United States

Cutting thick plates is affected not only by the laser power but also by the cut kerf width and the melt flow dynamics that determine the ejection of the molten material. Employing the same laser beam intensity distribution for various thicknesses is the limiting factor when cutting thicker plates. This paper investigates fiber laser fusion cutting of 25 mm thick aluminium with dynamic beam shaping (DBS). While both static and longitudinal dynamic intensity distributions fail to cut this thickness with a 4 kW laser power, a cut through is achieved using annular and elliptical intensity distributions. However, an improvement of 45&amp;nbsp;% in cutting speed can be achieved using an elliptical intensity distribution compared to an annular one. In order to understand the effect of the beam shape, an infrared thermal camera is used to study lateral heat propagation when using different process parameters. The more efficient heat propagation in the cutting direction employing elliptical intensity distribution decreases the power losses compared to the annular intensity distribution. Moreover, to analyze the melt flow when changing the DBS frequency, high-speed imaging is utilized to observe the molten material inside the cut kerf. Finally, the cut edge quality is investigated for different cutting conditions.

ICALEO 2023

Cutting Thick Aluminium Plates Using Laser Fusion Cutting Enhanced by Dynamic Beam Shaping

dynamic beam shaping

aluminium

thick plate

laser cutting

Cutting thick plates is affected not only by the laser power but also by the cut kerf width and the melt flow dynamics that determine the ejection of the molten material. Employing the same laser beam intensity distribution for various thicknesses is the limiting factor when cutting thicker plates. This paper investigates fiber laser fusion cutting of 25 mm thick aluminium with dynamic beam shaping (DBS). While both static and longitudinal dynamic intensity distributions fail to cut this thickness with a 4 kW laser power, a cut through is achieved using annular and elliptical intensity distributions. However, an improvement of 45&nbsp;% in cutting speed can be achieved using an elliptical intensity distribution compared to an annular one. In order to understand the effect of the beam shape, an infrared thermal camera is used to study lateral heat propagation when using different process parameters. The more efficient heat propagation in the cutting direction employing elliptical intensity distribution decreases the power losses compared to the annular intensity distribution. Moreover, to analyze the melt flow when changing the DBS frequency, high-speed imaging is utilized to observe the molten material inside the cut kerf. Finally, the cut edge quality is investigated for different cutting conditions.

technical paper

**General Chair Welcome**

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Welcome to ICALEO® 2023!
	
We were excited to host the world’s leading international conference on Lasers and Electro-Optics in Chicago. The Laser has been shown to have the potential to revolutionize solutions for major global challenges like energy usage and supply, global warming, and CO2 footprint. Even the fusion energy breakthrough is based on laser technology. The conference, with peer-reviewed scientific and technical presentations, focused on the newest results in Micro Applications, Macro Applications, Additive Manufacturing, Beam Shaping and Frontiers in Laser Applications. Additionally, the Battery-Manufacturing Track gave an overview of the process combined with the newest advances in laser application results. 

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Whether this is the first time you are hearing about ICALEO or you are a longtime attendee, you will find something of interest, new ideas, and an excellent opportunity to network with other laser specialists worldwide. 

**Klaus Löffler **  
ICALEO General Chair   
Managing Director, Precitec GmbH

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ICALEO® brings together the brightest minds, seasoned professionals, and pioneering researchers from around the world. With a laser-focused agenda, ICALEO offers an exceptional platform to delve into the cutting-edge advancements, diverse applications, and transformative research that define lasers and electro-optics.

Fiber laser cutting has been widely used in many industrial applications, but the further improvement is required in the reduction of dross. Recently, the control of laser intensity distributions has been investigated in many laser applications, and some researchers have reported that intensity distribution of laser beam has a possibility to improve the cutting quality. Our previous study revealed that the uniform intensity distribution in the kerf width direction enabled to reduce the dross height, and twin spot beam was obtained by dividing a Gaussian beam with a roof axicon lens to control the power ratio in the kerf width direction. However, twin spot beam setting in the kerf width direction could improve the dross adhesion only in one side. Therefore, twin spot beam was set in the scanning direction, and the proper control of power ratio was investigated in laser cutting experiments for cold rolled steel sheet of 3.2 mm thickness by 3 kW fiber laser with a nitrogen assist gas. A ray tracing analysis and high-speed observation of molten metal ejection made it clear that high intensity of rear beam smoothly ejects molten metal at the lower part of workpiece, and a small ejecting width and the forward slanting ejection of molten metal were important to reduce the dross height. The dross height could be reduced to 16 µm by using the rear beam power of 90 % and the front beam power of 10 %.

