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Processing constraints resulting from heat accumulation during pulsed and repetitive laser materials processing.

Rudolf Weber, Thomas Graf, Christian Freitag

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    |March 1, 2017
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    Summary

    Controlling heat accumulation is crucial in high-power pulsed laser processing. This study derives formulas to predict when residual heat (HAP and HAS) exceeds critical temperatures, ensuring process quality.

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    Area of Science:

    • Materials Science
    • Laser Physics
    • Thermal Engineering

    Background:

    • Pulsed laser processing generates residual heat, leading to temperature increase with successive pulses or scans.
    • Uncontrolled heat accumulation (HAP/HAS) can exceed material melting points, degrading process quality.
    • Predicting heat accumulation limits is vital for high-power, repetitive laser applications.

    Purpose of the Study:

    • To develop analytical scaling laws for heat accumulation in pulsed laser processing.
    • To determine the limiting number of pulses or scans before critical temperature thresholds are breached.
    • To provide practical formulas for managing heat accumulation in high-average-power laser systems.

    Main Methods:

    • Derivation of approximation formulas for heat accumulation under specific conditions (short heat input duration relative to cooling time).
    • Validation of formulas using surface ablation of CrNi-steel (HAP) and multi-scan cutting of CFRP (HAS).
    • Utilized picosecond laser systems with average power up to 1.1 kW.

    Main Results:

    • Analytical scaling laws for heat accumulation as a function of processing parameters were established.
    • Approximation formulas were validated for both heat accumulation by pulses (HAP) and scans (HAS).
    • For 1D heat flow, the number of allowed heat inputs inversely scales with the square of the average laser power.

    Conclusions:

    • The derived formulas provide a method to predict and control heat accumulation in pulsed laser materials processing.
    • Understanding heat accumulation limits is essential for optimizing process parameters and maintaining quality with high-power lasers.
    • The findings are applicable to various laser-based manufacturing processes, including ablation and cutting.