Lasers with average powers of several kilowatts have become an important tool for industrial applications. Temporal and spatial beam shaping was demonstrated to improve existing and enable novel applications. A very promising technology for both highly dynamic beam shaping and power scaling is the coherent combining of the beams of an array of high-power fundamental mode fibers. However, the limited number of fibers allows only limited spatial resolution of the common phase front. It is therefore favorable to work with plane or spherical common phase fronts, which generate a “point”, i.e., a diffraction pattern with a strong main lobe in the focal plane. By applying a tilt to the common phase front, points can be positioned in the focal plane with high spatial resolution. The Civan DBL 6–14 kW investigated in this work allows switching between positions of the points with 80 MHz. Sequences of points can be used to create arbitrary shapes. The time constants of points and shapes are very critical for this type of shape generation. The current paper analyzes the relevant time constants for setting points and creating shapes and relates them to time constants in laser processes. This is mandatory to deterministically influence laser processes.

Full-penetration laser beam welding is characterized by a weld seam whose depth equals the material thickness. It is associated with a stable capillary and is therefore widely used for welding of sheet metal components. The realization of lightweight concepts in car body production requires the application of high-strength aluminum alloys that contain magnesium as an alloying element, which significantly influences the evaporation temperature and pressure. This change of the evaporation processes influences the geometry of the capillary and therefore its absorptance. In order to quantify the influence of magnesium on the capillary, their geometries were captured by means of high-speed synchrotron X-ray imaging during the welding process of the aluminum alloys AA1050A (Al99.5), AA5754 (AlMg3) and AA6016 (AlSi1.2Mg0.4). The 3D-geometries of the capillaries were reconstructed from the intensity distribution in the recorded X-ray images and their absorptance of the incident laser beam was determined by the analysis of the reconstructed 3D-geometry with a raytracing algorithm. The results presented in this paper capture for the first time the influence of the magnesium content in high-strength aluminum alloys on the aspect ratio of the capillary, which explains the reduced absorptance in case of full-penetration laser beam welding of aluminum alloys with a high content of volatile elements. In order to improve the absorptance in full-penetration welding, these findings provide the information required for the deduction of new optimization approaches.

Full-penetration laser welding processes are necessarily associated with significant changes of the geometrical properties of the keyhole at the beginning of the process when the keyhole expands all the way through the workpiece and finally pierces the bottom of the sheet. The impact that this transition has on the absorptance was investigated by means of X-ray imaging to determine the geometry of the keyhole and subsequent raytracing to calculate the distribution of the absorbed irradiance. The results show a significant drop of the overall absorptance when the bottom of the capillary opens through the rear side of the workpiece which in practice is noticed by an unstable behavior of the keyhole. Since the drop of the absorptance is less pronounced for smaller diameters of the keyhole, one may recommend the application of laser beams with small diameters at least during the initial phase until the keyhole is fully developed and reliably reaches through the bottom surface of the welded sheet.

In this paper we propose a reduced two-dimensional finite-volume model for the fast calculation of the melt flow. This model was used to determine the influence of the welding speed, viscosity in the melt and vapour flow inside of the keyhole on the fluid flow field, the temperature distribution, and the resulting weld-pool geometry for laser beam welding of aluminium. The reduced computational time resulting from this approach allows the fast qualitative investigation of different aspects of the melt flow over a wide range of parameters. It was found that the effect of viscosity within the melt is more pronounced for lower welding speeds whereas the effect of friction at the keyhole walls is more pronounced for higher welding speeds. The weld-pool geometry mainly depends on the welding speed.

The investigation, description, and modeling of laser material processing requires knowledge of the power introduced into the workpiece and thus of the absorptance. Analytical expressions are derived for the calculation of the absorptance in a full-penetration welding keyhole that is opened at its top and bottom. The formulas can easily be adapted to also consider partial-penetration welding in which the keyhole is closed on the bottom. The absorptance is calculated as a function of the keyhole geometry, the Rayleigh length of the incident laser beam and the absorptivity of the welded material. Additionally, the absorptance during partial- and full-penetration welding of aluminum was determined experimentally by calorimetric measurements. The proposed model agrees well with the experimental results.