Lasers are essential tools for a wide variety of materials processing applications. The speed, quality, and process window are determined in part by the laser beam properties, including size, shape, and divergence. Most laser sources have fixed beam characteristics, resulting in processing and material limitations and nonoptimized performance. nLIGHT has developed a fiber-laser product line that provides rapid tunability of the beam characteristics directly from the delivery fiber using a novel, all-fiber mechanism. The broad range of beam sizes and shapes and real-time programmability allow adjustments on-the-fly and optimization of each process step using a single laser source, enabling development of versatile tools that provide optimum performance for a range of processing needs. We describe the underlying technology, performance, and beam characteristics and show results for the largest industrial laser applications, including metal cutting, welding, and additive manufacturing.
Industrial lasers used for materials processing have become essential tools in a wide array of applications, including cutting, welding, drilling, cladding, marking, hardening, and additive manufacturing. The speed, quality, and process window are determined in part by the laser beam properties such as beam size, shape, and divergence. nLIGHT has developed a new multi-kilowatt fiber laser, Corona™, that provides rapid tunability of the beam characteristics directly from the laser output fiber using a novel, all-fiber mechanism. Programmable beam shapes include flat top and donut beams with beam diameters from 100 μm to 390 μm and beam parameter products from 3 to 20 mm-mrad (M2 values from 9 to 59). We describe the Corona fiber laser performance and show processing results and advantages of specific beam shapes for sheet-metal cutting, the largest industrial laser application.
Next-generation industrial fiber lasers enable challenging applications that cannot be addressed with legacy fiber lasers. Key features of next-generation fiber lasers include robust back-reflection protection, high power stability, wide power tunability, high-speed modulation and waveform generation, and facile field serviceability. These capabilities are enabled by high-performance components, particularly pump diodes and optical fibers, and by advanced fiber laser designs. We summarize the performance and reliability of nLIGHT diodes, fibers, and next-generation industrial fiber lasers at power levels of 500 W – 8 kW. We show back-reflection studies with up to 1 kW of back-reflected power, power-stability measurements in cw and modulated operation exhibiting sub-1% stability over a 5 – 100% power range, and high-speed modulation (100 kHz) and waveform generation with a bandwidth 20x higher than standard fiber lasers. We show results from representative applications, including cutting and welding of highly reflective metals (Cu and Al) for production of Li-ion battery modules and processing of carbon fiber reinforced polymers.
We demonstrate flexible performance in a fiber MOPA system based on nLIGHT’s PFL seed laser platform and chirally coupled core (3C®) fiber. The 33μm core, 27μm MFD 3C fiber used in these demonstrations is fabricated in volume at nLIGHT’s Finland facility. A variety of pulse formats are amplified to nonlinearity-limited peak power <300kW, including single pulses in the 50ps to 1ns regime at a variety of repetition rates from 10’s of kHz to MHz. Beam quality in these 3C based MOPAs is exceptional with M2<1.15 and circularity <95% at all power levels. Beam pointing often evident in other LMA fiber technologies due to higher order mode content is minimal in these fiber MOPAs. Burst mode operation of the seed laser system using flexible burst packet repetition rates (10’s of kHz to several MHz) and adjustable pulse-to-pulse spacing within bursts (<10ns to 100ns) is demonstrated and amplified in the same 3C fibers. Bursts of up to ten 50ps pulses amplified to total energies exceeding 160μJ are demonstrated at 200kHz burst repetition rate and 32W average power at high efficiency (74% slope). Bursts of up to five 500ps pulses are also amplified to up to 360μJ total energy. In both cases, the varying degree of pulse saturation win a burst and mitigation paths are reviewed.
We describe a photofragment laser-induced fluorescence (PF-LIF) method that can be applied to the short-range-standoff
detection of low-volatility organophosphonate chemical warfare agents (OP-CWAs) on surfaces. It operates by
photofragmenting a surface-bound analyte and then actively interrogating a released phosphorous monoxide (PO)
fragment using LIF. We demonstrate a single-pulse-pair (pump = 500 μJ @ 266 nm; probe = 20 μJ @ 248 nm) surface
detection sensitivity of 30 μg/cm2 for the organophosphonate diisopropyl isothiocyanate phosphonate (DIPP) on
aluminum and 210 μg/cm2 for the same analyte on a more porous concrete surface. By detecting the PO photofragment,
the method indicates the presence of organophosphonates; however, we show that it also responds to other phosphorouscontaining
compounds. Because of its limited specificity, we believe that the method may have most immediate use as a
mapping tool to rapidly identify "hotspots" of OP-CWAs. These would then be confirmed using a more specific tool. As
one method of confirming the presence of OP-CWAs (and identifying the agent), we demonstrate that the probe beam
can be used to acquire Raman-scattering spectra of the target area.
