WS04: 2024 Laser Fabrication Workshop

Industrial Lasers Overview: Fiber, Disk & Diode
Several of the most common laser technologies will be presented with an explanation of their mode of operation, distinctive characteristics, and typical applications. Laser welding processes have been used for over 40 years. Many laser technologies have emerged to solve the most demanding challenges. From the high-power CO2 lasers to the more recent technologies such as high-power diode, disk and fiber lasers, each laser technology brings different advantages making welding processes more efficient.
JP Lavoie, Ph.D – Coherent Inc

Wire Based Laser Processing- Making Lasers More Flexible
Lasers have historically been limited to very precise applications with good fit-up and cleanliness. In recent times there have been advancements in laser technology that have opened up processing windows some, but not to the extent of arc welding. Incorporating wire into the laser process has allowed us to develop wider operating windows and address more for a diverse range of applications. We will be sharing these solutions and discussing how customizing the laser beam and wire delivery can be applied to today’s challenges.
Kyle G. Smith – Lincoln Electric Automation

Metal Powder Based Laser Additive Manufacturing Processes – Characteristics and Applications of Laser Metal Fusion and Direct Energy Deposition
Metal powder-based laser additive manufacturing processes, namely Laser Metal Fusion (LMF) and Direct Energy Deposition (DED), represent a significant advancement in the production of complex metal components. LMF, also known as Laser Powder Bed Fusion (LPBF), involves spreading a thin layer of metal powder and selectively melting it with a laser to build parts layer by layer. This method is highly precise and is used for producing intricate designs with fine features. On the other hand, DED, sometimes referred to as Laser Metal Deposition (LMD), involves feeding metal powder into a focused laser beam as it is scanned across the target surface, creating a melt pool where the material is deposited. DED is particularly useful for repairing components or adding material to existing parts. Both processes offer flexibility, speed, and the ability to create parts that would be challenging or impossible to manufacture with traditional methods.
Ulli Kraske – TRUMPF Inc.

Analysis of Critical Laser Parameters in Joining Applications
Using a high-power laser for material processing has its own unique set of challenges. Because of the relatively higher laser power densities required for joining processes, it is critical to understand and analyze key laser performance characteristics. In these cases, the performance of the laser must be more closely monitored and tightly controlled. For example, thermal effects on shorter focal length lenses can more easily cause more adverse effects on the process from loss of power density. This talk will discuss some of the case studies in laser joining processes and illustrate how and where measuring and analyzing key laser performance characteristics proved vital to the overall success of the manufacturing of their products.
John M. McCauley – MKS Instruments / Ophir

Novel Applications with High Power Diode Lasers
In recent years, diode lasers have evolved in output power beam quality and wavelength range, opening new innovative usability scenarios for this efficient robust, and inexpensive laser source. This presentation will shortly outline the diode laser technology and then focus on application examples in laser welding, metal additive manufacturing, laser cladding, and hardening. A focus will be put on automotive applications such as BIW laser welding and brazing as well as EV-related examples such as battery cathode drying, non-destructive testing, and copper welding for hairpins.
Oleg Raykis – Laserline Inc.

Laser Cladding Applications
Laser cladding uses a laser to deposit a layer of material onto a substrate by way of powder or wire. This process is used for refurbishing damaged parts to OEM specs, repairing worn surfaces, and providing enhanced corrosion / erosion resistance. This presentation will discuss laser cladding techniques and industrial applications in which these techniques may be applied.
Rick McRae – Alabama Laser