Endless carbon-fibre reinforced plastics (CFRP) are important lightweight construction materials. While the majority contains a thermoset matrix material, latest developments see an increase of CFRP with a thermoplastic matrix (CFRTP). This is due to their enhanced machinability and versatile material characteristics. However, high-performance thermoplastics and endless carbon fibres are both expensive resources. During the production of parts made from CFRTP, scrap-pieces and left-overs from the cutting process are usually disposed of. To increase the resource efficiency, a process is developed that includes the autonomous laser cutting of such CFRTP remnants to chips of unified dimensions, which can then be reused in the production of long-fibre reinforced CFRTP laminates. 
This study focuses on the laser process development for the cutting of CFRTP with a polyether ether ketone (PEEK) matrix. The development aims for short processing times and minimum thermal alteration of the PEEK. Laser cutting of semi-finished CFRTP is especially challenging, because although most fibres within a carbon fibre roving might be cut, individual fibres might still be intact and may cause fibre pull-out that would severely reduce the cutting-edge’s quality. Therefore, to verify that the CFRTP was completely cut, an optical process monitoring system is developed. 
In this investigation, process parameters are evaluated in terms of cutting time, surface appearance, and the completeness of the cuts. Surface analysis shows colour changes of the PEEK on an area of less than 1mm from the cutting edge. The monitoring system for cut completeness was introduced and showed good detection results.

Laser Cutting of Semi-finished CFRTP Products for Better Resource Efficiency

In this study, the application of the ABA cladding strategy to coaxial wire-based cladding processes is investigated. Individual weld seams (A) are first welded on the substrate and additional weld seams (B) are deposited into the intermediate spaces in the second step. Thereby two different seam geometries are present in the cladding. Unidirectional AAA and ABA claddings are generated using laser hot-wire cladding and analyzed with respect to the quality criteria height, waviness, degree of dilution and defects. Three different welding parameter sets are used to consider the effect of the contact angle on the applicability of the ABA cladding strategy. 
 
When the same process parameters and seam-to-seam offsets are used for the ABA cladding as for the AAA cladding, the B weld seams are higher than the A weld seams and an uneven ridged cladding surface is present. Two approaches to solving this problem are considered. The cross-sectional area of the B weld seams is reduced by adjusting the welding speeds or an increase of the seam-to-seam offset. Both measures result in a significant reduction in waviness of 30% to 58% compared to the AAA cladding. However, lack of fusion defects occur more frequently after deposition of the B weld seams. It was therefore necessary to adjust the process parameters for weld seam B.

Application of the ABA Cladding Technique to a Wire Based Laser Cladding Process

Laser-assisted double wire welding with nontransferred arc uses an electric arc to melt two welding wires fed towards each other. The molten material drips onto the substrate, where it is joined to the substrate without undercuts by means of oscillated laser radiation. The process offers the possibility of creating structures with high deposition rates (8,4&nbsp;kg/h), but faces challenges fulfilling the requirements for surface properties and geometric accuracy. One approach to meet the requirements is to confine the final seam geometry by applying the melt into a mold. Such a confinement can be a wall previously applied by a process with higher geometric accuracy. An investigation of this approach was carried out by studying the deposition of mild steel weld beads within two confining structures, in this case a groove. A particular interest in the evaluation is the connection of the weld bead to the base material in the corners, the bottom surface and the side surface of the groove. In a first step, weld beads are deposited in 12&nbsp;mm wide grooves in a mild steel substrate with variable laser beam oscillation amplitudes of 10&nbsp;mm to 13&nbsp;mm. In a second step, several layers are deposited with variable welding speeds. The oscillation amplitude that generates the best connection in the corners is 13&nbsp;mm. Bonding on the bottom and side surfaces could be achieved with all parameter sets. When applying several layers, the best lateral connection in the groove was produced with a welding speed of 200&nbsp;mm/min.

