Spatial Beam Shaping Research Articles

Enhanced Laser Damage Threshold in Optically Addressable Light Valves via Aluminum Nitride Photoconductors

AbstractOptically addressable light valves (OALVs) are specialized optical components utilized for spatial beam shaping in various laser‐based applications, including optics damage mitigation, and enhanced functionality in diode‐based additive manufacturing requiring high intensities. Current state‐of‐the‐art OALVs employ photoconductors such as Bismuth Silicon Oxide (BSO) or Bismuth Germanium Oxide (BGO), which suffer from limited laser‐induced damage thresholds (LiDT) and inadequate thermal conductivities, thus restricting their use in high peak and average power applications. Aluminum nitride (AlN), an emerging ultra‐wide band gap (UWBG) III–V semiconductor, offers promising optoelectronic properties and superior thermal conductivity (>300 Wm−1K−1 at 298° K, compared to BSO's 3.29 Wm−1K−1). In this study, the first AlN‐based OALVs are designed, fabricated, and experimentally demonstrated using commercially available single‐crystal AlN substrates. These AlN‐based OALVs have shown clear superiority over BSO and BGO‐based devices. Design considerations for OALVs incorporating UWBG photoconductors are discussed, and the photoresponsivity from defect‐mediated sub‐bandgap absorption in AlN crystals is verified as sufficient for OALVs operating under high light fluences. The optimum driving voltage for the AlN‐based OALV is determined to be ≈ 45 Vpp at 100 Hz, achieving a transmittance of 91.3%, an extinction ratio (ER) of more than 100, and a 51:1 image contrast.

Interference patterns of two-photon excited fluorescence by spatial beam shaping

We report on two-photon excited fluorescence interference patterns produced by spatial laser beam shaping. Thereto, a focused spatially modulated laser beam component is overlapped with an unfocused Gaussian beam component, and both are directed on a cuvette filled with dye. The phase retardance between the two common path laser components is precisely adjusted by a 2D liquid crystal modulator. With this method it is possible to generate various fluorescence patterns which exhibit sharp features and a high contrast due to constructive and destructive interference of a two-photon excitation process. The developed spatial shaping interference technique with two-photon excitations has a high potential for optical and biophotonic imaging applications.

Exploring spatial beam shaping in laser powder bed fusion: High-fidelity simulation and in-situ monitoring

Laser beam shaping is a novel and relatively unexplored method for controlling the melt pool conditions during metal additive manufacturing (MAM) processes, but even so it still holds good promise for achieving site-specific tailored properties. In this work, a comprehensive numerical and experimental campaign is carried out to explore this subject within metal laser powder bed fusion (LPBF). More specifically, a multiphysics numerical model is implemented for simulating the heat and fluid flow conditions during LPBF of Ti6Al4V using arbitrary circular beam shapes with various power distributions spanning from a pure Gaussian beam to a pure ring beam profile. The model is subsequently coupled with cellular automata to describe the beam shape effects on the microstructure evolution. Model validation is carried out in a two-fold manner. First, we compare the predicted melt pool cross-section with the one from ex-situ single track experiments, and we find a deviation of less than 9 % in melt pool dimensions. Secondly, advanced in-situ X-ray monitoring is carried out to unravel the melt pool dynamics and we find that the predicted morphology closely matches the in-situ X-ray results. Moreover, it is shown that at lower laser power, a bulge of liquid metal forms at the center of the melt pool when employing ring profiles, and this is ascribed to the absence of recoil pressure at the center of the ring beam. Furthermore, increasing the laser power seems to destabilize the melt pool regime, as the central bulge transforms into a liquid metal jet that periodically collapses and breaks up into hot spatter. Based on the results, we believe that our multiphysics modelling methodology, opens up new pathways for predicting how laser beam shaping influences porosity, surface roughness as well as microstructure formation in LPBF processes.