We report the development of fused-fiber pump and signal combiners. These combiners are enabling components of a ytterbium fiber-laser emitting 4 kW of 1080-nm radiation. The fiber-laser system consists of seven fiber laser modules and a 7:1 signal combiner. The laser modules are end-pumped by 90 915-nm JDSU L4 diode-lasers, yielding a nominal pump power of 900 W. The diode laser radiation is coupled into the laser fiber through a 91:1 fused-fiber pump combiner. The input fibers of this pump combiner are standard 105/125-um multimode fibers with an NA of 0.22. These fibers form a hexagonally packed fused-fiber bundle, which is tapered to match the cladding diameter of the laser fiber. Eighty-six percent of the light exiting the pump-combiner is emitted within an NA of 0.32, and all measurable power is emitted within an NA of 0.45. The typical insertion loss of the pump combiners is <1%. The high-brightness radiation of seven laser modules is combined into a single output fiber using a 7:1 fused-fiber signal combiner providing a total power of >4 kW in the single output beam. The beam parameter product of the combined output was 2.5 mm-mrad. The low insertion loss of < 2% indicates that the signal combiner is suitable to handle even higher laser powers.
We review what we have learned in the last few years from modeling nanosecond fiber amplifiers. We have developed a number of models that treat bent fiber mode profiles and bend loss, plus gain models and models of nonlinear processes such as self phase modulation, self focusing, SRS, SBS, and four wave mixing. The models have been validated by detailed comparisons with laboratory measurements.
Sandia National Laboratories' program in high-power fiber lasers has emphasized development of enabling technologies
for power scaling and gaining a quantitative understanding of fundamental limits, particularly for high-peak-power,
pulsed fiber sources. This paper provides an overview of the program, which includes: (1) power scaling of diffraction-limited
fiber amplifiers by bend-loss-induced mode filtering to produce >1 MW peak power and >1 mJ pulse energy
with a practical system architecture; (2) demonstration of a widely tunable repetition rate (7.1-27 kHz) while
maintaining constant pulse duration and pulse energy, linear output polarization, diffraction-limited beam quality, and
<1% pulse-energy fluctuations; (3) development of microlaser seed sources optimized for efficient energy extraction; (4)
high-fidelity, three-dimensional, time-dependent modeling of fiber amplifiers, including nonlinear processes; (5)
quantitative assessment of the limiting effects of four-wave mixing and self-focusing on fiber-amplifier performance; (6)
nonlinear frequency conversion to efficiently generate mid-infrared through deep-ultraviolet radiation; (7) direct diode-bar
pumping of a fiber laser using embedded-mirror side pumping, which provides 2.0x higher efficiency and much
more compact packaging than traditional approaches employing formatted, fiber-coupled diode bars; and (8)
fundamental studies of materials properties, including optical damage, photodarkening, and gamma-radiation-induced
darkening.
We summarize the performance of mode-filtered, Yb-doped fiber amplifiers seeded by microchip lasers with
nanosecond-duration pulses. These systems offer the advantages of compactness, efficiency, high peak power,
diffraction-limited beam quality, and widely variable pulse energy and repetition rate. We review the fundamental limits
on pulsed fiber amplifiers imposed by nonlinear processes, with a focus on the specific regime of nanosecond pulses.
Different design options for the fiber and the seed laser are discussed, including the effects of pulse duration,
wavelength, and linewidth. We show an example of a microchip-seeded, single-stage, single-pass fiber amplifier that
produced pulses with 1.1 MW peak power, 0.76 mJ pulse energy, smooth temporal and spectral profiles, diffractionlimited
beam quality, and linear polarization.
Recent EPA regulations targeting mercury (Hg) emissions from utility coal boilers have prompted increased activity in
the development of reliable chemical sensors for monitoring Hg emissions with high sensitivity, high specificity, and
fast time response. We are developing a portable, laser-based instrument for real-time, stand-off detection of Hg
emissions that involves exciting the Hg (6 3P1 ←6 1S0) transition at 253.7 nm and detecting the resulting resonant
emission from Hg (6 3P1). The laser for this approach must be tunable over the Hg absorption line at 253.7 nm, while
system performance modeling has indicated a desired output pulse energy ≥0.1 μJ and linewidth ≤5 GHz (full width at
half-maximum, FWHM). In addition, the laser must have the requisite physical characteristics for use in coal-fired
power plants. To meet these criteria, we are pursing a multistage frequency-conversion scheme involving an optical
parametric amplifier (OPA). The OPA is pumped by the frequency-doubled output of a passively Q-switched,
monolithic Nd:YAG micro-laser operating at 10-Hz repetition rate and is seeded by a 761-nm, cw distributed-feedback
diode laser. The resultant pulse-amplified seed beam is frequency tripled in two nonlinear frequency-conversion steps to
generate 253.7-nm light. The laser system is mounted on a 45.7 cm × 30.5 cm breadboard and can be further condensed
using custom optical mounts. Based on simulations of the nonlinear frequency-conversion processes and current results,
we expect this laser architecture to exceed the desired pulse energy. Moreover, this approach provides a compact, all-solid-
state source of tunable, narrow-linewidth visible and ultraviolet radiation, which is required for many chemical
sensing applications.
