Material Processing Capabilities in Handheld Laser Systems

Abstract

A nozzle assembly for performing material processing operations on a surface of a workpiece with a handheld laser system comprising a laser source configured to generate laser radiation, a handheld device to guide the laser radiation, and an optical fiber to couple the handheld device to the laser source. The nozzle assembly comprises a nozzle configured to deliver the laser radiation to the surface, and a coupling mechanism comprising a retaining portion formed on an output end of the handheld device and an engaging portion releasably attachable to the nozzle and configured to engage the retaining portion.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 212,290, entitled "MATERIAL PROCESSING FUNCTIONALITY IN HANDHELD LASER SYSTEM," filed June 18, 2021, the contents of which are incorporated herein by reference in their entirety.

[0002] This application is related to PCT International Application PCT / US2021 / 047498, entitled "HANDHELD LASER SYSTEM," filed on August 25, 2021. The contents of this PCT International Application are incorporated herein by reference in their entirety.

[0003] The field of technology relates generally to laser devices that can be used for material processing operations, and more particularly to laser devices configured with modular nozzle assemblies. [Background technology]

[0004] Laser-based material processing equipment with high power capabilities (e.g., at least 1 kW) has been used for industrial cutting and welding in the past, but these have generally been prohibitively expensive for many small machine shops or other small end users. Over time, however, the average power of laser diodes has increased significantly while their average price per watt has been exponentially decreasing. Furthermore, technological advances have been made in more powerful laser systems. These factors have made it more feasible to implement higher power lasers in smaller material processing systems, such as handheld laser devices. Not only are such systems desirable for smaller industrial shops, but these devices can be particularly useful in applications where larger systems are impractical or impossible to use.

[0005] In particular, fiber laser technology has several advantages over other laser technologies, such as Exima or CO2 systems: in addition to its low maintenance costs, fiber laser technology also offers high wall plug efficiency and long diode lifetimes, and can be more easily transported.

[0006] In addition to cutting and welding, other non-limiting examples of laser-based material processes include drilling, brazing, soldering, cladding, and other heat treatments, such as cleaning and passivation. Different nozzles may be used to perform different laser-based material processing operations. Some applications may require two or more different material processes. It is desirable to implement and provide a handheld laser device that can easily switch between different types of nozzles. This reduces equipment costs by eliminating the need for a completely different laser material processing device for the application, and reduces processing time for the operator by allowing the use of the same "base" handheld laser device or laser head that can easily switch between nozzle types to perform different material processing operations. Summary of the Invention [Means for solving the problem]

[0007] Aspects and embodiments relate to methods and systems for performing material processing operations using a handheld laser or laser head.

[0008] According to one exemplary embodiment, a nozzle assembly is provided for performing material processing operations on a surface of a workpiece with a handheld laser system having a laser source configured to generate laser radiation, a handheld device to guide the laser radiation, and an optical fiber to couple the handheld device to the laser source. The nozzle assembly includes a nozzle configured to deliver the laser radiation to the surface, and a coupling mechanism including a retaining portion formed on an output end of the handheld device and an engaging portion releasably attachable to the nozzle and configured to engage the retaining portion.

[0009] In one example, the retention portion is formed on an annular surface of the output end. In another example, the annular surface is configured with at least one recess and a ball disposed within the at least one recess. In another example, the engagement portion comprises an annular collar, an inner circumferential surface of the annular collar is configured with at least a pair of arc-shaped slots, each slot configured to receive at least one of the recesses and the ball. In another example, the pair of arc-shaped slots comprises a first arc-shaped slot configured to engage the ball and a second arc-shaped slot configured to lock the engagement portion relative to the retention portion when the engagement portion is rotated relative to the retention portion. In another example, the first arc-shaped slot is sized larger than the second arc-shaped slot. In another example, the annular collar is configured with indexing features corresponding to indexing features positioned on the output end of the handheld device. In another example, each of the indexing features is configured as a visible indexing mark.

[0010] In one example, the engagement portion further comprises a spring that engages an inner surface of the engagement portion. In another example, the engagement portion comprises an outer ring and an inner ring, the inner ring configured with an annular collar having a pair of arc-shaped slots, the outer ring configured with an inner surface that engages the spring. In another example, the nozzle assembly further comprises an O-ring positioned between the outer ring and the inner ring.

[0011] In one example, the coupling mechanism is configured as a twist lock mechanism.

[0012] In one example, the coupling mechanism does not include threads.