Laser beam shaping facilitates tailoring the mechanical properties of IN718 during powder bed fusion

One of the recent technological developments in the Laser Powder Bed Fusion (LPBF) process is the use of non-Gaussian beam profiles of power density distributions. Irrespective of the strategies used to change the beam profile, spatial beam shaping enhances process flexibility since it allows manipulation of the thermal field, the melt pool shape, and the microstructure. This work showcases the impact of novel ring and conventional Gaussian beams on density, melt pool characteristics, and mechanical properties of IN718 superalloy via LPBF. A novel laser source with beam shaping capabilities provided the beam profiles, ranging from Gaussian to ring beams. The results show clear differences between the crystalline patterns obtained with Gaussian and the other ring beams attempted. This study elucidates the impact of melting modes and solidification mechanisms on the texture index, arising from the interplay between laser beam shape modes and laser speed. It also shows how the crystalline configuration associated with each case studied influences the mechanical properties and how it is possible to modify the process parameters and the beam shape mode to extend control over the mechanical properties of the components manufactured using LPBF. This leads to a broader range of mechanical properties and grain size when tailoring the power density distribution towards ring beams. Additionally, the correlation between melt pool shape geometry, texture index, and mechanical properties is discussed, and the limitations and advantages of each mode are defined.

Temporal and Spatial Beam Shaping in LPBF for Fine and Porous Ti-Alloy Structures for Regenerative Fuel Cell Applications

AbstractLaser Powder Bed Fusion (LPBF) presents itself as a potential method to produce thin porous structures, which have numerous applications in the medical and energy industries, due to its in-process pore formation capabilities. Particularly, regenerative fuel cells, which are capable of both producing and storing energy through the use of hydrogen-based electrochemical fuel cell and electrolysers, respectively, can benefit from the LPBF-induced porosity for it porous layer components in the electrode. Numerous studies have reported that process parameters, such as laser power, scan speed and hatch spacing, are key factors affecting the formation of pores in LPBF material due to their control over the energy density and melt pool formation during the build. Contemporary fibre lasers offer novel temporal and spatial beam shaping capabilities. Temporal laser control means that the laser can use pulsed wave (PW) or single point exposure (SPE), and spatial beam shaping refers to variations in the intensity distribution of the laser, which can be modulated from Gaussian to ring shape via the use of multi-core fibers. These have seldom been studied in combination with LPBF. Therefore, the aim of this study was to utilise temporal and spatial beam shaping in LPBF to produce thin porous structures. To do this, PW and SPE laser temporal strategies were utilised and the duty cycle (which relates the on and off time of the laser) was varied between 50% and 100%. Beam shape indexes 0 (Gaussian), 3 and 6 (ring) were also investigated alongside more standard LPBF process parameters such as laser power and scan speed to manufacture thin porous walls, as well as fine struts. The thinnest wall obtained was 130 μm thick, while the smallest strut had a diameter of 168 μm. The duty cycle had a clear effect on the porosity of thin walls, where a duty cycle of 50% produced the highest number of porous walls and had the highest porosity due to its ability to control the intensity of the energy density during the LPBF process. The different beam shape indexes corresponded to different spatial distribution of the power density, and hence, modifying the temperature distribution in the meltpool during the laser material interaction. Beam shape index 6 (corresponding to a ring mode with lower peak irradiance) created more porous specimens and smaller meltpool sizes, with respect to its beam size. Overall, this study showed that temporal and spatial control of the beam (through duty cycle and beam shape index) are powerful tools which can control the distribution and intensity of the energy density during the LPBF process to produce thin porous structures for energy applications.

Optical sensing based on phase interrogation with a Young's interference hologram using a digital micromirror device.

We propose a new holographic interferometric technique of phase interrogation for nanophotonic sensors, allowing to reach low phase noise and fluctuation by using a digital micromirror device spatial light modulator. With the spatial light modulator, both beam shaping and phase shifting interferometry can be simultaneously managed, hence enabling the interrogation of nanophotonic devices with a common-path heterodyne Young's interference experiment. The efficiency of the technique is illustrated in the particular case of temperature sensing using Tamm plasmon photonic crystals. The hologram sensor allows to probe resonant structures with deep attenuation at resonance, such as resonant structures at critical coupling or with phase singularities.

