Deformable mirror technology takes laser welding and 3D printing to new heights

Yongcui Mi has developed a new technology that enables real-time shaping and control of laser beams for laser welding and directed energy deposition using lasers and wires. This innovation is based on the same mirror technology used in advanced telescopes for astronomy.

Within a few years, this new technology could lead to more efficient and reliable methods of using high-power lasers for laser-and-wire welding and directed energy deposition. Manufacturing industries could benefit from new opportunities to build more robust processes that meet stringent quality standards.

“We are the first to use deformable mirror technology for this application. The mirror optics can handle several kilowatts of laser power, and with the help of computer vision and AI, we can adapt the laser beam to adapt to changes in the joint. “There is a gap,” explains Yongkui, a newly completed Ph.D. in Industrial Technology from West University.

The industry currently faces major challenges in high-power laser welding without filler wire. Variations in the gap width of the joint often cause defects in the weld.

Dynamic laser beam shaping

“To achieve a strong and perfect joint, the shape of the laser beam must adapt to the varying widths along the weld seam. This technology allows us to dynamically shape the beam during the welding process. , it can fill joining gaps of up to 0.6 millimeters when welding steel ‘2 millimeter thick plates,’ says Yongcui.

“The shape of the laser beam changes within 10 milliseconds, and by using different elliptical beam shapes, we can also achieve higher weld quality compared to traditional circular static beams. Our tests have shown that workpiece deformation can be reduced by up to 80%.”

Yongcui also tested new techniques for directed energy deposition using lasers and wires. Again, dynamic laser beam shaping can create a more efficient and reliable process for high-power lasers.

save time and money

“My research results show that dynamic laser beam shaping has great potential for both laser welding and directed energy deposition with lasers and wires. This technique makes the process more flexible. In addition, material waste and energy consumption are significantly reduced, saving both time and money. ”

The deformable mirror was developed in close collaboration with Dynamic Optics, an Italian company that manufactures mirror optics for advanced telescopes primarily used by astronomers. Mirror technology was developed by the University of Padua in Italy in the 1950s, and has since allowed telescopes to provide more accurate images of stars, planets, and other celestial objects.

custom designed mirror

“Our project mirrors are customized for specific applications. Integrating, debugging, and validating prototypes of cutting-edge technology was the most difficult and time-consuming part of the research,” Yongcui said. says.

Yongcui also works with industrial partners such as GKN Aerospace, Brogren Industries, and Procada. This technology is attracting significant interest from industries working with high-power lasers, including manufacturers of next-generation aircraft engines, electric vehicles, and other demanding industrial applications.

“Further research is needed to bring this technology to full-scale production within the next few years. I hope to continue my research and contribute to broader and deeper knowledge in this field.”