing. Martin TraubPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 50FLOOR D


30



High-Power Dense Wavelength DivisionMultiplexing (HP-DWDM)

Direct diode applications as well as many pump modules require high-brightness butmedium brilliance. Therefore, we present a High-Power Dense Wavelength DivisionMultiplexer based on Volume Bragg Gratings (VBGs) for spectrally stabilized diode lasers.The center wavelengths of the five input channels with a spectral spacing of 1.5 nmare 973 nm, 974.5 nm, 976 nm, 977.5 nm and 979 nm. Multiplexing efficiencies of97 % ± 2 % have been demonstrated with single mode, frequency stabilized laserradiation. Since the diffraction efficiency strongly depends on the beam quality, themultiplexing efficiency decreases to 94 % (M² = 25) and 85 % ± 3 % (M² = 45) ifmultimode radiation is overlaid. Besides, the calculated multiplexing efficiency ofthe radiation with M² = 45 amounts to 87.5 %. Thus, calculations and measurementsare in good agreement. In addition, we present a dynamic temperature control forthe multiplexing VBGs and frequency stabilized diode laser bars with a spectral widthof < 120 pm.

Contact PersonDipl.-Ing. Stefan HengesbachPhone +49 241 8906 [email protected] für Lasertechnik ILT

BOOTH 55FLOOR D

Automated Assembly of Optical Systems

Presented is a mobile assembly cell for optical systems. Hereby the automated assemblyof individual optical systems should be realized. In order to reduce the size, cost andassembly effort, the system uses a planar design of the optical system developed here atthe Fraunhofer ILT. By using a high precision robot the optical components of the opticalsystem can be alligned accurately up to 300 nm. Another outstanding advantage is thatno adjustable mounts for the lenses are necessary, greatly simplifying the setup. Thesoftware for the cell is kept modular by using a Multi-Agent-System. This makes it easyto switch certain devices like the robot system, the optical model etc. in order to changethe setup or to work on another assembly cell without changing the whole software.This also makes later developments of a measurment system and fitting analyzing toolsfor the optical model very efficient.

Contact PersonM.Sc. Martin HoltersPhone +49 241 [email protected] für Technologie Optischer Systeme TOS

BOOTH 56FLOOR D

33




Laser Ultrasound Testing forCarbon-Fiber-Reinforced Polymers

In aerospace and automotive engineering lightweight design is of high significance.An essential task is the non-destructive testing of lightweight parts made of carbon-fiber-reinforced polymers (CFRP) and the adhesive joints of these parts. For this ultra-sound testing is the most common approach. For large and complex parts (e.g. in aero-space) classical contacting ultrasound devices are insufficient in terms of measurementspeed, contamination and flexibility. These disadvantages are overcome by using laser-based ultrasound testing which is contactless and highly flexible. At Fraunhofer ILT afiber coupled demonstration system for laser based non-destructive testing of CFRPparts and joints is developed. The focus is on the defined excitation of ultrasound wavesusing fiber coupled lasers in the wavelength range from 355 nm to 2700 nm as wellas the detection of ultrasound echos using a laser interometer. The excitation and de-tection laser are combined in a scanner head which enables a high measurement speed.

Contact PersonDr. Thomas WestphalenPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 53FLOOR D

Automated Alignment of Micro Opticsfor High Power Diode Lasers

The active alignment of fast axis collimator lenses (FAC) is the most challenging part in themanufacturing process of optical systems based on high power diode laser bars. This isdue to the required high positioning accuracy in up to 5 degrees of freedom and the com-plex relations between FAC misalignment and properties of the resulting power densitydistribution. ILT develops algorithms for automated alignment of FAC lenses with a mini-mized number of alignment steps and high reliability. The power density distribution be-hind the micro optics is analysed and compared to a wave optical model in real-time. Withthis approach the current misalignments in all axes can be predicted and corrected in onestep. The experimental verification shows a remaining misalignment of 0.8 µm and 0.01degrees after systematic tests on 16 different combinations of diode lasers and FAC lenseswith effective focal lengths of 910 µm and 1500 µm. The average alignment process du-ration is in the range of 20 to 25 seconds which is limited by the motion system accuracy.

Contact PersonDr. Thomas WestphalenPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 54FLOOR D


32



Pick & Align – Active Alignment of Optical Components

At the Fraunhofer Institute for Laser Technology ILT a soldering and mounting techniquehas been developed and established for high precision packaging. The specified environ-mental boundary conditions (e.g. a temperature range of -30 °C to +50 °C) and therequired degrees of freedom for the alignment of the components have been taken intoaccount for this technique. In general the advantage of soldering compared to gluingis that there is no outgassing. In addition no flux is needed in our special process. Thejoining process allows multiple alignments by remelting the solder. The alignment isdone in the liquid phase of the solder by a 6 axis manipulator with a step width in thenm range and a tilt in the arc second range. In a next step the optical components haveto pass the environmental tests. At the booth several results will be shown and themounting process presented.

