Experimental and Numerical Investigations of Laser Beam Welding with an Ultra-high Brightness Direct-diode Laser

Abstract Laser beam welding of steel sheets with conventional disc and fibre lasers is part of many manufacturing processes, e.g. car manufacturing. In modern times, all manufacturing processes are also evaluated regarding sustainability. Although conventional beam sources have an ever increasing efficiency, direct-diode lasers are said to make a step in the wall-plug efficiency in comparison to conventional beam sources due to a missing brightness-converter. Investigations concerning laser beam welding with ultra-high brightness direct-diode lasers were carried out, showing heat conduction welding as well as deep penetration welding of 22MnB5 steel sheets is possible. Furthermore a beam parameter product of about 8 mm-mrad was measured, showing comparable beam quality to conventional disc and fibre lasers. Metallographic cuts were used for determining the welding penetration depth and cross-section. Especially the cross-sections, as a measure for process efficiency, show almost the same result using a direct-diode laser or a disc laser. Due to the limited laser power of 500W, numerical simulations were used to extend the experimental results.