Generating brick-like melt pools for Laser-Based Powder Bed Fusion using flexible beam shaping: a proof of concept on bead-on-plate single tracks

Despite the highest industrial maturity among additive manufacturing processes, laser-based powder bed fusion of metals (PBF-LB/M) lacks the productivity to further establish as an industrial manufacturing process. One approach for adjusting the melt pool shape to increase productivity in PBF-LB/M is spatial beam shaping. The freedom of beam shaping is almost unlimited, owing to modern optical concepts. The key is a beam shape optimized for a specific target. In this publication, the target is a brick-like melt pool cross-section. The publication demonstrates how the corresponding laser beam shape is designed using numerical optimization. The computed beam shape is reproduced using reflective spatial light phase modulators. The calculation is validated based on single-track experiments. Applying the optimized beam shape results in a melt pool shape similar to the optimization target. The width and depth of the melt track produced deviate by a maximum of 7 % from the specified target values.

The effect of in-source spatial beam shaping on the laser welding of e-mobility metals and alloys

Electromobility applications require several welded connections using demanding materials often in dissimilar combinations. Copper, aluminium, or steel alloys are laser welded for energy storage and traction related components. On the one hand, high power fiber laser sources provide in-source beam shaping solutions able to modify the irradiance profile towards ring-shaped beams. On the other hand, research focused on the effect of the beam shapes on the melting mechanisms and process quality is still in progress. This work studies the effect of different beam profiles on AISI301LN, AA6082 and pure Cu with a 5 kW fiber laser. Linear trends of power over penetration depth as a function of speed confirms the validity of employing the lumped heat capacity model for ring-shaped beams. Moreover, the specific melting fluence is observed to exhibit an exponential decaying trend with the proportion of power allocated in the fiber core, irrespective of tested material.

Longitudinal to transversal conversion of mode-locked states in an empty optical resonator.

A longitudinal mode-locked state can be converted to a transverse mode-locked state by exploiting the spectral and spatial filtering of an empty optical resonator. Carrier and amplitude modulation sidebands were simultaneously transmitted by the conversion resonator, yielding phase-locked superpositions of up to five transverse modes. Equivalently, an amplitude-modulated beam was converted into a beam that periodically moved across the transverse plane. Precise control over the spatial beam shape during oscillation was gained by independently altering the set of transverse modes and their respective powers, which demonstrated an increased level of control in the generation of transverse mode-locked states.

Spiral phase plasma mirror

In this work we present a method for generating ultra-intense Laguerre–Gauss laser beams, using 3D direct laser writing of spiral phase plasma mirrors. These single-use mirrors provide an economical and scalable solution for arbitrary spatial beam shaping at ultra-high laser intensities. The use of these plasma-based optical devices is demonstrated for the case of an orbital angular momentum of , with incident laser intensity of 1017 W cm−2. We conclude by discussing practical considerations for using these optical elements on petawatt-class laser systems

Tunable optofluidic microbubble lens.

Optofluidic microlenses are one of the crucial components in many miniature lab-on-chip systems. However, many optofluidic microlenses are fabricated through complex micromachining and tuned by high-precision actuators. We propose a kind of tunable optofluidic microbubble lens that is made by the fuse-and-blow method with a fiber fusion splicer. The optical focusing properties of the microlens can be tuned by changing the refractive index of the liquid inside. The focal spot size is 2.8 µm and the focal length is 13.7 µm, which are better than those of other tunable optofluidic microlenses. The imaging capability of the optofluidic microbubble lens is demonstrated under a resolution test target and the imaging resolution can reach 1 µm. The results indicate that the optofluidic microbubble lens possesses good focusing properties and imaging capability for many applications, such as cell counting, optical trapping, spatial light coupling, beam shaping and imaging.

