Within the EKOLAS consortium, which is part of the BMBF-funded EffiLAS (Efficient high-performance laser beam sources) research initiative, we are developing fiber Bragg gratings (FBG) directly written into multimode fibers. Fiber lasers are an established beam source for high-power materials processing due to their high efficiency and high average output power at high beam quality. By using FBG as fiber-integrated output mirrors, which is state-of-the-art in singlemode fiber lasers, we aim to reduce the complexity and increase robustness and reliability of multimode fiber resonators. Therefore, we are investigating the use of FBG as outcoupling mirrors in multimode high-power multimode fiber lasers. As a first step, we directly write an FBG into an active extra-large mode area (XLMA) fiber with <100 μm core and use the FBG as low reflective outcoupling mirror for the fiber resonator with simultaneous frequency stabilization. The setup delivers an output power of more than 800 W at 1077 nm. The output power of the system was limited by the pump laser setup and not by the FBG or its temperature. The FBG is passively cooled and the measured temperature of the fiber at the grating is below 130 °C at 800 W output power. As the next step, we set up an active XLMA-fiber (core <100 μm) with an FBG as outcoupling mirror into a laser resonator with water cooling of the resonator fiber and optimized pump coupling. This setup delivers an output power of more than 8 kW at 1077 nm without failure of the FBG.
High-power fiber lasers have become one of the most important tools for material processing in the last decade. Laserline GmbH, which is primarily known for its multi-kilowatt direct-diode lasers, also introduced a fiber-laser platform as a brightness converter for its direct-diode lasers a few years ago. Currently, output powers up to 6 kW at beam qualities down to 4 mm mrad are commercially available. The platform is based on a single directly water-cooled ytterbium doped XLMA (extra-large mode area) fiber in an end-pumped configuration, which can easily be combined in series with a standard diode laser. In this paper, we present the latest progress in power scaling of our fiber-laser system. By improving the material properties of the active fiber, the thermal management and the thermo-mechanical stability of the resonator, up to 10 kW output power from a single, unidirectionally pumped fiber-laser oscillator with a beam parameter product in the range of 4 mm mrad to 8 mm mrad is demonstrated. Further power scaling up to 17.5 kW with 8 mm mrad was achieved by bidirectional pumping of the active fiber. In both cases, a rather high optical conversion efficiency of 75-77 % leads to a wall-plug efficiency of ~35 % for the whole laser system. Currently, we do not observe any physical limits, such as nonlinear effects for example.
In this paper, we present our current work towards a highly efficient XLMA (extra-large mode area) fiber-based laser, which is being performed in the EKOLAS consortium within the BMBF-funded EffiLAS (efficient high-performance laser beam sources) research alliance. To this end, the complete manufacturing process chain of the XLMA fiber was reviewed and optimized. The work started with the material composition of the active XLMA preform with the goal of improving the purity and thus the background loss. A successfully implemented fluorine co-doping process allows refractive index adjustment of the active core material which improves the beam quality of the laser fibers without changing the concentration of active ions in the glass composition. The preform is subjected to a screening in which possible scatter centers, e.g. bubbles, inclusions or contaminants, are mapped and categorized, in order to identify defects, which could lead to a failure in the drawn fiber, already at an early production stage. The subsequent fiber drawing is monitored for scattering using the emissions from the heated preform as well as for inhomogeneities of the dopants using a phase measurement technique. Finally, the fiber is tested for residual impurities and background losses using a multi-mode OTDR to ensure that the fibers are free of any defects.
Within the EKOLAS consortium, which is part of the BmBF-funded Effilas (Efficient high-performance laser beam sources) research alliance, we are developing Fiber Bragg Gratings (FBGs) written in extra-large mode area (XLMA) fibers. By using FBGs as fiber integrated output mirrors, which is state-of-the-art in single-mode fiber lasers, we aim to reduce complexity and increase robustness and reliability of multi-mode fiber resonators. To this end, we are investigating the use of FBGs as outcoupling mirrors with a reflectivity below 10 % in XLMA high-power multi-mode fiber lasers. As a first step, FBGs are written into a passive 105/125 μm multi-mode fiber. We present their application for frequency stabilization of a resonator based on XLMA fibers, and tested the FBGs up to an output power of 150 W at 1075 nm without failure. As the next step, transition from passive 105/125 μm fibers to active XLMA fibers is currently being investigated. For FBG inscription, we use a phase mask and an ultra-fast laser system (100 fs, 800 nm). The setup is adjustable in three translation and three rotation axes. Additionally it features a modular mechanical design for fast and flexible interchanging of fiber mounts, phase mask and process optics. The FBGs are pre-characterized in transmission with a white-light source and an optical spectrum analyzer.
