In addition to common parameters like wavelength, output power and brightness, requirements in defense vary from industrial products. Contrary to industrial applications, where key requirements are total cost of ownership and lifetime measured in operating hours, defense applications use size, weight and power (SWaP) as the key performance metrics. In addition, overall system efficiency is a crucial factor in saving space and weight. Reliability is typically measured in years of service with comparatively low overall laser on time and not in laser operating hours. We present new products based on the Coherent FACTOR series of fiber coupled high power diode laser modules, optimized for defense applications. Modules at 793 nm for Thulium fiber laser pumping and modules at 976 nm for Ytterbium fiber laser pumping are presented. Compared to industrial FACTOR series modules, these devices are optimized for highest output power and low weight compared to their industrial counter parts. Modules are designed, qualified and tested to ensure reliable operation in the demanding environmental conditions of defense applications. Modules at 793 nm ranging from 100 W to 500 W of output power are shown. The FACTOR-16 module is rated at 100 W from a 100 µm 0.22 NA fiber. 500 W are achieved from a T-Bar based packaged equipped with a 200 µm 0.2 NA fiber. At 976 nm, the new lightweight FACTOR-16 package with 150 W from a 100 µm 0.22 NA fiber is shown. In addition, power scaling results from FACTOR-22 and FACTOR-44 modules with power levels of 400 W and 600 W respectively are presented.
In this paper, we present the new FACTOR-series of fiber coupled high power diode lasers based on single emitters. While fiber coupled modules at DILAS and COHERENT have mostly been based on high power diode laser bars in the past, increased output power, advances in automated alignment processes and reduction in cost of optical components have tipped the scale towards single emitter-based packages in certain areas. The product portfolio includes emission wavelengths between 790 nm and 1060 nm with output power of up to 600 W. Fiber core sizes of 100 µm and 200 µm are offered. All products are available with optional wavelength stabilization to reduce the spectral line width and minimize the wavelength shift over varying output power and temperature. We present Ytterbium pump modules at 976 nm with up to 600 W output power, modules for Thulium pumping at 793 nm with up to 250 W and modules near 880 nm optimized for different absorption peaks of Vanadate, ranging in output power between 65 W and 150 W. In addition to pump modules, industrial turnkey systems for polymer welding and soldering have been developed based on the same product line. Up to 100 W of output power are offered from a 3 HU - ½ 19” rack mountable chassis including the power supply, diode controller, a pilot beam and safety features complying with performance level ‘e’.
Recent product releases of high power direct diode lasers in the blue spectral range of up to 1 kW of output power have sparked the demand for even higher optical output power for industrial copper welding applications, in particular related to e-mobility demands where high throughput is required. Blue laser bars maturing into a reliable technology present the ideal laser source for the task. While previously presented results of up to 500 W of output power from a 200μm NA 0.2 fiber were based on the Coherent ‘High Brightness’ product platform, the current work uses the ‘High Power’ product line, currently available with up to 8 kW of output power in the near infrared spectral range. This platform has the potential of reaching up to 4 kW of blue laser power from fibers with core diameters between 400μm and 800μm at wavelengths near 450nm. An increased number of laser bars compared to the existing product portfolio can achieve even higher output power. While the ‘High Brightness’ platform is based on mini-bars with 5mm length and designed for coupling into 200 μm core fibers, the ‘High Power’ product line uses 10mm wide laser bars. The focus lies on 400 μm core fibers in order to achieve high intensities at the work piece while maintaining a long working distance. However, for very high output power 600 μm and 800 μm fibers will be used. Here we present first results of the smallest laser module within the high power family with a goal of coupling 1500 W of optical power into a 400 μm NA0.22 fiber at an emission wavelength of approximately 450 nm. The product architecture and optical concept are described. Latest results showing 1.5 kW from a 600 μm core fiber at 5% duty cycle are presented and the next steps to reaching the goals of CW operation and 400 μm core size are discussed.
With the advent of high power blue laser diodes in general and blue laser bars in particular new applications are emerging, utilizing this new technology. Possibly the biggest benefits compared to traditional high power diode laser wavelengths in the infrared spectral range are the improvements seen in copper welding applications, both in weld quality and overall process efficiency. A new generation of high power diode lasers with emission wavelengths near 450 nm is being developed at Coherent DILAS. These modules achieve high brightness levels combined with high power, suitable for materials processing applications. 500 W of optical output power from a 200 μm core fiber and 550 W from a 400 μm core fiber, each with an NA of 0.22, have been demonstrated. Modules are based on existing infrared product platforms already manufactured in high volume, allowing the usage of known-good processes and fully automated manufacturing equipment. At the same time, material costs are kept low, due to the large volume produced at other wavelengths. The main challenge in developing industrial grade laser modules in the blue spectral range is the required life time. While tremendous progress has been made in recent years, the chip material is still more sensitive to environmental factors compared to other high power diode laser bars. The issue is approached by Coherent DILAS in multiple ways with the goal of finding the best possible solution to minimize complexity in module design and operation, while meeting reliability requirements. Latest results, including life-test data under a variety of operating conditions, are presented.