Ultrashort-pulsed laser processing with spatial and temporal beam shaping using a spatial light modulator and burst modes

We report on the effect of simultaneous spatial and temporal beam shaping on the ablation rate, ablation efficiency and the resulting surface characteristics of micromachined stainless steel using ultrashort-pulsed lasers. Beam shaping and the use of pulse bursts are promising methods to allocate the over the last decades increasing laser power of ultrashort-pulsed lasers in ablation processes. While the individual effects of beam shaping and pulse bursts on the ablation characteristics have recently been examined, the combination of both has not yet been adequately investigated. Using a spatial light modulator to generate different spot distributions with up to six spots and different separations it is possible to spatially distribute the available laser power. In combination with temporal beam shaping using a 200 kHz repetition rate and pulse bursts with a 40 MHz intra-burst rate, we investigate the influences in a scanning-based process and find an increasing ablation rate and efficiency for higher fluences. Subsequently using bursts in combination with a multi-spot beam profile, we found a distinctive emergence of cone like protrusions and a smoothing effect for fluences between 1.5 J/cm² and 3 J/cm² with six spot beam profile.

Beam shaping solutions for stable laser welding

AbstractThe laser beam is a highly flexible tool that is used for many material processing applications. New spatial beam shaping technology enables even further functionality to create up to four focal spots in an axial or lateral direction, which enables the distribution of the energy to be tailored. It was shown that certain beam shapes help to suppress spattering and increase the bridgeable gap size during deep penetration laser welding.

Aberration correction in stimulated emission depletion microscopy to increase imaging depth in living brain tissue.

.Significance: Stimulated emission depletion (STED) microscopy enables nanoscale imaging of live samples, but it requires a specific spatial beam shaping that is highly sensitive to optical aberrations, limiting its depth penetration. Therefore, there is a need for methods to reduce optical aberrations and improve the spatial resolution of STED microscopy inside thick biological tissue.Aim: The aim of our work was to develop and validate a method based on adaptive optics to achieve an a priori correction of spherical aberrations as a function of imaging depth.Approach: We first measured the aberrations in a phantom sample of gold and fluorescent nanoparticles suspended in an agarose gel with a refractive index closely matching living brain tissue. We then used a spatial light modulator to apply corrective phase shifts and validate this calibration approach by imaging neurons in living brain slices.Results: After quantifying the spatial resolution in depth in phantom samples, we demonstrated that the corrections can substantially increase image quality in living brain slices. Specifically, we could measure structures as small as 80 nm at a depth of inside the biological tissue and obtain a 60% signal increase after correction.Conclusion: We propose a simple and robust approach to calibrate and compensate the distortions of the STED beam profile introduced by spherical aberrations with increasing imaging depth and demonstrated that this method offers significant improvements in microscopy performance for nanoscale cellular imaging in live tissue.

Spatial beam shaping of a focused laser with quasi-near-field characteristics based on a concatenated fuzzy matching algorithm

We demonstrate a concatenated fuzzy matching algorithm to restrain local strong regions for the spatial beam shaping of a focused laser with quasi-near-field characteristics on the cross section in the focusing light path. Considering that the light field is redistributed according to the spatial angular spectrum after the laser beam is converged, modulations increasing with the propagation distance will decrease the smoothness of the beam. An effective algorithm for the spatial beam shaping of such focused laser is discussed by establishing the cascaded correspondence between the light field in the front stage and the later stage. The results show that the fluence contrast reduces from 37.2% to 21.4%, and the intensity modulation from 3.33:1–1.86:1. Meanwhile, the low-frequency components corresponding to local large-scale strong regions of the light field in the PSD distribution are effectively suppressed. A more regular spatial intensity profile of the focused laser is finally obtained.

Efficient Ultrashort Pulsed Laser Processing by Dynamic Spatial Light Modulator Beam Shaping for Industrial Use

We report on the effect of different transversal beam shapes on the efficiency of ablation processes and the resulting surface characteristics. A possibility to efficiently apply ultrashort pulsed lasers with high average power is beam shaping. By using a cooled reflective based liquid crystal spatial light modulator to generate different spot distributions, it is possible to spatially allocate the available power to avoid excessive high fluences. In our experiments, we determine the optimal fluence to ablate the maximum volume per watt to be in the range of 0.2-0.4 J/cm². Based on this fluence, we increase the number of spots from one to a maximum of twenty to ablate steel in a multilayer scanning-based process. In this context, we examine the influence of different separation distances between the spots on the ablation efficiency and roughness. Subsequently to these investigations, we develop an efficient roughing process with higher ablation rates and a nearly constant roughness.