Contact PersonDr. Michael LeersPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 59E112.4

3D-Absorption Measurements of Optics on a ppm Scale

Thermal properties of optical materials play a crucial role in the design and developmentof high-average-power lasers and optics. Temperature rise and gradients inside of opticalelements, caused by absorption of laser radiation, can severely diminish the efficiency andbeam quality of a laser (e.g. nonlinear frequency conversion, Faraday isolators). To achievean optimum system performance, materials with low absorption have to be selected first.Secondly, the unavoidable thermal effects have to be taken into account for the optimizeddesign. Both steps require a good knowledge of the absorption at optical surfaces andin the bulk. With the Photothermal Commonpath Interferometer (PCI) we are capableof performing 3D absorption measurements with ppm sensitivity in the bulk and at thesurface of numerous optical materials, e.g. TGG, LBO, BK7, fused silica and many more.

Contact PersonDipl.-Phys. Bastian GronlohPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 60E112.4

35




Novel Design Concepts for Laser Optics

Current development of laser systems pushes optical systems for laser beam guiding andshaping to their limits. Thermal lensing in high power laser applications and the efficientapplication of ultrashort laser pulses with high peak powers are up-to-date topics of highrelevance. In the case of thermal lensing, the absorption of a small amount of laser powerinduces a thermal profile into the lenses and influences the local refractive power of eachsingle component in the beam path. Ocurring defocus and other aberrations are the result,affecting processes and their stability. Presented will be methods for modelling andcompensation of thermal lensing by coupling thermal and optical simulation tools. Theapplication of ultrashort laser pulses requires systems for a fast distribution of thelaser power on the work piece. Approaches based on difractive beam splitters to enableparallel processing turn out to be particularly suitable for manufacturing of periodicalstructures. Design concepts for multi beam optics are presented as well as their abilitiesand limitations.

Contact PersonM.Sc. Lasse BüsingPhone +49 241 [email protected] für Technologie Optischer Systeme TOS

BOOTH 57FLOOR D

High Power Ultrafast Yb:Innoslab Amplifier

To transfer femtosecond technology from laboratory to industry, laser sources of highpower and high repetition rate are essential. They have to combine sub-picosecondpulses and diffraction-limited beam quality for high precision and hundreds Watts ofaverage output power and high repetition rates for high throughput. Ytterbium-dopedlaser crystals allow pulse durations from 100 fs to 1 ps. The presented Innoslab ampli-fication platform based on Yb:YAG allows amplification to kW average power. Theoptical-optical efficiency of 55 % and the beam quality M² < 1.5 are outstanding forkW ultrafast lasers. At 10 - 1000 MHz repetition rate up to 100 µJ pulse energy areattainable without chirped pulse amplification (CPA). With CPA 100 mJ at > 10 kHzrepetition rate are feasible. Due to the large beam cross section Innoslab amplifierscan sustain three orders of magnitude higher peak power than fiber amplifiers.

Contact PersonDr. Peter RußbüldtPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 58E112.1


34



WISSENSCHAFTSPREISDES STIFTERVERBANDES

2012

Powder Feeding Nozzles for Laser Metal Deposition

One key component for Laser Metal Deposition (LMD), also known as laser cladding,is the powder feeding head which provides the powder and the shielding gas for theprocess. The main demands in industry are flexibility, robustness and high powderefficiency. The Fraunhofer ILT has developed various powder feeding heads for severalindustrial applications. This includes discrete and coaxial powder feed nozzles and azoom optic (developed together with REIS Lasertec) which allows a flexible change oftrack width. A special application is the cladding of inside surfaces. Fraunhofer ILT hasdeveloped different processing heads together with IXUN Lasertechnik with integratedoptic and powder feeding for cladding of inner surfaces. The design allows the claddingof inner surfaces starting from either 25 mm or 50 mm diameter upwards. These opticsare presented at booth 66 together with the company IXUN Lasertechnik GmbH.

Contact PersonDipl.-Ing (FH) Stefan JungPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 66HALLWAY

Tunable Lasers & Frequency Converters for OutputWavelengths from UV to MIR

A converting laser radiation to new application specific wavelengths increases thepossibilities of using modern solid-state, fiber and diode lasers in industry and research.By tailoring the combination of fundamental laser source and frequency converter, theFraunhofer ILT develops efficient and cost-optimized beam sources for a wide variety ofapplications. The output parameters of our customized lasers and frequency converterscan provide laser wavelengths from UV to MIR output power from the Milliwatt levelup to multi-hundred Watts and all time regimes from CW operation to ultrafast pulses.Exhibits include compact packages of efficient frequency converters and of a blue diodepumped green emitting Pr:YLF laser, as well as exemplary oven designs for diode pumpedtunable Alexandrit lasers and for nonlinear crystals suitable for high power harmonic andparametrical generation.

