Guide to a Deterministic Control of Laser Materials Processing with Dynamic Beam Shaping

Dynamic beam shaping opens new possibilities for improving the quality and productivity of industrial laser material processing applications such as welding and cutting. However, dynamic beam shaping involves time constants and frequencies that must be selected correctly to successfully modify a given laser process. This paper proposes a standardized nomenclature for the possible types of dynamic beam shaping and the resulting dynamic process modifications, and relates these to characteristic time constants and frequencies at which the process modifications have a particularly strong influence on the process. These characteristic frequencies define three process regimes that have distinctly different effects on the process. An overview of typical time constants and frequencies in laser processes aids in understanding the occurrence of characteristic frequencies. Knowledge of the process regimes allows for a systematic selection of frequencies in dynamic beam shaping to achieve targeted dynamic process modifications, e.g., for pore reduction. Using a laser system capable of dynamic beam shaping at frequencies of up to 80 MHz, the influence of the three process zones on the porosity of the weld was demonstrated using deep welds in cast aluminum as an example.