A novel 3-dimensional arrangement of mirrors is used to re-arrange beams from 1-D and 2-D high power diode laser arrays. The approach allows for a variety of stacking geometries, depending on individual requirements. While basic building blocks, including collimating optics, always remain the same, most adaptations can be realized by simple rearrangement of a few optical components. Due to fully automated alignment processes, the required changes can be realized in software by changing coordinates, rather than requiring customized mechanical components.
This approach minimizes development costs due to its flexibility, while reducing overall product cost by using similar building blocks for a variety of products and utilizing a high grade of automation. The modules can be operated with industrial grade water, lowering overall system and maintenance cost.
Stackable macro coolers are used as the smallest building block of the system. Each cooler can hold up to five diode laser bars. Micro optical components, collimating the beam, are mounted directly to the cooler. All optical assembly steps are fully automated.
Initially, the beams from all laser bars propagate in the same direction. Key to the concept is an arrangement of deflectors, which re-arrange the beams into a 2-D array of the desired shape and high fill factor. Standard multiplexing techniques like polarization- or wavelengths-multiplexing have been implemented as well.
A variety of fiber coupled modules ranging from a few hundred watts of optical output power to multiple kilowatts of power, as well as customized laser spot geometries like uniform line sources, have been realized.
In this paper we report on further development of fiber coupled high-power diode lasers in the visible spectral range. New visible laser modules presented in this paper include the use of multi single emitter arrays @ 450 nm leading to a 120 W fiber coupled unit with a beam quality of 44 mm x mrad, as well as very compact modules with multi-W output power from 405 nm to 640 nm. However, as these lasers are based on single emitters, power scaling quickly leads to bulky laser units with a lot of optical components to be aligned.
We also report on a new approach based on 450 nm diode laser bars, which dramatically reduces size and alignment effort. These activities were performed within the German government-funded project “BlauLas”: a maximum output power of 80 W per bar has been demonstrated @ 450 nm. We show results of a 200 μm NA0.22 fiber coupled 35 W source @ 450 nm, which has been reduced in size by a factor of 25 compared to standard single emitter approach. In addition, we will present a 200 μm NA0.22 fiber coupled laser unit with an output power of 135 W.
We present performance and reliability data of high-brightness QCW arrays and stacks with a custom, compact and robust design for an operation at high duty cycles. The presented designs are based on single diodes consisting of a 10mm laser bar which is AuSn soldered between two WCu submounts, as well as 10mm laser bars AuSn soldered to WCu submounts or Indium directly mounted to micro channel heat sinks. The available optical output strongly depends on the wavelength and fill factor of the laser bars as well as the duty cycle, the base plate temperature and the thermal performance to handle the thermal loss. Based on the applications requirements, conduction cooled stacks can be used in conjunction with thermo-electric coolers, water manifolds, or forced air cooling. For most demanding requirements at highest peak power and duty cycle, micro channel coolers with conditioned DI water offer the best cooling performance.
One important aspect for the increasing use of diode lasers in industrial applications is the flexibility of diode lasers to tailor the beam properties to the specific needs demanded from the application. For fiber coupled solutions beam shaping with appropriate micro-optical elements is used for efficient fiber coupling of the highly asymmetric diode laser beam, whereas for direct applications optical elements are used to generate specific intensity distributions, like homogenized lines, areas and rings. Applications with diode lasers like solid state laser pump sources often require tailored spectral characteristics with narrow bandwidth, which is realized by using volume Bragg gratings for wavelength stabilization.
In this paper we will summarize several concepts for adapting beam properties of diode lasers by using specific optical components. For building very compact laser modules of up to 2 kW we already presented a concept based on beam shaping of high fill factor bars. In this paper we will focus on further tailoring the beam properties of these very compact laser modules in the wavelength range from 808 nm up to 1020 nm. Fiber coupling of such modules into an 800 μm NA0.22 fiber yielded 1.6 kW without using polarization coupling. Another example is the generation of a 2.5 kW homogenized line with 40 mm length and a width of 4 mm.