Contact PersonDr. Bernd JungbluthPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 67HALLWAY

37




2 µm Lasers with Holmiumand Thulium Doped Laser Materials

In processing of plastics and medical applications 2 µm radiation is useful for itsstronger absorption compared to 1 µm. A variety of laser sources including e.g. Cr2+lasers or OPO sources for wavelength above 3 µm can efficiently be pumped with 2 µmradiation. Military and sensing applications benefit from an atmospheric water absorptionwindow and several absorption lines of gases such as CO2. In addition laser safetyprecautions are relaxed because of a MPE (Maximum Permissible Exposure) that ist atleast one order of magnitude higher than at 1 µm. In this setup a MOPA demonstratorfor a pulsed CO2 LIDAR emitter is developed. It will produce 20 ns single frequencyTEM00 double pulses at 2051 nm and 50 Hz with 40 mJ and 20 mJ pulse energy.To achieve this a compact single frequency Ho:YLF oscillator with 4 mJ pulse energyand maximum PRF of 4 kHz is developed. A INNOSLAB Ho:YLF amplifier boosts theenergy to 40 mJ with scaling capabilities to several 100 mJ. The pump source for theamplifier is a stable/stable Tm:YLF INNOSLAB laser with 200 W of output power at 1.9 µm.

Contact PersonM.Sc. Philipp KucirekPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 61E103.2

Inverse Laser Drilling: High Aspect Ratio Microstructuringof Dielectrical Materials

Inverse Laser Drilling is a laser microstructuring technique to drill geometries of highaspect ratio into dielectric materials like glass. The sample is placed on a vertically movabletranslation table with a polished surface facing upwards. The laser beam is focusedthrough the top surface onto the bottom surface of the bulk. The beam is deflected byscanning mirrors in the horizontal plane, this way the desired geometry’s first layer is ablated.By moving the translation table and ablating layers step by step the entire geometry canbe ablated or “drilled”. Drilling of holes with aspect ratios < 1:200 has been demonstrated.Recent achievements are: Photonic Crystal Fiber preform with 60 holes (0.8 mm diameter,80 mm length), 6.35 mm thick laser mirrors with slits (width down to 80 µm) or holes(diameter down to 50 µm) for geometric separation of beams, interleaving mirror withthree or more slits for geometric coupling of diode laser stacks to increase radiance.

Contact PersonDipl.-Phys. Dipl.-Volksw. Dominik EsserPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 62E103.2


36



Laser Treatment of TCO Thin Films for OLED Lighting

ITO (Indium Tin Oxide) thin films are used as transparent conducting oxide materials(TCO) in electrodes for e.g. organic light emitting diodes (OLED) since they combinehigh electrical conductivity and high visual transparency. These materials are commonlyapplied by physical oder chemical vapour deposition (PVD/CVD) onto glass substrates.Still their electrical conductivities fall behind those of their non-transparent metal coun-terparts and do not suffice to manufacture bigger OLED panels for e.g. ceiling panellighting or television backside illumination: The OLED luminance decreases towardsthe planes' mids due to electrical losses. Besides the laser-based deposition of thinconducting metal grids onto these TCO thin films Fraunhofer ILT is investigating thepossibility of increasing the electrical conductivity by a laser-based treatment of theTCO thin films themselfs.

Contact PersonDr. Christian VedderPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 76U120.1

39

NANO PROCESSING


Customized Electronics and Drivers for Laser Applications

Beratron is specialized in electronic solutions for laser applications. Our productsranges from small drivers for fiber-coupled diodes or superluminescence-diodesover TEC cooling solutions to high current 19 inch systems up to 500 A current.The products are build in a modular way and can be customized after your specialneeds. The modules include CW, QCW and pulse driver electronics for laser diodesand are equipped with various analogue or digital interfaces (e.g. EIA-232, CAN,USB, Ethernet …).Beratron also offer special trigger solutions (e.g. pulse-picking, frequency stabilizedlasers) and customized laser control boards for complex laser systems. Applicationsare R&D, material processing, pumping, imaging, ranging, etc.