[0013] In one example, the nozzle assembly further comprises a fastening device configured to releasably secure the nozzle in abutting relation against the engagement portion.

[0014] In one example, the output end of the handheld device is configured with at least one gas port for supplying gas to the nozzle.

[0015] In one example, the nozzle is configured as a cutting nozzle, which includes an outlet for allowing laser radiation and gas to exit the cutting nozzle, and a z-axis focal length adjustment mechanism.

[0016] In one example, the nozzle comprises a nozzle extension having an inlet, an outlet, and a central aperture, the nozzle extension for allowing laser radiation and gas to enter the central aperture through the inlet and exit through the outlet. In another example, at least a portion of an interior surface of the central aperture of the nozzle extension is configured with a debris shield that prevents the passage of debris generated during material processing operations. In one example, the debris shield comprises threads on the interior surface of the central aperture. In another example, the portion of the interior surface configured with the debris shield is at least partially tapered. In one example, the nozzle is configured with a protective window, the debris shield prevents material processing debris from reaching the window.

[0017] In one example, the engagement portion further comprises an attachment mechanism that is attached to the nozzle extension.

[0018] In one example, the nozzle further comprises an external wire delivery device mounted to the nozzle extension, the wire delivery device configured to deliver wire material to the surface. In one example, the external wire delivery device is disposed below the nozzle extension. In one example, the gas exiting through the nozzle extension outlet is a primary gas source, and the nozzle further comprises an external wire delivery and gas device mounted to the nozzle extension, the external wire delivery and gas device configured to deliver wire material and a secondary gas source to the surface. In one example, the external wire delivery and gas device comprises a central aperture sized to fit around at least a portion of the outer peripheral wall of the nozzle extension, a gas inlet coupled to a gas source, a gas outlet configured as an annular opening surrounding the central aperture, a wire material inlet coupled to a wire material source, and a wire material outlet configured to deliver wire material to the surface. In another example, the wire material outlet is disposed below the gas outlet.

[0019] In one example, the nozzle assembly further includes a gas lens device configured to surround at least a portion of the nozzle extension and at least a portion of the nozzle tip attached to the nozzle extension, the gas lens device having a gas outlet configured as an annular opening surrounding the nozzle tip.

[0020] In one example, the nozzle is configured to perform at least one of welding, drilling, cutting, brazing, soldering, cladding, ablation, and heat treating material process operations.

[0021] According to another exemplary embodiment, a nozzle assembly for performing a material processing operation on a surface of a workpiece using laser radiation is provided. The nozzle assembly includes a nozzle configured to deliver laser radiation to the surface, and a coupling mechanism including a retaining portion formed on an output end of a laser head that delivers laser radiation from a laser source, and an engagement portion releasably mountable to the nozzle and configured to engage the retaining portion. In one example, the retaining portion is formed on an annular surface of the output end of the laser head. In one example, the annular surface is configured with at least one recess and a ball disposed within the at least one recess. In one example, the engagement portion includes an annular collar, an inner circumferential surface of the annular collar is configured with at least one pair of arc-shaped slots, each slot configured to receive at least one of the recesses and the ball. In one example, the pair of arc-shaped slots includes a first arc-shaped slot configured to engage the ball and a second arc-shaped slot configured to lock the engagement portion relative to the retention portion when the engagement portion is rotated relative to the retention portion. In one example, the first arc-shaped slot is sized larger than the second arc-shaped slot. In one example, the engagement portion further comprises a spring engaging an inner surface of the engagement portion. In one example, the engagement portion comprises an outer ring and an inner ring, the inner ring configured with an annular collar having a pair of arc-shaped slots, the outer ring configured with an inner surface engaging the spring. In one example, the nozzle assembly further comprises an O-ring positioned between the outer ring and the inner ring. In one example, the coupling mechanism is configured as a twist lock mechanism. In one example, the coupling mechanism does not include threads. In one example, the nozzle assembly further comprises a fastening device configured to releasably secure the nozzle in abutment against the engagement portion. In one example, the output end of the laser head is configured with at least one gas port for supplying gas to the nozzle.In one example, the nozzle comprises a nozzle extension having an inlet, an outlet, and a central aperture, the nozzle extension for allowing laser radiation and gas to enter the central aperture through the inlet and exit through the outlet. In one example, at least a portion of an inner surface of the central aperture of the nozzle extension is configured with a debris shield that prevents the passage of debris generated during a material processing operation. In one example, the debris shield comprises threads on the inner surface of the central aperture. In one example, the portion of the inner surface that is configured with the debris shield is at least partially tapered. In one example, the nozzle is configured with a protective window, the debris shield prevents material processing debris from reaching the window. In one example, the engagement portion further comprises an attachment mechanism that is attached to the nozzle extension. In one example, the nozzle is configured to perform at least one of welding, drilling, cutting, brazing, soldering, cladding, ablation, and heat treating material processing operations.

