Wednesday, September 23, 2015

Pump and signal combiner for bi-directional pumping of all-fiber lasers and amplifiers(9)

6. Demonstration of 440 W pump power handling

After detailed theoretical and experimental characterization of fiber pump combiners with multiple pump ports, a pump power handling performance test was conducted. For these investigations each pump port of a 4 + 1x1 combiner was connected to a fiber coupled pump diode (nLight Pearl) with an output power of ~110 W at a wavelength of 976 nm. The PFF and the delivery fiber of the pump diode had a core diameter of 105 µm with a NA of 0.22. At each fiber output end of the IF, a pump light stripper was applied to avoid the Fresnel reflection of the TP, and therefore the TP was not measured. Up to the maximum total pump diode power of 440 W, a coupling efficiency of 90.2% was experimentally determined (Fig. 13
fiber pump combiners
Fig. 13 Combined pump power for a 4+1x1 high power fiber combiner, * ratio of coupled power to total diode power in percent.
). In the simulations a slightly higher coupling efficiency of 92.8% was obtained. The difference of 2.6% in simulated and measured pump light coupling must be distributed among TP, PAA and PCT, with simulated values of 3.0, 1.4 and 1.7%, respectively. It can be assumed that the PAA-fraction is higher than 1.4%, since the fibers of the combiner are contaminated with dust particles in spite of intensive cleaning. If we assume for each individual loss mechanism an error of 1% related to the total diode power then PCT was 7.5 W ± 4.4 W, i.e. the coating of the TF and the pump power stripper had to handle this fraction of power.
About DK Photonics
DK Photonics – www.dkphotonics.com  specializes in designing and manufacturing of high qualityoptical passive components mainly for fiber laser applications such as 1064nm high power isolator,Cladding Power Stripper, High Power Isolator,pump combiner,1064nm Band-pass Filter,(6+1)X1 Pump and Signal Combiner,PM Circulator,PM Isolator,optical Coupler.More information,please contact us.

Monday, September 14, 2015

Pump and signal combiner for bi-directional pumping of all-fiber lasers and amplifiers(8)

Pump and signal combiner for bi-directional pumping of all-fiber lasers and amplifiers(8)

5.2 Simulations of the loss mechanism caused by additional pump ports

As already discussed, the total power loss is comprised of TP, PAA and PCT. Since a TL of 20 mm and a TR of 6 seem to be promising parameters for a fiber combiner with multiple pump ports, Fig. 9
pump combiner
Fig. 9 Simulated losses for a pump combiner with a TL of 20 mm and a TR of 6 providing up to 6 pump ports. Please see Fig. 1for TP, PCT and PAA.
illustrates the behavior of the 3 different loss mechanisms and the total power loss against the number of pump ports. The input pump light NA of the PFFs was 0.22. The simulations clearly show that the TP-fraction as well as the PAA-fraction increase with the total power loss, and the PCT-fraction stays almost constant. The NA-mismatched pump light, which couples into the coating of the target fiber (PCT) can be kept below 1.7%, even up to 6 pump ports. Hence, an increasing number of pump ports and, therefore, scaling of the combined pump power results in additional power losses, but with an insignificant increase of thermal load to the coating of the TF. Of course, due to an increased PAA the combiner housing would be exposed to a higher thermal load, but this can be handled by an adequate thermalconcept. The increased PAA can be explained by pump light rays which couple back from the TF into one of the IFs, further propagate in the converging taper portion of the IF, increase in NA and undergo refraction into the ambient air. The increase of the TP-fraction with additional pump ports can be caused by pump light rays with a low NA which reverse couple into one of the IFs and further propagate there.
Finally, the simulations show that the total pump power loss increases with each additional pump port but the PCT, resulting in thermal load of the TF, does not increase significantly compared to a fiber combiner with a single pump port. In general, for the optical design of a side-pumped coupler with multiple pump ports, a TL as short as possible in conjunction with a TR as low as possible, but still satisfying the required pump coupling efficiency for the desired number of pump ports, ensures efficient pump light combining with low power losses. In contrast, for a single pump port, a longer TL in conjunction with a low TR is advantageous for increasing the pump coupling efficiency and reducing PCT-losses in particular.

