Change of dominant material properties in laser perforation process with high-energy lasers up to 120 kilowatt.

In laser materials processing, energy losses due to reflection, heat conduction and thermal radiation play an important role. In this publication, we show that with increasing laser intensity, the energy lost within the sample becomes less important for metal perforation processes. We compare the laser-matter interaction of aluminum and steel plates. Material parameters such as density, melting point and especially thermal conductivity differ strongly, leading to much longer perforation times for aluminum in comparison to steel at laser powers of 20 kW. However, this behavior changes at laser powers of more than 80 kW where the perforation times of aluminum become shorter than the corresponding times for steel. By comparing experimental data and simulations, we conclude that thermal conduction is the dominant factor of energy loss at low powers, but is reduced at high laser powers.

2D and 3D Triangulation Are Suitable In Situ Measurement Tools for High-Power Large Spot Laser Penetration Processes to Visualize Depressions and Protrusions before Perforating.

During laser penetration, the irradiated samples form a melt pool before perforation. Knowledge of the dynamics of this melt pool is of interest for the correct physical description of the process and leads to improved simulations. However, a direct investigation, especially at the location of high-power laser interaction with large spot diameters in the centimeter range is missing until now. Here, the applicability of 2D triangulation for surface topology observations is demonstrated. With the designed bidirectional 2D triangulation setup, the material cross-section is measured by profile detection at the front and back side. This allows a comprehensive description of the penetration process to be established, which is important for a detailed explanation of the process. Specific steps such as surface melting, indentations, protrusions during melt pool development and their dynamics, and the perforation are visualized, which were unknown until now. Furthermore, a scanning 3D triangulation setup is developed to obtain more information about the entire melt pool at the front side, and not just a single intersection line. The measurements exhibit a mirror-symmetric melt pool and the possibility to extrapolate from the central profile to the outer regions in most cases.