[0022] According to one exemplary embodiment, a method is provided for performing a material processing operation on a surface of a workpiece with a handheld laser system. The handheld laser system has a laser source configured to generate laser radiation, a handheld device to guide the laser radiation, and an optical fiber to couple the handheld device to the laser source. The method includes providing a coupling mechanism. The coupling mechanism includes a retention portion formed on an output end of the handheld device and an engagement portion releasably attachable to a nozzle and configured to engage the retention portion. In one example, the method further includes providing a nozzle. In one example, the coupling mechanism is configured as a twist lock mechanism.

[0023] Further aspects, embodiments, and advantages of these exemplary aspects and embodiments are discussed in detail below. Moreover, all of the above information and the detailed description below are merely examples of various aspects and embodiments, and are intended to provide an overview or framework for understanding the characteristics and features of the claimed aspects and embodiments. The embodiments disclosed herein may be combined with other embodiments, and terms such as "one embodiment," "one example," "some embodiments," "some examples," "an alternative embodiment," "various embodiments," "one embodiment," "at least one embodiment," "this and other embodiments," or "particular embodiment" are not necessarily mutually exclusive and are intended to suggest that a particular feature, structure, or characteristic described may be included in at least one embodiment. When such terms are used in this specification, they do not necessarily refer to the same embodiment.

[0024] Various aspects of at least one embodiment will be discussed below with reference to the accompanying drawings. The accompanying drawings are not intended to be drawn to scale. These drawings are included to provide illustration and further understanding of the various aspects and embodiments, and are incorporated into and constitute a part of this specification, but are not intended to define the scope of any embodiment. The drawings and other parts of the specification serve to explain the principles and operation of the described and claimed aspects and embodiments. In these figures, each identical or nearly identical component shown in the various drawings is designated by a similar numeral. For clarity, not every component is labeled in every drawing. [Brief description of the drawings]