Reproducible process regimes during glass welding by bursts of subpicosecond laser pulses.

During welding of glass with ultrafast lasers, an irregular formation of weld seams was prevented by modulation of the average laser power and spatial beam shaping. The formation of individual molten volumes in regular intervals was achieved by means of power modulation, resulting in a predictable and reproducible weld seam with a regular structure. At constant average power, a homogeneous weld seam without a periodic signature was alternatively achieved by means of a shaped beam generating an elongated interaction volume and resulting in a continuous melting of the material. The influence of the two approaches, and their combination on the process dynamics, was analyzed by means of high-speed videos of the plasma emission and of the formation of the seams.

Electrical modulation of the LWIR absorption and refractive index in InAsSb-based strained layer superlattice heterostructures

InAsSb-based strained layer superlattices (SLS) have strong fundamental absorption, which can be easily modified in a controlled manner by injecting excess carriers. This makes them attractive for intensity modulation of infrared lasers as well as beam steering and spatial beam shaping with a nanosecond-scale time response. This paper reports the modulation of the fundamental absorption and the refractive index by carrier injection in a 3.45-nm-period InAsSb0.65/InAsSb0.35 SLS with a low temperature energy gap of 85 meV grown by molecular beam epitaxy on a GaSb substrate with a GaInSb metamorphic buffer. The SLS absorber was sandwiched by n- and p-type wider energy gap layers for electrical injection and confinement of excess carriers. The population of conduction band states was obtained by measuring the intensity modulation of a 10.6 μm CO2 laser for temperatures ranging from T = 77 to 200 K. An increase of the electron quasi-Fermi level with electrical injection up to 20 meV was observed. The experimental data imply a decrease in the Auger coefficient with temperature, from 3 × 1024 cm6/s at 77 K to 1 × 1024 cm6/s at T = 200 K attributed to recombination involving two electrons and a heavy hole. The refractive index changes obtained by electrical injection of excess carriers can reach 0.05 at T = 77 K and 0.035 at T = 200 K, which are at least three orders of magnitude greater than those obtained with electro-optical materials.

Optical method for micrometer-scale tracerless visualization of ultrafast laser induced gas flow at a water/air interface.

We study femtosecond-laser-induced flows of air at a water/air interface, at micrometer length scales. To visualize the flow velocity field, we simultaneously induce two flow fronts using two adjacent laser pump spots. Where the flows meet, a stationary shockwave is produced, the length of which is a measure of the local flow velocity at a given radial position. By changing the distance between the spots using a spatial light modulator, we map out the flow velocity around the pump spots. We find gas front velocities near the speed of sound in air vs for two laser excitation energies. We find an energy scaling that is inconsistent with the Sedov-Taylor model. Due to the flexibility offered by spatial beam shaping, our method can be applied to study subsonic laser-induced gas flow fronts in more complicated geometries.

Phase smoothing and polarisation-phase synchronous smoothing based on liquid crystal Pancharatnam-Berry phase devices

ABSTRACT In this paper, we proposed and fabricated a liquid crystal random-phase plate (LCRPP) for laser beam phase smoothing, while the simulation and experimental verification of LCRPP applied to laser beam’s smoothing were also carried out simultaneously. A new beam smoothing technology named polarisation-phase synchronous smoothing and an improved algorithm based on G-S algorithm specially designed for polarisation-phase synchronous beam smoothing are also proposed based on liquid crystal Pancharatnam-Berry (LC PB) phase devices. Our work on beam smoothing taking advantage of LC PB phase devices not only simplifies the process, deduces the cost and greatly improves the precision and effect of beam smoothing but also provides a novel way for spatial beam shaping, which is of wide applications in laser processing.