Due to their low quantum defect, diode pumped alkali metal vapor lasers (DPALs) offer the promise of scalability to very high average power levels while maintaining excellent beam quality. Research on DPALs has progressed to ever increasing power levels across multiple gain media species over the last years, necessitating pump power in the kW range. Each material requires a specific pump wavelength: near 852nm for cesium, 780nm for rubidium, 766nm for potassium, and 670nm for lithium atoms. The shorter pump wavelength below 800nm are outside the typical wavelength range for pump diodes developed for diode pumped solid state lasers (DPSS).
The biggest challenge in pumping these materials efficiently is the need for maintaining the narrow gain media absorption band of approximately 0.01nm while greatly increasing power. Typical high power diode lasers achieve spectral widths around 3nm (FWHM) in the near infrared spectrum, but optical gratings may be used internal or external to the cavity to reduce the spectral width. Recently, experimental results have shown yet narrower line widths ranging from picometers at very low power levels to sub-100 picometers for water cooled stacks around 1kW of output power.
The focus of this work is the development of a fiber-based pump system for potassium DPAL. The individual tasks are the development of high power 766nm chip material, a fiber-coupled module as a building block, and a scalable system design to address power requirements from hundreds of watts to tens of kilowatts. Results for a 3kW system achieving ~30GHz bandwidth at 766nm will be shown. Approaches for power-scaling and size reduction will be discussed.
Recent advances in high power diode laser technologies have enabled advanced research on diode pumped alkali metal
vapor lasers (DPALs). Due to their low quantum defect, DPALs offer the promise of scalability to very high average
power levels while maintaining excellent beam quality. Research is being conducted on a variety of gain media species,
requiring different pump wavelengths: near 852nm for cesium, 780nm for rubidium, 766nm for potassium, and 670nm
for lithium atoms. The biggest challenge in pumping these materials efficiently is the narrow gain media absorption band
of approximately 0.01nm.
Typical high power diode lasers achieve spectral widths around 3nm (FWHM) in the near infrared spectrum. Gratings
may be used internal or external to the cavity to reduce the spectral width to 0.5nm to 1nm for high power diode laser
modules. Recently, experimental results have shown narrower line widths ranging from picometers (pm) at very low
power levels to sub-100 picometers for water cooled stacks around 1kW of output power.
The focus of this work is a further reduction in the spectral line width of high power diode laser bars emitting at 766nm,
with full applicability to other wavelengths of interest. One factor limiting the reduction of the spectral line width is the
optical absorption induced thermal gradient inside the volume Bragg grating (VBG). Simulated profiles and
demonstrated techniques to minimize thermal gradients will be presented. To enable the next stage of DPAL research, a
new series of fiber coupled modules is being introduced featuring greater than 400W from a 600μm core fiber of
0.22NA. The modules achieve a spectral width of <<0.1nm and wavelength tunability of +/- 0.15nm.
KEYWORDS: Semiconductor lasers, High power lasers, Absorption, Diodes, Collimation, Volume holography, Holography, Spatial filters, Spectrum analysis, Signal to noise ratio
Alkali gas lasers based on rubidium vapor have an extremely narrow absorption band (<0.01 nm at STP) at 780 nm. Diode-pumped alkali lasers (DPALs) require high-power diode arrays having emission spectra which are closely matched to this absorption peak. There are several methods which can be used for narrowing and stabilizing the output spectrum of a diode laser bar including external locking via a volumetric holographic grating (VHG). While this approach offers several advantages over internal stabilization techniques, the effect of pointing error arising from bar smile can be detrimental to the locked performance of the lensed array. In order to investigate the effect of smile on wavelength locking, a system capable of mapping the emission spectrum of the lensed diode laser bar was developed. The approach utilizes an imaging system and spatial filter to couple light from individual emitters of the lensed array into a commercial optical spectrum analyzer. This approach offers a larger dynamic range than traditional spectral mapping techniques, with a resolved signal to noise ratio in excess of 60 dB. Results from the characterization of a VHG-locked 780 nm laser bar array will be presented.