Contact PersonDipl.-Ing. Ulf RadenzPhone +49 241 [email protected] GmbH

BOOTH 72HALLWAY

Functional Layers for Electronic Applications

Functional layers play a central role in electronic devices. Especially conductive structures(e.g. conductive paths, electrical contact areas or transparent conductive oxide coatings)are of great interest in this field of application. Conductive structures on metallicsubstrate need additional insulating layers. Printing techniques show great potentialdue to resource-efficient, flexible and cheap application of structures only onto desiredareas of the substrate. To reach the functional properties of the applied nanoparticulatematerials heating steps are usually necessary. The replacement of conventional heatingfor drying, sintering and even partial melting or crystallisation by laser treatment allowsus to reach high temperatures in top layers with high temperature gradients so thateven temperature sensitive substrates can be used. High vacuum processes (CVD, PVD)or electroplating and time and energy consuming thermal processes can be avoidedby the combination of laser and printing processes.

Contact PersonDipl.-Phys. Melanie MeixnerPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 75U120.1


38


NANO PROCESSING

Additive Manufacturing by Laser Metal Deposition

Laser Metal Deposition (LMD) also known as laser cladding can be used as an additivemanufacturing process by cladding layer upon layer. The result is a near net-shapecomponent with almost 100 % density and a property profile which meets the speci-fications of the used material, or even performs better due to the fine microstructurecreated by the high cooling rates during LMD. The size of the components is onlylimited by the handling system. In contrast to powder bed based technologies LMDoffers the possibility to produce new material concepts e.g. gradient properties orbuild-up of lightweight hybrid components consisting of various alloys. Preheatingand low oxygen atmosphere are often mandatory, especially for manufacturing brittlematerials as e.g. intermetallics. Potential applications are the production of functionalprototypes and small batch parts. LMD can also be used to modify components fora more individualized production when small numbers of derivatives are required.

Contact PersonM.Sc. Silja-Katharina RittinghausPhone +49 241 8906-8138siljakatharina.rittinghaus@ilt.fraunhofer.deFraunhofer-Institut für Lasertechnik ILT

BOOTH 10E100.A11

Laser Metal Deposition of Fe-Al based alloys

Iron aluminde based alloys are considered as a possible resoruce efficient replacementfor nickel base alloys up to service temperatures of 1000 °C because of their lowerdensity, high temperature strength and outstanding corrosion resistance. However, lowductility has limited the use of iron aluminide based alloys to niche applications up tonow. The brittleness is mainly due to the coarse grain of these alloys. A new approachto overcome this is the additive manufacturing via Laser Metal Deposition (LMD). Dueto the high cooling rates fine grained microstructures are obtained whereby the ductilitycan be increased. Furthermore, the near net-shape production of parts will reduce thecosts for tooling, which is expensive in case of these brittle and high strength alloys.Various Fe-Al are investigated starting with a binary Fe-Al alloy to identify processwindows for Additive Manufacturing (AM). Bulk volumes are build-up to determine themechanical properties. In the next step demonstrator parts for industrial applicationswill be build-up and tested.

Contact PersonDipl.-Ing. Gesa RolinkPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 11E100.B12

41

ADDITIVE MANUFACTURING



Aachen Center for 3D-Printing

SMEs are screening the fields of applications and the chances of Additive Manufacturing(AM) for their own production environment. While large companies invest considerablyin the technology to open new business areas or to improve existing processes, thereis for many SMEs a bottleneck in terms of skilled 3D-printing specialists or of capitalfor investments. Subsequently SMEs run the risk of lacking competitiveness. This marksthe starting point of the collaborative AM group formed by the Fraunhofer ILT andthe Aachen Univ. of Applied Science (FH Aachen). It combines the knowledge of theFH Aachen especially in 3D applications with the deep understanding of generatingparts and the detailed knowledge of machine’s architecture of the Fraunhofer ILTspecialists. The collaborative team offers to SMEs services like feasibility studies,development of AM process chains, process parameter evaluation, sample productionand transfer of results to machines. In any case the goal is to provide SMEs in the regionof Aachen a quick and effective approach to the forward-looking AM technology.

Contact PersonDr. Damien BuchbinderPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 04ENTRANCE

Development of a Technology Processorfor Laser Metal Depositon

An often used repair technology for turbomachiniery components – such as compressorblades – is Laser metal deposition (LMD). In order to achieve a near net-shape builtup and a small heat input, the LMD process has to be adjusted to each component’sgeometry and material combination (substrate and powder additive) separately. Upto now those adjustments are predominantly carried out experimentally. One scope ofthe new Fraunhofer Innovation Cluster »AdaM« is to reduce the experimental effortsfor developing or adjusting new LMD repair processes for turbomachinery components.Therefore a "Technology Processor for LMD" is going to be developed which will beable to compute a set of process parameters for user-defined welding track geometrieswith respect to geometry and material combination. This "Technology Processor" willconsist of a data base, a modelling and an user interface module. As first results LMDof user-defined welding track geometries on flat substrate material is presented.