We present an experimental and theoretical analysis of four-wave-mixing (FWM) in nanosecond pulsed fiber amplifiers
FWM leads to a saturation of the in-band amplified pulse energy and to distortions of the spectral and temporal profiles,
and it is the main limiting effect in the ~1 ns temporal regime. A simple model considering both Raman and FWM
contributions provides a good description of the measured behaviours, allowing optimization and design tradeoffs to be
explored for mitigating FWM.
We have numerically compared the performance of various designs for the core refractive-index (RI) and
rare-earth-dopant distributions of large-mode-area fibers for use in bend-loss-filtered, high-power
amplifiers. We first established quantitative targets for the key parameters that determine fiber-amplifier
performance, including effective LP01 modal area (Aeff, both straight and coiled), bend sensitivity (for
handling and packaging), high-order mode discrimination, mode-field displacement upon coiling, and
index contrast (manufacturability). We compared design families based on various power-law and hybrid
profiles for the RI and evaluated confined rare-earth doping for hybrid profiles. Step-index fibers with
straight-fiber Aeff values > 1000 &mgr;m2 exhibit large decreases in Aeff and transverse mode-field displacements
upon coiling, in agreement with recent calculations of Hadley et al. [Proc. of SPIE, Vol. 6102, 61021S
(2006)] and Fini [Opt. Exp. 14, 69 (2006)]. Triangular-profile fibers substantially mitigate these effects,
but suffer from excessive bend sensitivity at Aeff values of interest. Square-law (parabolic) profile fibers are
free of modal distortion but are hampered by high bend sensitivity (although to a lesser degree than
triangular profiles) and exhibit the largest mode displacements. We find that hybrid (combined power-law)
profiles provide some decoupling of these tradeoffs and allow all design goals to be achieved
simultaneously. We present optimized fiber designs based on this analysis.
The design and optimization of high-power fiber amplifiers requires a simulation tool capable of including a wide range of effects simultaneously, including mode distortion
and loss due to bending, spatially-dependent saturable gain, guiding from arbitrary index of refraction profiles and self-focusing. In addition, the nonlinear effects are power
dependent and thus will distort the pulse shape. We have constructed a numerical model to address these issues and serve as a platform for data analysis and system optimization.
We have numerically investigated the behavior of the LP01 fundamental mode of a step-index, multimode
(MM) fiber as the optical power approaches the self-focusing limit (Pcrit). The analysis includes the effects
of optical gain and fiber bending and are thus applicable to coiled fiber amplifiers. We find that at powers
below Pcrit, there exist stably propagating power-dependent modifications of the LP01 mode, in contrast to
some previous solutions that exhibited large-amplitude oscillations in beam waist along the fiber. For the
first time, to our knowledge, we show that in a MM fiber amplifier seeded with the low-power LP01
eigenmode, the transverse spatial profile will adiabatically evolve through power-dependent stationary
solutions as the beam is amplified toward Pcrit. In addition, for a given value of the nonlinear index, Pcrit is
found to be nearly the same in the bulk material and in a step-index fiber. These conclusions hold for both
straight and bent fibers, although the quantitative details are somewhat different.
We report a pulsed, Nd:YAG (1064 nm) microchip laser amplified by a mode-filtered, Yb-doped fiber amplifier. The
system provided a widely tunable repetition rate (7.1-27 kHz) with constant pulse duration (1.0 ns), pulse energy up to
0.41 mJ, linear output polarization, diffraction-limited beam quality, and <1% pulse-energy fluctuations. Detailed
spectral and temporal characterization of the output pulses revealed the effects of four-wave mixing and stimulated
Raman scattering, and we investigated the effects of fiber length and Yb-doping level on system performance. The
amplifier output was efficiently converted to a variety of wavelengths between 213 and 4400 nm by harmonic generation
and optical parametric generation, with Watt-level output powers. The laser system employs a simple architecture and is
therefore suitable for use in practical applications.
The design and optimization of high-power fiber lasers and amplifiers requires a detailed understanding of several important physical processes, both linear and nonlinear. The influence of bending on the overlap of the propagating mode as well as its resistance to deleterious nonlinear effects such as self-focusing must be accurately predicted. To this end we have developed a number of models, both analytic and numerical, that allow us to treat these effects in detail.
We report results from Yb-doped fiber amplifiers seeded with two microchip lasers having 0.38-ns and 2.3-ns pulse durations. The shorter duration seed resulted in output pulses with a peak power of >1.2 MW and pulse energy of 0.67 mJ. Peak power was limited by nonlinear processes that caused breakup and broadening of the pulse envelope as the pump power increased. The 2.3-ns duration seed laser resulted in output pulses with a peak power of >300 kW and pulse energy of >1.1 mJ. Pulse energies were limited by the onset of stimulated Brillouin scattering and ultimately by internal optical damage (fluences in excess of 400 J/cm2 were generated). In both experiments, nearly diffraction-limited beam profiles were obtained, with M2 values of <1.2. Preliminary results of a pulse-amplification model are in excellent agreement with the experimental results of the amplifiers operating in the low-to-moderate gain-depletion regime.
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