Diode pumped alkali metal vapor lasers (DPALs) offer the promise of scalability to very high average power levels while maintaining excellent beam quality, making them an attractive candidate for future defense applications. A variety of gain media are used and each requires a different pump wavelength: near 852nm for cesium, 780nm for rubidium, 766nm for potassium, and 670nm for lithium atoms. The biggest challenge in pumping these materials efficiently is the narrow gain media absorption band of approximately 0.01nm. Typical high power diode lasers achieve spectral widths around 3nm (FWHM) in the near infrared spectrum. With state of the art locking techniques, either internal to the cavity or externally mounted gratings, the spectral width can typically be reduced to 0.5nm to 1nm for kW-class, high power stacks. More narrow spectral width has been achieved at lower power levels. The diode’s inherent wavelength drift over operating temperature and output power is largely, but not completely, eliminated. However, standard locking techniques cannot achieve the required accuracy on the location of the spectral output or the spectral width for efficient DPAL pumping. Actively cooled diode laser stacks with continuous wave output power of up to 100W per 10mm bar at 780nm optimized for rubidium pumping will be presented. Custom designed external volume holographic gratings (VHGs) in conjunction with optimized chip material are used to narrow and stabilize the optical spectrum. Temperature tuning on a per-bar-level is used to overlap up to fifteen individual bar spectra into one narrow peak. At the same time, this tuning capability can be used to adjust the pump wavelength to match the absorption band of the active medium. A spectral width of <0.1nm for the entire stack is achieved at <1kW optical output power. Tuning of the peak wavelength is demonstrated for up to 0.15nm. The technology can easily be adapted to other diode laser wavelengths to pump different materials.
New applications require diode lasers to be driven with short pulses in the sub-micro second range. The goal is to minimize both the cost and size of the diode laser module by minimizing the number of laser bars required while maintaining the lifetime that is desired for the application. Products demanded by the market using such short pulses range from QCW stacks to fiber coupled modules. While many short pulsed applications use high fill factor bars, these bars are not suited for high brightness applications or coupling into small fiber cores. The focus of this work is the analysis of CW diode designs commonly used for high brightness fiber coupled modules under short pulsed conditions.
Three key parameters need to be known in order to design a diode laser module that is suited for high peak powers. First is the damage threshold of the facet. The damage threshold determines the maximum power level at which the laser can be operated safely, considering a proper safety margin dependent on application. The damage threshold is a function of the input pulse width and amplitude. The second parameter which is influenced by the drive current is the slow axis divergence of the diode laser. Knowledge of this parameter is critical when designing the system optics. The third parameter is the effective emitter size which may increase with operating current. An increase in emitter size will lead to larger divergences after collimating optics for a given focal length lens and may result in a larger spot when coupling into an optical fiber. All these parameters have to be considered when designing a new product.
Presented here is a study on these three critical parameters as a function of operating conditions. Results for different diode designs will be presented. The data presented includes damage thresholds, as well as near field and far field data at various operating currents. A design study for fiber coupled modules with high pulse energies based on the test results will be shown for various wavelengths.
We present performance and reliability data of high-brightness QCW arrays with a custom, compact and robust design for an operation with high duty cycles. The presented designs are based on single diodes consisting of a 1cm laser bar that is AuSn soldered between two CuW submounts. Arrays of up to 15 diodes as well as one single diode are connected to ceramic base plates on different heat sinks. The available optical output power is shown to be strongly depending on the wavelength and fill factor of the laser bars as well as on the duty cycle, the base plate temperature and the thermal conductivity of the applied ceramic materials. Operation at increased heat sink temperatures up to 45°C is possible without active water cooling or conduction cooling with the help of Peltier elements. Using an array of 15 bars at 980 nm with 20% fill factor and 2 mm cavity on standard ceramics, we can reach an optical output power of 1150 W at 45°C base plate temperature operating the array with 15 Hz and 15% duty cycle. Novel materials allow for more efficient operation and higher optical output powers.
Steve Patterson, Tobias Koenning, Bernd Köhler, Sandra Ahlert, Andreas Bayer, Heiko Kissel, Holger Müntz, Axel Noeske, Karsten Rotter, Armin Segref, Michael Stoiber, Andreas Unger, Paul Wolf, Jens Biesenbach
Advances in both diode laser design and packaging technology, particularly thermal management, are needed to
enhance the brightness of fiber coupled diode lasers while maintaining the small size and light weight required for
defense applications. The principles of design for high efficiency fiber coupling are briefly covered. Examples are
provided of fielded and demonstrated 100 and 200 micron diameter fiber coupled packages ranging in output from a
few hundred to kW-class units in fibers, to include sub-kg/kW capabilities.
The demand for high-power and high-brightness fiber coupled diode laser devices is mainly driven by applications
for solid-state and fiber laser pumping. The ongoing power scaling of fiber lasers requires scalable fiber-coupled
diode laser devices with increased power and brightness.
A modular diode laser concept combining high power, high brightness, wavelength stabilization and low weight,
which is considerable concern in the SWaP trades needed to field defense systems, has been developed. In particular
the defense technology requires robust but lightweight high-power diode laser sources in combination with high
brightness.