5.3 Experimental characterization of pump combiners with multiple pump ports

Since the simulation results indicate that a TL of 20 mm and a TR of 6 are useful taper parameters, fiber combiners with two, four and six pump ports were developed. Each pump port consisted of an IF with a measured TL of 18 mm and a measured TR of 6.7. Each PFF had a NA of 0.15, and to characterize the combiner was connected to a pump diode (Oclaro BMU25) with a pigtail fiber delivering a maximum output power of about 25 W at a wavelength of 976 nm. The delivery fiber of the pump diode had parameters identical to the PFF.
Figure 10(a)
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Fig. 10 (a) Combined and transmitted power measured for a fiber combiner with 4 pump ports and (b) combined pump power measured for a fiber combiner with 6 pump ports, * ratio of coupled or transmitted power to total diode power in percent.
shows the total diode power with respect to the combined pump power and TP for a fiber combiner with four pump ports. For the combined pump power a coupling efficiency of 92% (93.1% in the simulation) was measured, and the fraction of TP was 3.6% (3.9% in the simulation) compared to the total diode power. Thus, the measured TP of 3.6% was 45% of the total power loss of 8% (Fig. 10(a)). Based on the good agreement between simulation and experiments it can be assumed that the PCT-fraction and PAA-fraction were about 0.6% and 2.3% of the total diode power, respectively.
Microscope images of the top view and of the cross section view, close to the taper waist, of a fiber combiner with 4 pump ports are depicted in Fig. 11(a)
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Fig. 11 Microscope image of (a) the top view and (b) the cross section view of a fiber combiner with 4 pump ports.
and 11(b).
The experimental results of a developed six pump port fiber combiner with a combined pump power of 141.5 W and an obtained coupling efficiency of 89.6% (91.1% in the simulations) is shown in Fig. 10(b). The fiber combiner with six pump ports was limited by the available pump power and not by thermal problems. For the combiner presented in Fig. 10(b), Fig. 12(a)
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Fig. 12 (a) Pump coupling efficiency of the individual pump ports of the six pump port fiber combiner presented in Fig. 10(b) and10(b) comparison of the experimentally achieved pump coupling efficiencies with the simulation results for fiber combiners with multiple pump ports.
shows the pump coupling efficiency of each individual pump port with a maximum and minimum pump coupling efficiency of 90.2 and 88.8%. The difference of only 1.4% indicates a very homogeneous fiber bundle structure, and supports the assumption of identical optical behavior of the individual pump ports.
An overview of the experimentally obtained coupling efficiencies with the corresponding simulation results for a fiber combiner with 1, 2, 4 and 6 pump ports is depicted in Fig. 12(b). An agreement of the experimental and simulated results within 1% confirms the applicability of the simulation approach for multiple pump ports. For each fiber combiner a TL of 18 mm, a TR of 6.7 and a PFF with a core NA of 0.15 was applied.
About DK Photonics
DK Photonics – www.dkphotonics.com  specializes in designing and manufacturing of high qualityoptical passive components mainly for fiber laser applications such as 1064nm high power isolator,Cladding Power Stripper,Multimode High Power Isolator,pump combiner,1064nm Band-pass Filter,(6+1)X1 Pump and Signal Combiner,PM Circulator,PM Isolator,optical Coupler.More information,please contact us.

Wednesday, September 2, 2015

Fiber Laser Welding: Some Traits and Applications(2)

Technological parameter of laser welding:
(1) Power density
Power density is one of the key parameters in laser processing. When the power density is relatively high, the surface would be heated to boiling point in microseconds, thus generate mass vaporization. As a result, high power density is good for material removal processing such as punching, cutting and carving. When the power density is relatively low, it would take some microseconds to meet the boiling point, the bottom can reach the melting point before vaporization occurs, thus a good melt welding is successfully formed. So the power density ranges from 104~106W/cm2 in conductive laser welding.
(2) Laser pulse shape
Laser pulse shape is an important question in laser welding, especially for foil welding. When high strength laser beam reaches the material surface, 60~98% of the laser energy will be lost by reflection and the reflectivity is changeable by the temperature of the material surface. The reflectivity of metal can vary greatly in a laser pulse period.
(3) Laser pulse width
Laser pulse width is an important parameter to distinguish material removal and material melting; it is also a key parameter to decide the cost and volume of processing equipment.
(4) Influence of defocusing amount on weld quality
There are two ways of defocus: positive defocus and negative defocus. It is positive defocus when focal plane is above the workpieces, vise versa. According to geometry optical theory, when positive and negative defocusing plane equals to welding plane, the power densities are almost the same in the corresponding panels, but the actual laser pools have different forms. It can achieve larger depth of fusion when it is negative defocus.
Application field of laser welding
Laser welding machine has wide application in manufacturing industry, powder metallurgy field, automobile industry, electronics and some other fields.
fiber laser 3
Source : demarlaser
Application of laser welding in automobile industry
Volkswagen AG has adopted laser welding in car roof of brands like AudiA6, GolfA4 and Passat. BMW and GM have used laser welding in top of the car frame while Mercedes-Benz has applied laser welding in drive disk assembly. Except for laser welding, other laser technologies have be applied as well. Companies like Volkswagen GM, Benz and Nissan have used laser to cut covering parts while FIAT and Toyota have adopted laser for coating engine exhaust valve; Volkswagen has used laser for surface hardening on engine camshaft. Domestic vehicle models like Passat, Polo, Touran, Audi, Dongfeng Peugeot and Focus have adopted laser welding technology.
Independent automobile brands like Brilliance, Chery and Geely have adopted laser welding as well.
Improvement and development of new laser welding technology
Laser welding technology is continuously developing along with the progress of the time. The following three technologies can help expanding laser's application scop and enhancing the automatic control level of laser welding.
  1. filler wire laser welding
Laser welding generally doesn't fill wires but has high requirement on assembling clearance, which is hard to be guaranteed thus limits the application scope. Filler wire laser welding method has lower requirement on assembling clearance. For example, if the aluminum alloy plate is of 2 mm's thickness, the clearance must be zero for a good shaping. When adopting φ1.6mm welding wire as filler metal, it can form good shape even the clearance is 1.0 mm. Besides, filler wire can be used for adjusting chemical components and multi-layer welding on thick board.
  1. Beam rotation laser welding
By the adoption of laser beam rotation laser welding methods, demands on welding assembly and beam centering are reduced greatly.
  1. On-line detection and control of laser welding quality
It is becoming a hot researching topic on detecting laser welding process by using plasma such as light, sound and electric charge; some researches have achieved closed-loop control.
DK Photonics – www.dkphotonics.com  specializes in designing and manufacturing of high quality optical passive components mainly for fiber laser applications such as 1064nm high power isolator, Cladding Power Stripper, Multimode High Power Isolator, pump combiner,1064nm Band-pass Filter,(6+1)X1 Pump and Signal Combiner, PM Circulator, PM Isolator, optical Coupler. More information, please contact us.