Contact PersonDipl.-Phys. Marco GöbelPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 08E100.A10


40



Produtivity Increase by Using Adaptive SLM Process Strategy

A central aspect of SLM process development to enter series production is increasingthe productivity. Thereby the challenge is to resolve the conflict of objectives betweena high build-up rate and a high surface quality. An analysis of the component underholistic consideration of the entire process chain has to be done. Aspects like functionalityand post processing determine the SLM surface quality of local areas. On the one handlocal areas, which will be obtained a post processing like milling, can be generated witha high build-up rate and a high surface roughness. On the other hand 3D functionalareas need the best possible surface quality. Such a SLM process requires a low build-uprate with high detail resolution. A build up strategy that depends on these local require-ments is realized by the adaptive SLM process strategy, which is evaluated based on theprocess time by manufacturing of a guide vane cluster in context of the conventionaland skin-core strategy.

Contact PersonDipl.-Ing. Anders SuchPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 14E100.A14

High Power Selective Laser Melting (HP-SLM)

The Fraunhofer ILT developed Selective Laser Melting (SLM), an additive manufacturingtechnology, which can be used to manufacture series - identical materials such as steel,aluminium-, titanium- and nickel- based alloys layer by layer according to a 3D-CADvolume model. This process enables the production of nearly unlimited complex geo-metries without the need for part-specific tooling or preproduction costs. Accordingto the current state of the art SLM is used to manufacture functional prototypes andto build up final parts in small batches directly. For SLM to enter series productionwith higher lot sizes, increased productivity is necessary. Therefore Fraunhofer ILT isconducting research in the field of High Power Selective Laser Melting (HP-SLM).The aim is to identify process strategies corresponding to the material and geometryof the manufactured part with which the increased laser power can be converted intoan increased productivity efficiently, while maintaining the requirements for surfacequality, microstructure and resulting mechanical properties.

Contact PersonDipl.-Wirt.-Ing. Sebastian BremenPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 15E100.A14

43




Additive Manufacturing of Parts for Energyand Aerospace Applications

The additive manufacturing process Selective Laser Melting (SLM) is used for directfabrication of functional metallic parts. Advantages like low material consumption, highgeometrical freedom or short lead time are principally placing this process at a frontposition to produce high value small-scale series, like for instance found in gas turbinesin the energy and aerospace industry. Regarding materials such as Inconel 625 andInconel 718, weldable superalloys which are widely used in both industry sectors, thisfront position is step by step reached by major OEMs right now. Nevertheless, majordrawbacks like process robustness and reproducibility, achievable surface quality orlimited material range still exist and are adressed at fundamental research level as wellin application oriented projects with industrial partners at Fraunhofer ILT. Presentedresults cover process development and applications for the cobalt-based superalloyMAR M509 and the advanced nickel-based superalloy Inconel 738LC.

Contact PersonDipl.-Ing. Jeroen RissePhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 12E100.A14

Additive Manufacturing of Microstructures with SLM

In recent years the Additive Manufacturing (AM) process SLM has taken a large steptowards series production. New developements have paved the way to higher productionrates and even bigger parts. In order to further expand the capabilities of the SLMprocess, the Fraunhofer ILT has developed the µSLM process which now opens up theworld of microstructures for this promising AM technology. Adapting the powders,machinery and the process itself, SLM parts with dimensions smaller than 100 µm cannow be produced without the need for specific tooling and an almost infinite freedomof geometry. Using the µSLM process, a surface roughness Sa of 1 - 2 µm can be achievedwhile retaining the accustomed contour accuracy of the SLM process. This developementoffers new applications of the SLM process in the field of medicine, electronics andoptical technologies where individual geometries with high resolutions and good surfacequalities are required.

Contact PersonDipl.-Ing. Rui João Santos BatistaPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 13E100.A14


42



LIFTSYS – Laser-Induced-Forward-Transfer of Cells

The Laser-indueced Forward Transfer process is capable to pick-up a single cell outof a sample and to transfer this cell to a specific site on a substrate. Under optimumconditions single cells can be placed with a position accuracy of +/-20 µm. This opensup the chance to construct specific micro-environments for realization of tissue-likestructures cell by cell. Such structures can be used to generate cell-based in vitro assays.They are very useful to investigate the differentiation of stem cells or to investigatethe cell metbolism of drugs. An important feature is the integration of a microscopeand image analysis in the transfer tool. Hence every single cell can be analized beforethe transfer.