The heart of the concept is a specially tailored diode laser bar, with the epitaxial and lateral structures designed such
that only standard fast- and slow-axis collimator lenses in combination with appropriate focusing optics are required
to couple the beam into a fiber with a core diameter of 200 μm and a numerical aperture (NA) of 0.22. The spectral
quality, which is an important issue especially for fiber laser pump sources, is ensured by means of Volume
Holographic Gratings (VHG) for wavelength stabilization.
This paper presents a detailed characterization of different diode laser sources based on the scalable modular
concept. The optical output power is scaled from 180 W coupled into a 100 μm NA 0.22 fiber up to 800W coupled
into a 400 μm NA 0.22 fiber. In addition we present a lightweight laser unit with an output power of more than 300
W for a 200 μm NA 0.22 fiber with a weight vs. power ratio of only 0.9 kg/kW.
A new series of high power diode laser line sources is reported. The modules are designed for the industrial materials
processing market and include both fiber coupled and direct beam configurations. Typical applications include welding,
hardening and semiconductor processing. The biggest challenge in delivering line sources lies in the variety of
application specific requirements. This problem is approached with modular concepts that allow for power scaling and
custom beam shaping. All modules are available either as an OEM laser head or as a turn-key solution including power
supply and chiller.
Fiber coupled diode laser modules are available at power levels ranging from 600W to 4kW at various wavelengths.
New developments include a 1kW module with a single wavelength and 400um / 0.22NA fiber and a 2kW module based
on two wavelengths. Dilas offers up to 5kW from a 1mm / 0.22NA fiber with a single wavelength. At 200 μm fiber
diameter, power levels of 850W are available with a single wavelength.
While fiber coupled modules allow for easy power scaling, free space systems are capable of even higher overall electrooptical
efficiencies and lower cost. Based on modular building blocks, Dilas provides customized solutions that are
optimized for individual applications. Two modules will be described in detail. The first module is a 600W line source
with line dimensions of 10.5mm x 350 μm at a working distance of 160mm. The second module operates at 3kW output
power and creates a homogenized line with dimensions of 9mm x 1.3mm at a working distance of 200mm.
Optical design trade-offs will be discussed and concepts for the modules described above are shown. Experimental
results are presented.
The Beam Parameter Product (BPP) of a passive, lossless system is a constant and cannot be improved upon but the
beams may be reshaped for enhanced coupling performance. The function of the optical designer of fiber coupled diode
lasers is to preserve the brightness of the diode sources while maximizing the coupling efficiency. In coupling diode
laser power into fiber output, the symmetrical geometry of the fiber core makes it highly desirable to have symmetrical
BPPs at the fiber input surface, but this is not always practical. It is therefore desirable to be able to know the 'diagonal'
(fiber) BPP, using the BPPs of the fast and slow axes, before detailed design and simulation processes. A commonly
used expression for this purpose, i.e. the square root of the sum of the squares of the BPPs in the fast and slow axes, has
been found to consistently under-predict the fiber BPP (i.e. better beam quality is predicted than is actually achievable in
practice). In this paper, using a simplified model, we provide the proof of the proper calculation of the diagonal (i.e. the
fiber) BPP using BPPs of the fast and slow axes as input. Using the same simplified model, we also offer the proof that
the fiber BPP can be shown to have a minimum (optimal) value for given diode BPPs and this optimized condition can
be obtained before any detailed design and simulation are carried out. Measured and simulated data confirms satisfactory
correlation between the BPPs of the diode and the predicted fiber BPP.
Tobias Koenning, Kim Alegria, Zuolan Wang, Armin Segref, Dean Stapleton, Wilhelm Faßbender, Marco Flament, Karsten Rotter, Axel Noeske, Jens Biesenbach
We report on a new series of fiber coupled diode laser modules exceeding 1.2kW of single wavelength optical power
from a 400um / 0.2NA fiber. The units are constructed from passively cooled laser bars as opposed to other comparably
powered, commercially available modules that use micro-channel heat-sinks. Micro-channel heat sinks require cooling
water to meet demanding specifications and are therefore prone to failures due to contamination and increase the overall
cost to operate and maintain the laser. Dilas' new series of high power fiber coupled diode lasers are designed to
eliminate micro channel coolers and their associated failure mechanisms.
Low-smile soldering processes were developed to maximize the brightness available from each diode laser bar. The
diode laser brightness is optimally conserved using Dilas' recently developed propriety laser bar stacking geometry and
optics. A total of 24 bars are coupled into a single fiber core using a polarization multiplexing scheme. The modular
design permits further power scaling through wavelength multiplexing. Other customer critical features such as
industrial grade fibers, pilot beams, fiber interlocks and power monitoring are standard features on these modules.
The optical design and the beam parameter calculations will be presented to explain the inherit design trade offs. Results
for single and dual wavelengths modules will be presented.
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