Researchers use synchrotron radiation to visualize industrial laser processes – for more efficient production, new materials, and shorter development cycles.
Experimental setup for performing phase contrast videography at beamline P61A at DESY Petra III.
RWTH Aachen – Lehrstuhl für Lasertechnik
Researchers at the Fraunhofer Institute for Laser Technology ILT and the Chair of Laser Technology at RWTH Aachen University want to sustainably improve the quality of laser processes such as welding, drilling, and cutting. To this end, they are investigating industrial laser processes at the German Electron Synchrotron (DESY) in Hamburg using synchrotron radiation. For the first time, the formation of vapor capillaries, melt movements, and defects are being visualized in high resolution and in real time.
The research team conducts up to 700 test series within a week. High-speed cameras with rates of up to 50,000 frames per second and special optical systems enable resolution in the micro and nanometer range. Initial results have shown that targeted adjustment of the laser settings can reduce stress cracks, decrease pore formation, and increase electrical conductivity, according to Fraunhofer ILT.
Classic and Complex Connections
The investigations cover both classic metal joints and complex material combinations such as copper-aluminum or aluminum-titanium, which are used in electric mobility and aviation, among other areas. Laser powder welding of nickel-based superalloys and the processing of ultra-thin copper structures for microelectronics are also being analyzed.
A key component of the research work is the evaluation of the extensive measurement data: up to 50 TB is generated per week. Special software solutions are used to process the data and convert it into usable information. In addition to optimizing existing processes, the findings are expected to open up new possibilities for the development of customized materials. Companies such as Audi, Bosch Research, and Denso are already using the results to increase efficiency and shorten development cycles.
This is a partly automated translation of this german article.