In surface processing applications the correlation of laser power to processing speed demands a further enhancement of the performance of short-pulsed laser sources with respect to the investment costs. The frequently applied concept of master oscillator power amplifier relies on a complex structure, parts of which are highly sensitive to back reflected amplified radiation. Aiming for a simpler, robust source using only a single ytterbium doped XLMA fiber in a q-switched resonator appears as promising design approach eliminating the need for subsequent amplification. This concept requires a high power-tolerant resonator which is provided by the multikilowatt laser platform of Laserline including directly water-cooled active fiber thermal management.
Laserline GmbH and Fraunhofer Institute for Laser Technology joined their forces1 to upgrade standard high power laser sources for short-pulsed operation exceeding 1 kW of average power. Therefor a compact, modular qswitch has been developed.
In this paper the implementation of a polarization independent q-switch into an off-the-shelf multi-kilowatt diodepumped continuous wave fiber source is shown. In this early step of implementation we demonstrated more than 1000 W of average power at pulse lengths below 50 ns FWHM and 7.5 mJ pulse energy. The M2 corresponds to 9.5. Reliability of the system is demonstrated based on measurements including temperature and stability records. We investigated the variation possibilities concerning pulse parameters and shape as well as upcoming challenges in power up-scaling.
In this paper we present the next step on the roadmap “system scalability towards an output power above 100 kW”, first
time presented in 2014 [1].
To take a step forward the optical power of the fiber-coupled diode laser has been increased beyond the power level
40kW. The power conversion efficiency exceeds 40%. The laser contains modules with 4 different wavelengths (960nm,
1020nm, 1040nm, 1060nm) there are two modules for each wavelength polarization multiplexed. After the slow-axis
collimation these wavelengths are combined using dense wavelength coupling before focusing onto the fiber endface.
The delivery-fiber is an uncoated fiber with a diameter of 2 mm and NA 0.22 corresponding a BPP of 220 mm mrad.
In a stability test the laser delivered a constant maximum output power with less than ±0.5 % variation over 100h.
Further results of the optical properties of the laser will be presented in this paper.
This new laser is based on a turn-key industrial platform, allowing straight-forward integration into almost any industrial
application, like welding or large area heat treatment. As application examples laser welding of thick sheet metal and
pumping of an active fiber will be presented. The footprint of the complete system is 2.8 m² with a height below 1.8 m.
Fiber laser based brightness converters enable diode laser beam sources to access a superior beam quality of better than 10 mm × mrad in combination with multi kW output power. A design of a fiber laser that is based on a single active optical converter fiber that is pumped by a direct diode is presented. Due to the high transfer efficiency of such brightness converters an electrical/optical efficiency > 25% can be achieved. The current status with an output power > 4 kW in combination with a beam quality of < 5 mm × mrad will be described. The principal design of such diode laser based fiber brightness converters will be presented and building blocks of such lasers will be outlined. As an application example laser welding will be presented of both the fiber converter laser and direct diode laser using optical light guides with identical core diameters on both lasers for comparison. Additionally, fibers with a core diameter of 200μm will be used on the fiber converter laser to perform remote welding. The weld results will be compared regarding welding depth and surface quality of the weld samples to determine the optimum power/brightness levels for different aluminum and steel materials.
XLMA fibers based on Yb-doped bulk silica possess an excellent refractive index and doping level homogeneity [1]. To
achieve the highest optical-to-optical efficiency and long-term operation without degradation we simulated the effect of the brightness conversion factor of different core dopant compositions of such XLMA fibers. We also investigated the beam quality of a multi-kW single XLMA fiber laser system and its long-term stability. The current state-of-the-art
XLMA single fiber laser has 5 kW maximum output power and a degradation rate of about 0.5 % / 500 h at 4 kW
measured over a period of 1700 h. Several application tests demonstrate the excellent performance of the XLMA fiber
laser.