Fiber Laser Cutting of Steel Plate by Twin Spot Beam Setting in Scanning Direction

Artificial intelligence is a trend that has been on innovation leader's radar for a long time. It is a technological enabler for a more sustainable future and will significantly increase business efficiency if used meaningfully. It affects our daily lives, and the way people and companies will work now and in the future. Insights into practical applications with various maturity degree will be presented from the perspective of a leading solution provider in the sheet metal industry. In times when there is a shortage of experienced operators, it is especially important to have a solution that enables machine operators to find the optimal machine settings and parameters to achieve the best performance and quality in shortest time. Artificial intelligence also supports the increase of the automatization degree of systems achieving a low-man production and ensures 24/7 production with assisting systems for monitoring the status of the laser cutting machines in operation and especially, during cutting. In addition to the monitoring, control procedures are presented to enhance the performance and quality demands of a laser cutting machine. A method for in-process quality control is presented prior to bending the sheet metals avoiding the processing of defect parts at an early stage.

AI in Laser Cutting - Insights Into Recent Achievements

Powder-based Laser Metal Deposition (LMD) offers a promising additive manufacturing process given the large number of available materials for cladding or generative applications. In laser cladding of dissimilar materials, it is necessary to control the mixing of substrate and additive in the interaction zone to ensure safe metallurgical bonding whilst avoiding critical chemical compositions that lead to undesired phase precipitation. However, the generation of empirical data for LMD process development is very challenging and time-consuming. In this context, different machine learning models are examined to identify whether they can converge with a small amount of empirical data. 
In this work, the prediction accuracy of Back Propagation Neural Network (BPNN), Long Short-Term Memory (LSTM) and eXtreme Gradient Boosting (XGBoost) were compared using Mean Squared Error (MSE) and Mean Absolute Percentage Error (MAPE). A hyperparameter optimization was performed for each model. The materials used are 316L as substrate and VDM Alloy 780 as additive. The data set used consists of 40 empirically determined values. The input parameters are laser power, feed rate and powder mass flow rate. The quality characteristics height, width, dilution, Fe-amount and the seam contour are defined as output. 
As results, the predictions were compared with retained validation data and described as MSE and MAPE to determine the prediction accuracy for the models. BPNN achieved a prediction accuracy of 0.0072 MSE and 4.37% MAPE and XGBoost of 0.0084 MSE and 6.34% MAPE. The most accurate prediction was achieved by LSTM with 0.0053 MSE and 3.75% MAPE.

Prediction of Clad Quality in Laser Metal Deposition Using Dissimilar Materials: Performance Comparison of Machine Learning-Based Approaches

Lattice structures in additive manufacturing of 316L stainless steel has gained increasing attention due to their well suited mechanical properties and lightweight characteristics. Infill structures such as honeycomb, lattice, and gyroid have shown promise in achieving desirable mechanical properties for various applications. However, the design process of these structures is complex and time-consuming. In this study, we propose a machine learning-based approach to optimize the design of honeycomb, lattice, and gyroid infill structures in 316L stainless steel fabricated using Laser Powder Bed Fusion (L-PBF) technology under different loading conditions. 
A dataset of simulated lattice structures with varying geometries, wall thickness, distance and angle using a computational model that simulates the mechanical behavior of infill structures under different loading conditions was generated. The dataset was then used to train a machine learning model to predict the mechanical properties of infill structures based on their design parameters. 
Using the trained machine learning model, we then performed a design exploration to identify the optimal infill structure geometry for a given set of mechanical requirements and loading conditions. 
Finally, we fabricated the optimized infill structures using L-PBF technology and conducted a series of mechanical tests to validate their performance under different loading conditions. 
Overall, our study demonstrates the potential of machine learning-based approaches for the efficient and effective design of honeycomb, lattice, and gyroid infill structures in 316L stainless steel fabricated using L-PBF technology under different loading conditions. Furthermore, this approach can be used for dynamic loading studies of infill structures.