Contact PersonDipl.-Biol. Dominik RiesterPhone +49 241 [email protected] für Lasertechnik ILT

E055.2

3D-Photopolymerzation

Photopolymerzation is a chemical reaction (curing) of liquid monomers and/or pre-polymers triggered by radiation. This type of reaction is widely spread across manyapplications like UV-coatings and varnishes, lithography (positive or negative resists)or photo-resins for 3D-printing (stereolithography). In comparison to lithography, thecontrol of polymerization in the third dimension (vertical, z-) besides the lateral resolution(x-/y-) for the building of 3D-objects is an additional challenge in development. In thegroup “biofabrication and laser therapy” at Fraunhofer ILT new processes and combi-nations with innovative materials for 3D-printing technologies are investigated. Thefocus of recent work is the use of thiol-ene chemistry as an alternative to acrylate andepoxy resins for stereolithographic processes. In Laboratory E023 a 3D-printing techno-logy based on DLP (digital light processing) and approaches in the development ofnew materials for photopolymerization are demonstrated.

Contact PersonDipl.-Chem. Holger LeonardsPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 41E023

45

LIVE SCIENCE

LIVE SCIENCE

BOOTH 40


LMD of Steam Turbine Blades by using LMDCAM Software

Laser Metal Deposition (LMD) is an useful technology for the repair of high valuedmetal parts or application of wear-resistant coatings, for example on turbine blades outof gas- or steam turbines. Typical challenge that has to be faced is, beside the depositionof materials that are similar to the component material and usually difficult to weld,LMD on 3D-surfaces for which CNC programs cannot be generated manually. Therefore,the software LMDCAM has been developed by Fraunhofer ILT, that is capable of gene-rating CNC tracks on the surface of STL-files. To obtain STL-files of the part to be repaired,the relevant area of the part is scanned optically and the resulting point cloud is convertedinto STL-data. In case CNC- programs for different CNC control systems have to becreated, suitable post processors can be integrated into the software. The process chainconsistig of scanning process, creating CNC- programs by the LMDCAM in-house soft-ware and LMD of the correspondent area on a steam turbine blade by using powderadditive material is shown.

Contact PersonDipl.-Ing. Stefanie LinnenbrinkPhone +49 241 89060-575stefanie.linnenbrink@ilt.fraunhofer.deFraunhofer-Institut für Lasertechnik ILT

BOOTH 17E100.A09

Automated Tip Repair of Blade Tipsby Laser Metal Depostition (LMD)

Laser metal deposition is a powerful technology for repairing compressor and turbineblades of aero engines. The wear on the tips leads to the blades being rejected fromservice. Apart from wear the blades get deformed during service which leads to achallenging situation for the repair process due to the fact that the processing has tobe adapted to each blade. In order to speed up the repair and thereby reduce the costs,the repair process has been designed and installed as an automated process chain.After the tip has been captured by a laser scanner the data is analysed and pointsfor the LMD track are calculated and transferred to the NC. The track points are readby a custom designed flexible NC-program which applies the LMD tracks to build upthe volume on the blade tip. To efficiently run the LMD process an external powderswitch device is added to the setup which allows saving powder and precise handling.With the LMD process the missing volume on the blade tip can be filled up again.After a post machining step the blades can go back to service.

Contact PersonDipl.-Ing. Jochen KittelPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 32E100.A05


44



LASER TECHNOLOGY L IVE - AKL’14LASER TECHNOLOGY L IVE - AKL’14

46 47

Process Monitoring for Selective Laser Melting SLM

Process control for Selective Laser Melting (SLM) is seen as one of the key enablersfor future production of individualised parts. The Fraunhofer ILT shows a manufacturingsystem at lab-level which makes a vital step towards this goal. As a laboratory system,the optical train is specifically designed and optimised for process control. It uses apre-focus system in combination with a fast closed loop scanning system and interfacesto a set of coaxially coupled sensors to observe the melting process. Pyrometric sensorsdetect radiation from the melt pool and a camera system to provide a geometric imageof the processing zone while the beam position is recorded synchronously. These signalsare acquired at a data rate of 100 kHz providing a spatial resolution of 100 micron evenat scanning speeds of 10 m/min. The software visualises the result of the measurementas a so called emission map which allows detection of local melting temperatures duringprocessing.

Contact PersonM.Sc. Dipl. Ing. (FH) B. Eng. (hon) Ulrich ThombansenPhone +49 241 [email protected] für Lasertechnik ILT

MAIN HALL

GENERATIVE METHODS BOOTH 63

Live Cell Imaging and Automated Cell Tracking

Fluorescence microscopy is a powerful tool in Life Science. Not only high resolutionpictures of stained samples, but also life images of fluorescence labeled cells allow insightsinto biological aspects. At Fraunhofer ILT this is used for the analysis of cell behavior onlaser patterned surfaces. These patterns can be of different shape (ripples, lines etc.) andsizes (from nano- to micrometer) and work as cell guiding structures. Live cell imagingallows, with a subsequent image processing, an insight into the effect of these structureson cell growth. For demonstration purpose we show fluorescence labeled bacteria in aOlympus IX81 fluorescence microscope.

