Freeform Mirror Design Based on Zonal Energy Mapping

In laser phase-transformation hardening and laser cladding processes, the inherent thermodynamic limitations of conventional intensity distributions severely restrict the uniformity of metallurgical reaction. Although programmable beam shaping devices offer flexibility in profile reconstruction, their transmissive structure results in a low laser-induced damage threshold (LIDT), making them unsuitable for long-term stable operation at kilowatt-level power. This study proposes a reflective freeform mirror design method based on the principle of zonal energy mapping. The method constructs energy mapping relations that correlate the irradiance distribution in every sub-region of the incident Gaussian beam with the desired M-shaped irradiance profile. Relying on such mappings, the local surface generatrices of all sub-regions are solved separately; these generatrices are subsequently assembled to yield an integrated mirror surface. Optical performance was verified through Zemax non-sequential ray tracing simulations. The mirror was precisely machined using single-point diamond turning (SPDT). The experimental results show that the measured intensity distribution on the observation screen exhibits a typical M-shaped profile, with a peak-to-valley ratio of 1.28, which is in good agreement with the design target. This method provides a technically feasible and engineering-robust solution for complex thermal flux control requirements in high-power laser material processing.