Predictive Modeling of Lattice Structure Design for 316L Stainless Steel Using Machine Learning in the L-PBF Process

Powder bed fusion of metals using laser beam (PBF‑LB/M) is a commonly used additive manufacturing process for the production of high-performance metal parts. AlSi10Mg is a widely used material in PBF-LB/M due to its excellent mechanical and thermal properties. However, the part quality of AlSi10Mg parts produced using PBF-LB/M can vary significantly depending on the process parameters. This study investigates the use of machine learning (ML) algorithms for the prediction of the resulting part density of AlSi10Mg parts produced using PBF-LB/M. An empirical dataset of PBF-LB/M process parameters and resulting part densities is used to train a ML models. Furthermore, a methodology is developed to allow density predictions based on simulated meltpool dimensions for different process parameters. This approach uses finite element simulations to calculate the meltpool dimensions, which are then used as input parameters for the ML models. The accuracy of this methodology is evaluated by comparing the predicted densities with experimental measurements. The results show that ML models can accurately predict the part density of AlSi10Mg parts produced using PBF-LB/M. Moreover, the methodology based on simulated meltpool dimensions can provide accurate predictions while significantly reducing the experimental effort needed in process development in PBF-LB/M. This study provides insights into the development of data-driven approaches for the optimization of PBF-LB/M process parameters and the prediction of part properties.

Data-Driven Density Prediction of AlSi10Mg Parts Produced by Laser Powder Bed Fusion Using Machine Learning and Finite Element Simulation

In aerospace, thermal applications demand compact, lightweight and efficient heat exchangers. Additive manufacturing processes offer the potential to create highly complex structures that are not achievable through traditional manufacturing methods. This work presents the development of an additively manufactured fluid-fluid heat exchanger that enhances performance, reduces weight and increases compactness compared to a conventional plate heat exchanger. A numerical model of the conventional plate heat exchanger was created, and fluid dynamics simulations with heat transfer were performed. Verification of the simulations was done by experiments. Then a novel heat exchanger was designed using a bottom-up approach and investigated at different levels of complexity using computational fluid dynamics. The internal structure of the final heat exchanger consists of a repeating triple-periodic Schwarz diamond minimum surface elongated in the direction of flow. The heat exchanger was manufactured in the laser powder bed fusion process in AlSi10Mg. It had a 108% higher compactness and 54% lower weight compared to the plate heat exchanger. Numerical analysis yielded the pressure loss was reduced by 50 to 59% while heat transfer was improved by 3 to 5%. Simulation results were validated by experimental assessment of the novel additively manufactured heat exchanger. Further investigations can be conducted to increase compactness and heat transfer by analyzing the minimum partition wall thickness and the impact of wall roughness and deposit formation.

Design and Assessment of an Additively Manufactured Schwarz Diamond Triply Periodic Minimal Surface Fluid-Fluid Heat Exchanger

Nowadays the technologies have to be more efficient, propose cutting edge processes, be more versatile while being environmental friendly. In this presentation, LASEA will introduce how the beam-shaping can improve the laser processes in particular in microfluidics, aeronautics, photovoltaic applications but also how the beam shaping is expected to increase the productivity of the machine in roller applications, roll-to-roll or batch-to-batch applications. 
Different technologies can be used to shape the laser beam as spatial light modulator (SLM), double SLM, diffractive optical element (DOE) or as well multi-plane light conversion (MPLC) to produce versatile shaped beam (square, round, triangular, specific shape…) or multiple beams (line of beams, matrix of beams,…). The direct laser interference patterning (DLIP) is also a technology that shapes the beam enabling the production of multi-scales processes; micrometric and sub-micrometric structures. Consequently, LASEA will present these different possibilities, their expected impacts and how to integrate them in a laser machine to achieve high throughputs processes. 
Moreover, the beam-shaping leading to multiple beams introduces many challenges in terms of laser machine design and laser development. Indeed, when the number of beams increases the laser has to be more powerful. During this presentation, LASEA will also expose the challenges to manage multiple beams and powerful laser source. Finally, the impacts and improvements expected by these types of technologies will also be present.