[0025] [Figure 1] FIG. 1 is a schematic diagram of an example of a handheld laser system according to aspects of the present disclosure. [Diagram 2] FIG. 2 is a perspective view of a nozzle assembly mounted to a handheld laser device according to an aspect of the present invention. [Figure 3A]1 is a photograph of a nozzle assembly according to an embodiment of the present invention. [Figure 3B] 1 is a photograph of a nozzle assembly according to an embodiment of the present invention. [Figure 4] FIG. 2 is a first perspective view of a nozzle assembly removed from a handheld laser device according to an embodiment of the present invention. [Diagram 5] 5 is a close-up view of a portion of FIG. 4 illustrating a coupling mechanism used to attach a nozzle assembly to a handheld laser device according to an embodiment of the present invention. [Figure 6] FIG. 13 is a second perspective view of a nozzle assembly removed from a handheld laser device according to an embodiment of the present invention. [Figure 7A] 1 is a photograph of a retaining portion of a coupling mechanism according to an embodiment of the present invention. [Figure 7B] 1 is a photograph of a retaining portion of a coupling mechanism according to an embodiment of the present invention. [Figure 7C] 1 is a photograph of a retaining portion of a coupling mechanism according to an embodiment of the present invention. [Figure 7D] 1 is a photograph of a retaining portion of a coupling mechanism according to an embodiment of the present invention. [Figure 8] FIG. 2 is a partially cutaway perspective view of a coupling mechanism according to an aspect of the present invention. [Figure 9] 1 is a photograph of an engagement portion and a fastening device according to an embodiment of the present invention. [Figure 10] 10 is a photograph of the engagement portion of FIG. 9 with the fastening device removed. [Figure 11] 1 is a photograph of an engaging portion of a coupling mechanism according to an embodiment of the present invention. [Figure 12] 1 is a photograph of an indexing feature on a handheld laser device according to an aspect of the present invention. [Figure 13] 1 is a photograph showing a side view of an engagement portion and a fastening device according to an embodiment of the present invention. [Figure 13A] 14 is a photograph showing a front view of the engagement portion of FIG. 13. [Figure 13B] 14 is a photograph showing a perspective view of the fastening device of FIG. 13. [Figure 14A]13 is a photograph showing a side perspective view of a second example of an engagement portion and fastening device according to an embodiment of the present invention. [Figure 14B] FIG. 14B is a photograph showing a front perspective view of the engagement portion of FIG. 14A. [Figure 15] 14C is a partial cutaway perspective view of a coupling mechanism using the engaging portions of FIGS. 14A and 14B according to an embodiment of the present invention. FIG. [Figure 16] 1 is a photograph of the input end of a handheld laser device according to an embodiment of the present invention. [Figure 17A] 1 is a photograph of an example welding nozzle tip and nozzle extension according to an aspect of the present invention. [Figure 17B] 1 is a photograph of an example welding nozzle tip and nozzle extension according to an aspect of the present invention. [Figure 18] 1 is a photograph of another example of a welded nozzle tip and nozzle extension according to an aspect of the present invention. [Figure 19] FIG. 19 is a schematic cross-sectional view of the nozzle extension of FIGS. 17A, 17B, and 18. [Figure 20] 1 is a photograph of an example of a nozzle configured with wire delivery in accordance with an aspect of the present invention. [Figure 21A] FIG. 13 is a photograph of a side view of another example of a nozzle configured with wire delivery capabilities in accordance with an aspect of the present invention. [Figure 21B] FIG. 21B is a photograph of an end view of the nozzle of FIG. 21A. [Figure 22A] 13 is a photograph of another example of a nozzle configured with wire delivery capabilities in accordance with an aspect of the present invention. [Figure 22B] 13 is a photograph of another example of a nozzle configured with wire delivery capabilities in accordance with an aspect of the present invention. [Figure 23] FIG. 24 is a schematic end view of the nozzle of FIGS. 22A and 22B. [Figure 24A] 1 is a photograph of an example gas lens configuration according to an aspect of the present invention. [Figure 24B] 1 is a photograph of an example gas lens configuration according to an aspect of the present invention. [Diagram 25] FIG. 2 is a perspective view of a cutting nozzle according to an aspect of the present invention. [Figure 26] FIG. 2 is a schematic diagram of a nozzle assembly mounted to a laser head in accordance with an aspect of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] Reference is made herein to PCT International Application PCT / US2021 / 047498, hereinafter referred to as the "Handheld Laser Basic Application." The Handheld Laser Basic Application describes a handheld laser system that includes an air-cooled laser source coupled to a handheld component via an optical fiber. The handheld laser system has an output power capability of at least about 1 kW and is configured with beam wobbling capabilities.

[0027] FIG. 1 shows a schematic diagram of an example of a handheld laser system 100 having similarities to the handheld laser system disclosed in the Handheld Laser Preliminary Application. These similarities include a laser source 115, a controller 150, a housing configured as a handheld device 120 (also referred to herein as a handheld device), an optical fiber 130 coupling the laser source 115 to the handheld device 120, a laser module 110 housing the laser source 115, the controller 150, and an air cooling system 140 cooling the laser source 115. The laser module 110 may be disposed on a movable cart. The laser source 115 emits laser light at a wavelength (e.g., Yb1030-1090 nm) to perform material processing operations on a workpiece 105 with an emitted laser beam 122 of laser light. In some embodiments, the laser source 115 emits laser radiation having a power output of about 1500 W. Handheld device 120 is also configured with beam wobbling capabilities.

[0028] The housing, configured as a handheld device 120, has an outlet 123 or exit for the laser beam 122. Throughout this description, the term "handheld" is understood to refer to a laser device that is both small and lightweight enough to be easily held and operated in one or both hands of a user. Additionally, a handheld laser device should be portable such that a user can easily move it during laser processing. However, while embodiments of the present invention are referred to as "handheld" and can be used as a separate portable device, the handheld laser device may be coupled to and used in combination with a fixed fixture in some embodiments.

[0029] According to at least one embodiment, and referring now to Figures 2-6, there is shown a nozzle assembly generally designated 155. The nozzle assembly 155 may be used to perform material processing operations on a surface of a workpiece using a handheld laser system, such as those described in the Handheld Laser Foundation Application. As discussed above with reference to Figure 1, such a handheld laser system has a laser source 115 configured to generate laser radiation, a handheld device 120 that guides the laser radiation, and an optical fiber 130 that couples the handheld device 120 to the laser source 115. The nozzle assembly 155 includes a nozzle (e.g., nozzle 170, as shown in Figures 17A, 17B, 18, 20, nozzles 180, 190, 200, discussed below, etc.) configured to deliver laser radiation to the surface of the workpiece, and a coupling mechanism 160 configured to mount the nozzle to the handheld device 120.