Contact PersonDipl.-Biol. Nadine Nottrodt / Dipl.-Phys. Michael UngersPhone +49 241 8906-605 / [email protected] / [email protected] für Lasertechnik ILT

BOOTH 45E055.1

Micro SLM (Selective Laser Melting)

IQ evolution is specialized in Micro-SLM and cooling technologies, a rapid manu-facturing procedure of three dimensional complex products made of metal powder.• Our products are micro cooler for high-power laser diodes, cooler for powerelectronics or LED as well as other complex 3D-structures

• Our micro coolers are leading f.e. to a significant increase in the lifetimeof the laser bars compared to the current copper based cooling echnology(the new materials used here are not exposed to corrosion and erosion)

• We have special know-how in the Selective Laser Melting processand machines as well as in using special materials, pure materials andcustom made material compounds

• We are able to produce micro structures from 50 µm up

Contact PersonDr. Thomas EbertPhone +49 241 [email protected] Evolution GmbH

BOOTH 16E100.15

LIVE SCIENCE

LASER COMPONENTS

AKL e.V. – Aix Laser People

Arbeitskreis Lasertechnik AKL e.V. is a registered non-profit association formed in1990 by a group of companies and private individuals aiming to pool their experienceand conduct joint public - relations activities in order to spread the use of lasertechnology in industry and promote the sharing of scientific ideas. The “InnovationAward Laser Technology” aims to reward excellent achievements in applied researchand outstanding innovation in the field of laser technology and to shine a spotlighton their authors. In 2013, around 124 laser experts and enthusiasts were signed up asactive members of the AKL network. The association's activities include disseminatinginformation on innovations in laser technology, organizing conferences and seminars,compiling educational material dealing with laser technology, stimulating the interestof future young scientists, and providing advice to industry and research scientists onquestions relating to laser technology.

Contact PersonDipl.-Physik. Axel BauerPhone +49 241 [email protected] Lasertechnik AKL e.V.

BOOTH 02aENTRANCE

49

CENTRAL INFORMATION


RWTH Aachen Campus

RWTH Aachen University aims to become one of the world‘s leading technical universities.With the RWTH Aachen Campus, the university is creating a unique portfolio of servicesfor cooperation in specialist clusters in which RWTH Aachen University is providingboth know-how and a unique research infrastructure. Up to 19 research clusters withoffices, seminar rooms and workshops as well as laboratories and the correspondinginfrastructure will be built over the coming years on an area covering approx. 800,000 m².National and international technology firms (research partners) thus have the chanceto locate their own research and development capacities on the campus together withuniversity institutes and to get involved in the research and further training activitiesof RWTH Aachen University – above and beyond individual research cooperations.Six clusters are currently being realized on Campus Melaten: Logistics, ProductionEngineering, Photonics, Bio-Medical Engineering, Heavy-Duty Drives as well as SustainableEnergy.

Contact PersonM.A. Wiebke Kühlken / Dipl.-Phys. Christian HinkePhone +49 241 80 25332 / +49 241 [email protected] / [email protected] Aachen Campus GmbH / Lehrstuhl für Lasertechnik LLT

BOOTH 03MAIN HALL


48

EXCELLENCE NETWORKS

ELI – European Laser Institute

Optical technology is taking an increasing hold on all domains of industry and science.Europe already possesses a strong position in this field by virtue of its numerous expertsand excellent research and development facilities. Nevertheless, it has been realizedthat there is an urgent need to link the existing sources of know-how and expertise,and to enhance the performance of joint research activities. Consequently, the EuropeanLaser Institute (ELI) has created an efficient platform bringing together the necessarycompetence and knowledge on optical technologies. By promoting technology transferwithin Europe, ELI aims to enhance the international lead of European industry andresearch in the field of laser technology and photonics. By working in close collaborationwith existing national and international organizations, the ELI network of industrialand academic research institutions helps to influence R&D policy on a national andEuropean level.

Contact PersonDr. Alexander OlowinskyPhone +49 241 [email protected] Laser Institute ELI e.V.

BOOTH 02bENTRANCE

CENTRAL INFORMATION

Fraunhofer Institute for Laser Technolgy ILT / Press Counter

With about 420 employees and more than 11.000 m² of usable floor space theFraunhofer ILT is world-wide one of the leading development and contract researchinstitutes of its specific field. In the technological area “lasers and optics” developmentactivities are concentrated on innovative diode and solid state lasers for industrial useas well as design and assembly of optical components and systems. The technologicalarea “laser material processing” offers solutions in cutting, ablation, drilling, welding,soldering, surface treatment and micro processing. The activities cover a wide range ofapplications from macro processing via micro processing up to nano structuring. In thearea “medical technology and biophotonics” innovative procedures for therapeuticlaser treatments and processes for the production of medical technology products,particularly for microsurgery techniques, are developed. In the area “laser measurementand EUV technology” processes and systems for inspection of surfaces, for chemicalanalysis and for testing geometrical accuracies, as well as EUV beam sources for litho-graphy microscopy and nano structuring, are developed.

