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University of Virginia - November 2010Advances in High Power Lasers

Advances in High Power LasersFiber delivered disk & direct diode lasers

University of Virginia - November 2010Advances in High Power Lasers 2

Disk / Fiber

LPSS DPSS

BPP

[mm

mra

d]

Output power [kW]

Jan 2008: not published15 kWnearly diffraction limited

TruDiskProducts 2008

TruDiskProducts 2009

5

10

15

20

25

June 2008: Boeing> 25 kWnearly diffraction limited

5 10 15 20 25 30

Advances in SSL technology


Rod Laser Disk Laser

r

T

r

T

Pump lightQuasi frontal

- Parabolic temperature profile- Cooling and Pumping

via lateral area

- Flat temperature profile- Cooling via base area

Laser Emission

Disk Laser Concept


TruDisk – Product portfolio

8 - 12

8

4 - 8

4 - 8

BPP(mm-mrad)

≥ 200

≥ 200

≥ 100

≥ 100

Fiber φ(μm)

3>8 - 12

4>12 - 16

2>4 - 8

12 - 4

Number of disks

Power [1]

(kW)

[1] Power guaranteed at workpiece


TruDisk – Extremely long diode life

Passively cooled diodes

Cooled with non-DI water

Life expectancy commensurate with single emitter diodes

Modular, non-spliced architecture


TruDisk – Compact

5

4

3

2

1 Pump unit

Cavity

Laser resonator

Power feedback sensor

Central shutter

1

2

3

4

5


TruDisk 4002 – 4 outputs


TruDisk – Power scaling / field upgradeability

6 pump modules per disk w/ 4 kW laser power per disk

Power scaling per disk by number of pump modules

Output power scaling of laser with number of coupled disks

6 pump modules per disk w/ 4 kW laser power per disk

Power scaling per disk by number of pump modules

Output power scaling of laser with number of coupled disks

2

2.6

3.3

4

Power per disk (kW)

4

3

5

6

# of pump modules


Laser power is constant at the work piece

Reproducible processing results

Back reflections without any influence!

No warm-up time

Power range 3% - 100%

TruDisk - Closed loop power control


TruDisk – Industrial optical interface

Fiber exchange without any alignment

Laser safe compartment

Hot-plug capable

Field upgradeable fiber outputs

TRUMPF Laser Network


TruDisk – Cost effective

0%

25%

50%

75%

100%

1 2HLD4002 TruDisk 4002 (4C)0%

25%

50%

75%

100%

1 2HLD4002 TruDisk 4002 (4C)

Diodes from TRUMPF Photonics, USA

Higher diode power per bar

Less components

Extremely low operating cost

Manufacturing in N.A.


TruDisk – Cost effective

0%

20%

40%

60%

80%

100%

HLD 4002 TruDisk 4002HLD 40022006

TruDisk 40022009

Footprint

0%

20%

40%

60%

80%

100%

HLD 4002 TruDisk 40022006 2009

Running cost

HLD 40022006

TruDisk 40022009

0%

20%

40%

60%

80%

100%

HLD 4002 TruDisk 4002

Invest

HLD 40022006

TruDisk 40022009

0%

100%

200%

300%

400%

500%


Max. output power

HLD2006

TruDisk2009

0%

20%

40%

60%

80%

100%


Diode lifetime

TruDisk 40022009

HLD 40022006

HLD 4002 = 1st generation disk laser / TruDisk 4002 = 3rd generation disk laser


Industrial applications

Remote welding

Conventional laser keyhole welding

Hybrid laser welding

Laser metal deposition

Laser cutting

Remote laser cutting

….


Why did Trumpf choose the disk laser architecture over the fiber laser architecture for high power?

Both are solid stateBoth are diode pumped with long life diodesBoth are fiber optic deliveredBoth have excellent BPPBoth are compactBoth have excellent WPEBoth are “non-monolithic” for industrial applicationsOnly the disk laser is truly modular:

- Field upgradability of power with no splicing required- The disk laser yields the minimum risk & downtime- There are no potential failure modes that require factory repair- Therefore, no need for the laser itself to be a “spare part”- Diode replacement without splicing

Only the disk laser has uncritical power densities on the active mediumOnly the disk laser is insensitive to back reflections


Rod Laser Disk Laser

r

T

r

T

Pump lightQuasi frontal

- Parabolic temperature profile- Cooling and Pumping

via lateral area

- Flat temperature profile- Cooling via base area

Laser Emission

- +

Diode Laser

Direct conversionof current to light

Diode Laser Concept


Application fields

BPP

[mm

mra

d]

Laser power in kW

10

20

30

40

50

1 2 3 4 5

Heat treatment / brazing

Cutting / Remote welding

Welding

84

TruDiode

TruDisk


TruDiode Series

Long diode lifetime

Highest wall plug efficiency

Compact & Modular design

Beam quality and power

TruDiodeL A S E R

Lowest running costs


Increase of wall plug efficiency of high-powered solid-state lasers

Wal

l plu

g ef

ficie

ncy

[%]

Year1995 2000 2005 2010

10

20

30

40

HL 4006D(lamp pumped rod)

HLD 4506(diode pumped rod)

TruDisk 4002(diode pumped disk)

TruDiode 4006(direct diode)


TruDiode Products

0.11

0.11

0.11

0.11

0.11

NA

≥ 6004TruDiode 4006 [1]

≥ 6003TruDiode 3006



≥ 4000.8TruDiode 804

Fiber ∅[µm]

Power[kW]

[1] Available Q2, 2011


TRUMPF Diode Module – the building blockExtremely long life due to …

Passive Cooling- Simple macro-channel heat sinks remove all issues

with water chemistry and erosion- No voltage present in the heat sink channels

removing all electro-corrosion issues

Hard solder- No soft solders used removing all solder migration

and thermal fatigue issues

CTE matched heat sinks- Expansion matched packaging allows high current

thermal cycling and minimizes thermal fatigue issues


Power Scaling

Power scaling

P = N x Pmodule

BPP = N0,5 x BPPmodule

N = 19

d = 5 x dmodule

N = 7

d = 3 x dmodule


Power ScalingEfficient coupling of up to 19 modules

Laser unit


Laser unit 2Wavelength λ2Power P2 Beam quality BPP2

Laser unit 1Wavelength λ1Power P1Beam quality BPP1

Wavelength coupling

Exit laser beamWavelength λ1+ λ2Power Pges = P1 + P2 ex 600 µmBPP = BPP1 = BPP2

Efficient coupling of up to 3 laser units

Power Scaling


Optical design of a TruDiode 3006

Integrated beam guidance

Customer benefit

Plug & Play

Power feedback control

Power scaling


Industrial applications

Conventional laser keyhole welding

Laser brazing

Hardening

Cladding

Heat conduction welding

Heat treatment

….


Why will the direct diode laser be the disruptive laser technology of the not too distant future?

Eliminates the “middle-man”

Highest WPE of all solid state lasers

Extremely compact

Lowest cost high power laser architecture

Good BPP, and getting better & better !

When BPP’s & power levels of the direct diode match the high power disk & fiber lasers, the direct diode laser will take over those associated applications (i.e. remote welding, high speed cutting, hybrid welding, etc.)

University of Virginia - November 2010Advances in High Power Lasers

Thank you for your attention!

David HavrillaTRUMPF Inc.

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