The quality of Yb-doped fused bulk silica produced by sintering of Yb-doped fused silica granulates has improved
greatly in the past five years [1 - 4]. In particular, the refractive index and doping level homogeneity of such materials
are excellent and we achieved excellent background fiber attenuation of the active core material down to about 20 dB/km
at 1200 nm. The improvement of the Yb-doped fused bulk silica has enabled the development of multi-kW fiber laser
systems based on a single extra large multimode laser fiber (XLMA fiber).
When a single active fiber is used in combination with the XLMA multimode fiber of 1200 μm diameter simple and
robust high power fiber laser setups without complex fiber coupling and fiber combiner systems become possible. In this
papper, we will discuss in detail the development of the core material based on Yb-doped bulk silica and the
characterization of Yb-doped fibers with different core compositions.
We will also report on the excellent performance of a 4 kW fiber laser based on a single XLMA-fiber and show the first
experimental welding results of steel sheets achieved with such a laser.
Sintering of Yb-doped fused silica granulates is a well established technique developed by the IPHT and Heraeus
Quarzglas and it produces very homogeneous rare earth doped bulk silica core rods for fiber laser applications. By using
a newly developed laser induced deflection (LID) technique we are able to pre-characterize directly the material
absorption properties of the bulk material prior to the laser fiber production. The bulk absorption results measured by
LID are without scattering effects and they are typically in good agreement with the total attenuation measured in the
fibers. We achieved a fiber background loss of 20 dB/km. Furthermore, we present detailed studies of the refractive
index homogeneity of the Yb-doped bulk materials and laser fibers to show the unique features of the Yb-doped bulk
silica.
Multimode double cladding laser fibers with an extra large mode area XLMA fiber design (core diameter up to 100 μm)
have been produced from the Yb-doped bulk silica rods by two different techniques. One is a classical jacketing method;
the other employs the stacking of un-doped, Yb- and F-doped rods and F-doped tubes.
Different fiber types have been tested in different fiber laser setups. The influence of the fiber end cap properties on the
fiber laser focus shift is discussed in detail. We have achieved fiber laser output powers up to 1.925 kW, limited only by
the pump power. We also investigated the long term laser stability at different power levels.
At the Photonics West 2008 we presented our rare earth doped fused bulk silica for fiber laser applications [1]. This
approach overcame the typical geometrical limitations of other well known production methods for rare earth doped
silica materials. Our unique production technique is based on the sintering of Yb-doped granulates of high-purity SiO2
particles. We have processed our Yb-doped bulk silica rods into ultra large mode area (XLMA) multi-mode double
cladding laser fibers with an active core diameter in the range of 40 μm to 100 μm (depending on the core doping level).
In the XLMA fiber the active core is surrounded by a so-called 2D- or 4D-shaped pure silica pump cladding (with
diameter between 850 μm and 900 μm) and an F-doped outer silica cladding with an outer diameter of 1000 μm.
We have investigated the refractive index and the intrinsic stress profiles of different XLMA laser fibers and their
preforms to visualize interface effects. The fiber cross section designs, the quality of all interfaces and the material
composition are important factors for the laser fiber performance. The laser properties of these fibers have been
investigated in detail. In addition, the preparation of the fiber end-face is important to reduce heat effects and we have
developed concepts to mitigate such thermal load at the fiber end face.
We have developed a production process for rare earth doped bulk silica to fulfill the demand of such material for fiber
laser applications. In contrast to the standard techniques such as a combination of MCVD (modified chemical vapor
deposition) and solution doping, our novel technology is based on a granulate process that enables novel ultra large mode
area fiber designs (XLMA) with active core diameters above 100 μm as well as larger batch sizes. Several Yb-doped
fibers with two different fiber designs were manufactured and successfully tested in both side- and end-pumped fiber
laser setups. Both fiber designs have been compared to similar MCVD fibers. The influence of the material composition
on the photodarkening properties has been investigated.
We have developed a new technique to produce a Yb-doped fused silica bulk glass which is very well suited for fiber
laser applications. The starting point is a liquid suspension of SiO2 particles which is doped by a solution of rare earth
ions. After dehydration, purification and vitrification we achieve a bubble-free homogeneous Yb-doped fused bulk silica,
which is further processed by the plasma outside deposition (POD) technique into preforms for active laser fibers with a
large active fiber core. The laser function of our Yb-doped silica was successfully proved in a side-pumped fiber laser
setup. We present the results of the laser experiments.
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