Contact PersonDipl.-Phys. Axel BauerPhone +49 241 [email protected] für Lasertechnik ILT

BOOTH 01ENTRANCE

CENTRAL INFORMATION

Published byFraunhofer-Institut für Lasertechnik ILTSteinbachstraße 1552074 Aachen, Germany

Phone +49 241 8906-0Fax +49 241 8906-121info@ilt.fraunhofer.dewww.ilt.fraunhofer.dewww.lasercongress.org

ContactMarketing & CommunicationsDipl.-Betrw. Silke BoehrPhone +49 241 8906-288Dipl.-Phys. Axel BauerPhone +49 241 8906-194

Design & ProductionDipl.-Des. Andrea Crollwww.andrea-croll.de

© Fraunhofer-Institut für Lasertechnik ILT, Aachen 2014

IMPR INT

51

PUBLISHING NOTES


Chamber of Industry and Commerce Aachen (IHK Aachen)

As an economic sector’s organization, the Chamber of Industry and Commerce Aachenrepresents economy’s interests and is crucial for the development of the businesslocation “Region of Aachen”. The Chamber is acting as a critical partner of thepolitical and the administrational level as well as an independent market’s advocateand customer-oriented institution providing services for its member companies.The Chamber of Industry and Commerce Aachen provides concrete company-basedservices to its approximately 76.000 member companies. Examples are advice onbusiness start-ups and enterprise’s growth, network activities, providing foreigntrade information, innovation and technology transfer, informative meetings andseminars as well as information regarding new laws and current developments.Further important functions are the German Dual Vocational Educational System,the appointment of experts and issuing foreign trade documents. Please visitwww.aachen.ihk.de

Contact PersonDipl.-Ing. Markus WolffPhone +49 241 [email protected] of Industry and Commerce Aachen (IHK Aachen)

BOOTH 06ENTRANCE


50

CHAMBER OF COMMERCE

MICRO TECHNOLOGY

Micro Scanners for Selective Laser Induced Etching (SLE)

SLE is a two-step process for 3D-Micro-Structuring of transparent materials likeglasses and crystals. Laser radiation is focused down to a micro-sized spot insidethe transparent material and is absorbed in the focal volume exclusively (first step)inducing a material modification. The laser modified material is selectively removedby wet chemical etching (second step).For the movement of a 2 micron-sized focal spot at a speed up to 10 m/s two kindsof microscanners have been developed: A flexible microscanner is designed for proto-typing and small series of complex 3D-structures, and a high speed microscannerfor special structures to be produced with a high throughput. Both scanners aremade commercially available by the newly founded spin-off company LightFab.The scanners and structures fabricated with SLE are demonstrated at the booth.

Contact PersonDipl.-Phys. Martin HermansPhone +49 241 [email protected] für Lasertechnik LLT

BOOTH 49aE110

Structuring of Materials with High Power fs-Laser

A high power fs-laser with average power > 400 W is used for processing of materials.3D-structuring of transparent materials is enabled by Selective Laser InducedEtching (SLE). By SLE complex hollow micro structures are fabricated with high speedand high efficiency inside fused silica glass. In the joint research project Digital PhotonicProduction "Femto" we are going to investigate the structuring, drilling and cuttingof other materials like boro silikate glasses togeher with our industrial partners.Moreover, results of ultrashort pulse laser materials processing with high average powerare presented with special attention paid to the ablation of titanium- and nickel-basedsuper alloys.

Contact PersonDr. Jens GottmannPhone +49 241 [email protected] für Lasertechnik LLT

BOOTH 58aE112.3

1

MICRO TECHNOLOGY

ADDITIONAL

Nano- and Microstructuring with Micro Scannerin IMRA Premier Applications Lab

A high precision scanner and tightly focusing (NA>0.3) are utilized together witha 1.5 W femtosecond fiber laser source µJewel from IMRA (in the Premier ApplicationsLab at LLT) to process transparent dielectrics. With this set up the fabrication ofwaveguides, in-volume marking and surface nanostructuring for different applicationsbecomes productive. With our CAM-software we print arbitrary 3D structures fromCAD-files into the volume of samples.Moreover it is possible to remove 3D-structure modifications selectively by using a wetchemical etching (SLE). E.g. sapphire and fused silica are used as materials for fabricatingof micro devices. This devices are e.g. micromechanics, micro optics or microfludic devices.

Contact PersonDipl.-Phys. Sebastian NippgenPhone +49 241 [email protected] für Lasertechnik LLT

BOOTH 49bE111


2

MICRO TECHNOLOGY

laser technology live -...

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