Laser Beam Shaping in the Industry

Beam shaping has become increasingly important for laser-based processing, enabling improved efficiency, quality, and precision in a wide range of applications. In this paper, we discuss the challenges of characterizing and defining the appropriate criteria to evaluate a shaped beam for laser material processing applications. 
Beam shaping is essential for many continuous wave (CW) processes, such as high-quality welding of copper and aluminum for e-mobility applications. Similarly, beam shaping is crucial for pulsed applications, particularly surface texturing, enabling precise control of the laser's energy distribution and enhancing the process's quality and scalability. 
We explore various beam shaping technologies, including Diffractive Optical Elements, Refractive Optics, Shaping via Double Core Fiber Laser, Coherent Beam Combining, and Multi-Plane Light Conversion, describing their advantages and limitations. Since these technologies manipulate beams differently, their use can significantly impact the process's outcome. 
We propose various criteria to evaluate the performance of a shaped beam for laser material processing, such as efficiency, uniformity, sharpness, robustness to instabilities, and depth of field. These criteria are critical in defining a good beam for a specific process, ensuring a reliable and repeatable process outcome. 
In conclusion, this paper highlights the importance of proper characterization and evaluation of shaped beams for laser material processing applications. With the appropriate criteria, manufacturers and researchers can optimize the laser's performance and enhance the quality, efficiency, and scalability of laser-based processes.

Defining the Right Criteria to Characterize a Shaped Beam for Laser Material Processing Applications

On-the-fly evaluation and process control of laser surface microprocessing can be realized with the detection of infrared (IR) thermal radiation. In this study, a new multi-focus mirror was developed and tested for large-area detection of IR-thermal radiation during ultrashort pulsed laser surface micromachining. The IR-thermal detection in the laser micromachining was for the first time combined with a fast hardware signal analysis and laser power control using a field programmable gate array (FPGA) module. The new mirror has a long-line distribution of focused points on one side to collect the emitted thermal radiation along a laser scanning line and focuses the captured IR-thermal radiation to a point on the other side for signal analysis. The length of the detection line of the developed multi-focus mirror was 120 mm and it can be expanded up to tens of centimeters. This IR-thermal radiation signal is processed by the FPGA module with a fast evaluation of heat accumulation at a cycle time loop of 50 ns and on-the-fly control of the laser power during surface microprocessing. When the detected heat accumulation signal grows higher than the required value, then the average laser power is automatically decreased, and vice versa. This lR-thermal tracking system was applied for laser surface micromachining of metals and ceramics with polygon- and galvo-scanners. The presented lR-thermal tracking system with the multi-focus mirror can be used also in other applications, such as beam shaping, line scanning spectroscopy, linear surface irradiation, or non-destructive testing (IR-NDT).

Fast IR-Thermal Tracking of Laser Microprocessing with Multi-focus Mirror

Modern beam sources and system technology allows to adjust a large number of parameters relevant to the machining process, and often these parameters can even be varied as a function of time. In principle, a large parameter space makes it possible to find and use particularly well-suited parameter regimes for the specific application, but this generally increases the experimental effort considerably. The efficient optimization of process parameters, incorporating all the possibilities of modern flexible laser beam sources and system technology, in perspective also opens the door to high quality and high throughput. 
Semiconductors as Silicon and Germanium show on the one hand significantly higher ablation efficiencies when they are machined with bursts but then suffers from lower machining quality. On the other hand, especially (100) oriented wafers, can be machined with very low surface roughness due to a melting effect ocuring if a certain peak fluence is exceeded. Combination of these two processes would further exceed the parameter space for a process optimization when high throughput and surface quality is demanded. We will demonstrate the potential of machine learning to significantly shorten the demanded time and effort for the process optimization when these materials are machined with ultra-short laser pulses.

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Cutting Thick Aluminium Plates Using Laser Fusion Cutting Enhanced by Dynamic Beam Shaping

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Fiber Laser Cutting of Steel Plate by Twin Spot Beam Setting in Scanning Direction

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