Welding Between Confinements as a New approach for high deposition rate Additive Manufacturing with laser-assised double-wire welding with nontransferred arc

Brass represents a large part in the production of components within the copper alloy group. Laser beam welding of this alloy offers great potential for many applications in terms of achievable seam quality and productivity. However, there is a very high tendency of the process to produce irregular seam surfaces, ejection of the molten metal and pore formation. These are due, among other things, to instabilities of the keyhole, which is favored by the evaporation of the alloy component zinc. Furthermore, near-infrared laser beam wavelength can couple poorly into the material due to the low absorption level of brass, whereas absorption jumps during the melt transition. In recent years, high-brilliance near-infrared laser beam sources with adjustable beam profiles have been developed that can lead to keyhole stabilization. 
The experimental process investigations are on deep penetration welding of different brass alloys (CuZn37 and CuZn39Pb3). A multi-kW laser beam source with combined core and ring beam is used for this purpose. Main process parameters are identified and systematically varied. The produced seams are analyzed and evaluated using different methods (including micrograph analysis and topography images). The results are correlated with the process parameters. Line Energy per unit length, spot size and process gas supply have a significant effect on the weld seam resulting. Process parameters were found to produce high quality bead on plate and butt welds for sheet thicknesses of 2 mm.

Laser Beam Welding of Brass With Combined Core and Ring Beam

Today, welding of quartz glass is mainly carried out with gas torches and by hand. The use of gas torches means that a lot of energy gets lost in the actual process zone. In addition, the manual process can result in inhomogeneous weld seams. 
An automated laser process would make the quartz glass welding process more energy efficient and more repeatable. In this study, quartz glass plates up to 4.5 mm in thickness are welded together at an angle of 125° using filler materials. The purpose is to achieve a homogeneous weld (V-seam) with as few defects as possible using a lateral fiber or rod based deposition welding process. 
The main challenge is to get the melt to the contact point of the two glasses so that no air inclusions occur. A 400 µm fiber and a 1 mm rod are investigated as additional materials. The advantage of the fiber compared to the rod is that the lower area (contact point of the glasses) is easier to reach during the welding process. The disadvantage is that a very high fiber feed rate is required to fill the gap. This leads to a high consumption of filler material. Process parameters include the substrate to fiber feed ratio, laser power, spot diameter, and process gas pressure and angle. The samples are analyzed using an optical microscope and a laser confocal microscope.&nbsp;Preliminary studies have shown that comparable results can be achieved with both filler materials.

Using Fiber or Rod? - The Influence of Different Filler Materials During CO2 Laser Welding of Quartz Glass

MACRO Track - Laser Processing of Plastics

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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**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.

Participants will be immersed in a dynamic environment that fosters collaborative learning, networking, and idea exchange. Through engaging plenary presentations, technical sessions, an industry business panel, and networking events, attendees gain insights into the forefront of laser technology. From industrial applications to medical breakthroughs, additive manufacturing to materials processing, ICALEO covers the entire spectrum of laser-related disciplines. Moreover, the event serves as a launching pad for synergistic partnerships, paving the way for professionals to forge connections that shape the future of our industry.

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Medical professionals investigating laser-based medical advancements, entrepreneurs seeking to innovate with lasers, educators aiming to stay updated with the latest in laser education, and policy makers shaping the industry's landscape are all essential attendees. Whether you're an established expert or a rising star, the 42nd annual ICALEO promises to offer a diverse ecosystem of expertise, connections, and knowledge sharing that caters to the laser and electro-optics communities.

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ICALEO 2023

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.

Stefan Kaierle

5

11

Presentations

Laser Cutting of Semi-finished CFRTP Products for Better Resource Efficiency

Application of the ABA Cladding Technique to a Wire Based Laser Cladding Process

Welding Between Confinements as a New approach for high deposition rate Additive Manufacturing with laser-assised double-wire welding with nontransferred arc

Laser Beam Welding of Brass With Combined Core and Ring Beam

Using Fiber or Rod? - The Influence of Different Filler Materials During CO2 Laser Welding of Quartz Glass

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