Deformable mirror technology takes laser welding and 3D printing to new heights
With further research, the technology will be ready for full-scale production in the coming years
Yongcui Mi, a newly minted Ph.D. in Production Technology from University West, has developed an innovative technology that enables the real-time shaping and control of laser beams, which could revolutionize the fields of laser welding and directed energy deposition using laser and wire. The breakthrough is based on advanced deformable mirror technology, originally designed for use in telescopes, that allows high-power lasers to adapt instantly to variations in joint gaps, improving both process efficiency and quality.
Mi’s pioneering work utilizes mirror optics that can withstand multi-kilowatt laser power. By integrating computer vision and artificial intelligence, the laser beam can be shaped dynamically during the welding process, adapting in real-time to variations in joint gaps. This capability is a game-changer for industries facing challenges in high-power laser welding, especially when dealing with filler wire. Defects caused by inconsistent joint gaps have long been a significant hurdle, but this technology provides a solution for creating strong, flawless welds.
The mirror optics can handle multi-kilowatt laser power, and with the help of computer vision and AI, the laser beam can be shaped in real time to adapt to variations in joint gaps.
The technology’s impact extends beyond laser welding. Mi has also tested it for directed energy deposition with laser and wire, showing promising results for improving the reliability and efficiency of high-power laser applications.
Dynamic Laser Beam Shaping for Precision and Quality
One of the key advantages of this technology is its ability to dynamically adjust the laser beam shape in real-time. “To achieve a strong and flawless joint, the laser beam shape needs to adapt to the varying widths along a weld seam,” Mi explains.
With this technology, the beam can be dynamically shaped during the welding process to bridge joint gaps up to 0.6 millimeters when welding steel plates that are 2 millimeters thick.
The laser beam shape can change within just 10 milliseconds, allowing for a range of elliptical beam shapes that provide a higher-quality weld compared to traditional circular static beams. “Our tests show that we can reduce deformations in the workpiece by up to 80%,” Mi adds.
Cost-Effective and Sustainable Solution
The technology not only enhances precision and reliability but also brings significant cost savings. Mi’s research reveals that dynamic laser beam shaping reduces material waste and energy consumption, leading to more sustainable processes. “This technology makes the process more flexible and achieves higher quality. Additionally, it significantly reduces material waste and energy consumption, saving both time and money,” Mi says.
Collaboration and Industry Interest
This mirror technology has allowed astronomers to achieve more precise images of distant celestial bodies. Mi’s team has customized the mirrors to meet the specific needs of industrial laser applications.
The research also involved collaboration with leading industrial partners, including GKN Aerospace, Brogren Industries, and Procada. The technology has garnered significant interest from industries utilizing high-power lasers, such as manufacturers of next-generation aircraft engines, electrified vehicles, and other industrial sectors with demanding requirements.
Looking Ahead
With further research, Mi believes the technology will be ready for full-scale production in the coming years.
The potential for dynamic laser beam shaping in laser welding and directed energy deposition is immense
As the technology matures, it promises to provide more efficient and reliable methods for laser welding and directed energy deposition, offering manufacturers new opportunities to develop more robust processes that meet the stringent quality standards of modern industries.
Source: University West
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