MECH 605 Laser Materials Processing Laser Cutting

Power Control

Figure 1.13 Laser System Panel

5. Process Monitoring:
The internal operation of the laser system could be observed through viewing ports (Figure
1.14), providing visual confirmation of proper system function. The HeNe alignment beam
served as a visible guide for the invisible CO₂ beam path.

Figure 1.14 Inner working of laser

The integration of these components and procedures demonstrates the complexity and precision
required in industrial laser processing systems. Understanding each element's function is
crucial for optimal system operation and maintenance.

Part 2 Laser Set up (in Lab)

Details given by the professor:

A number of techniques will be demonstrated that are commonly used in the setting up of a
CO2 laser processing head for applications such as laser cutting, welding etc.

Processing nozzle alignment:

The nozzle, which contains the focussing lens and carries the process assist gas, is manipulated
in the X and Y directions (orthogonal to the laser beam axis), using micrometer/screw
manipulators, to achieve a central alignment of the focussed laser beam coaxial with the exit
aperture of the nozzle. This ensures that the laser beam and process gas jet are coaxially aligned,
which gives rise to best omni-directional process efficiency in the laser process.

9
MECH 605 Laser Materials Processing Laser Cutting

‘Blue flash’ test:

When the focussed laser beam impinges on the material surface, a plasma is created just above
the surface. If the beam is slightly out of focus, the colour of this will appear white. As the
focus is reached, the plasma becomes more intense and its colour changes to a blue-ish hue.
This has been used to indicate that the beam is in focus with respect to the surface of the
material.

Kapton film test:

Bursts of laser energy impinging on Kapton film will give an indication of the spot size as well
(the diameter of the beam waist at the material surface). This is a common material used in the
alignment and beam spot size analysis in Nd:YAG/fibre lasers, but can also be used with CO 2
laser beams.

Notes taken by me
We have a beam delivery system as shown in the below figure.

Figure 15 Beam Delivery System

We also have gold mirrors with volt inlet and outlet. This is placed at 45 degree, the laser comes in
and gets deflected at 90 degrees.

10
MECH 605 Laser Materials Processing Laser Cutting

Figure 16 Gold Mirror

The raw beam diameter is around 15 mm depicted in the below figure.

Figure 17 Raw beam diameter

The ZnSe lense placed in the laser head as given in the figure below, has a focal length of 100 mm.

Figure 18 ZnSe Lens

For safety reasons, a safety beam is used. The ZnSe lense helps focus the laser beam, the below
figures display how the beam diameter changes with reducing the focal length.

11
MECH 605 Laser Materials Processing Laser Cutting

Figure 19 Reducing beam diameter

In order to proceed with the operation, we need to the focal position to be exactly 100 mm because
the depth of focus is very short so we need to be very accurate with our focal position. In order to
attain this for the laser cutting nozzle, with narrow diameter (1 mm), we use a wider diameter nozzle
of laser welding in order to account for the difficulty to get the beam through the narrow hole of the
laser cutting nozzle. Once the laser is aligned at the centre with the assist gases around, we replace
the welding nozzle with the cutting nozzle.

Figure 20 Laser cutting and laser welding nozzles

Now that the set up for aligning the laser has been done with the nozzles attached, we start working
with the laser, for safety reasons, we wear the safety goggles.

Now we remove the focusing optic in order to receive the raw laser beam on the piece of wood
underneath.

12
MECH 605 Laser Materials Processing Laser Cutting

Figure 21 Removed laser focusing optic

A laser beam with power 1500 W is fired onto the piece of wood, and the alignment is checked.

Figure 22 Raw Laser Beam

The focusing lens optic is checked for cleanliness and fitted in the laser head ensuring fitting.
The spot size or beam dia at the focal position is then found see below figure.

Figure 23 Focused beam size

Now that the focal postion is found with respect to piece of wood, we now find it wrt to the material
being used, a 3mm Mild Steel plate. For this, the plate is placed below the laser head.

Now we do the blue flash test, we turn the power high around 1000 W. the assist gases are turned on
to avoid fumes.

The laser is fired, and initially we get yellow coloured spark, however, we adjust the focal position until
we get blue spark. Blue spark means the focal distance is achieved.

Figure 24 Blue flash test

13
MECH 605 Laser Materials Processing Laser Cutting

Next procedure is to measure the distance between the top of the workpiece and the bottom of the
nozzle. The focal position from the lens to the material has been found. Now we need the stand off
distance between the workpiece and the top of the nozzle to be less than one mm. a field gauge is
used to make the standoff distance to 1mm.

Field Gauge

Figure 25 1mm standoff distance set

Now, the next task is the laser beam is focused at the center of the nozzle, for this we are using the
welding nozzle because of the higher diameter. A piece of tape with some amount of debrie is fixed
on the bottom of the nozzle. The laser is then fired and the position of the of the laser is checked. At
the first instance, it is too close to the edge of the nozzle which can damage the nozzle.

Laser

Figure 26 Aligning the laser beam to the centre for welding nozzle

TO align the laser to the centre, there are adjustments made in the laser head by using the screws.
Once adjestments are made, the laser becomes focused in the centre for the welding nozzle. The
same is repeated for the narrower, 1 mm nozzle, the cutting nozzle.

14
MECH 605 Laser Materials Processing Laser Cutting

Figure 27 Laser at the centre for welding nozzle

Figure 28 Laser aligned at center for 1 mm cutting nozzle

Now we do the Kapton film test. And the minimum spot size is found.

Minimum spot Size

Figure 29 Kapton Film Test

15