[0030] According to some embodiments, the coupling mechanism 160 is configured as a twist-lock mechanism. One non-limiting example of a twist-lock mechanism is described below. This twist-lock mechanism uses a post and groove configuration, where posts are formed on one component and grooves of a selected configuration are formed on the second component. The grooves are shaped to initially seat the posts and then, as the first component is turned, move the posts further into the grooves to secure the first and second components together.

[0031] According to one or more embodiments, the coupling mechanism 160 and / or one or more components of the coupling mechanism 160 are not threaded. This provides several advantages, including allowing for quick replacement of attachments, longer operational life, reduced risk of damage (e.g., cross-threading), elimination of the need for a separate tool, and tighter engagement and locking (compared to partial threads). According to at least one embodiment, the retaining portion 161 (described in more detail below) is not threaded.

[0032] 4-13 illustrate aspects of a coupling mechanism 160 according to at least one embodiment. The coupling mechanism 160 comprises a retaining portion 161 (shown in at least FIGS. 4, 5, 7A-7D, which may also be referred to as a receiving portion) formed on the output end 124 of the handheld device 120 (see, e.g., FIGS. 4 and 5) and an engagement portion 162 (shown in at least FIGS. 5, 6, 8-11, 13, 13A) that is releasably attachable to the nozzle and configured to engage the retaining portion 161.

[0033] The retaining portion 161 is formed on annular surface 126 of output end 124 of handheld device 120. Annular surface 126 is configured with at least one recess 163 and a ball or pin 165 disposed within at least one recess 163. In one embodiment, a combination of recesses 163 and balls 165 are disposed at equidistantly spaced locations along the outer edge of annular surface 126.

[0034] The engagement portion 162 includes an annular collar 167 (see, e.g., FIGS. 6 and 11). The inner peripheral surface of the annular collar 167 is configured with at least a pair of arc-shaped slots 166, 168, each of which is configured to receive a ball 165. As will be appreciated, each ball 165 of the retention portion 161 is associated with a pair of arc-shaped slots 166, 168, such that there are an equal number of balls and pairs of arc-shaped slots. The pair of arc-shaped slots 166, 168 includes a first arc-shaped slot 166 configured to initially engage the ball, and a second arc-shaped slot 168 configured to lock the engagement portion 162 relative to the retention portion 161 when the engagement portion 162 is rotated relative to the retention portion 161. Thus, the ball 165 is first inserted into the slot 166, and then inserted into the slot 168 when the engagement portion 162 is rotated. The first arc-shaped slot 166 is sized larger than the second arc-shaped slot 168 .

[0035] The engagement portion 162 also includes a spring 152 (see FIG. 8 ) that engages an inner (annular) surface 1052 of the engagement portion. The inner surface 1052 includes a lip or other protrusion that provides a surface against which one end of the spring 152 rests. The spring 152 is at least partially compressed when the engagement portion 162 is fully locked onto the retention portion 161, and is at least partially decompressed when the engagement portion 162 is removed from the retention portion 161.

[0036] To remove the nozzle from the handheld device 120, the engagement portion 162 is rotated in the opposite direction and simultaneously pressure is applied, i.e. pressure that overcomes the force applied by the spring 152 positioned within the engagement portion 162 and moves the ball 165 out of the second slot 168 and into the first slot 166 until it engages with the first slot 166 so that the nozzle can be removed.

[0037] As shown in Figures 11 and 12, according to some embodiments, one or more components of the coupling mechanism 160 are configured with indexing features 169. In this example, the annular collar 167 of the engagement portion 162 is configured with indexing feature 169a that corresponds to indexing feature 169d positioned on the output end 124 of the handheld device 120. This allows an operator to align the retention portion 161 with respect to the engagement portion 162 of the coupling mechanism 160. In one embodiment, these indexing features 169 are configured as visible indexing marks, as shown by the red dots in Figures 11 and 12. According to some embodiments, additional indexing features may be used on the engagement portion 162 or components of the nozzle, such as indexing features 169b and 169c shown in Figures 6 and 11. For example, indexing feature 169b is located on the core member 153 and indexing feature 169c is located on the ring enclosure that holds the protective window 178.

[0038] 2, 4, 5, 6, and as shown in Figures 3A, 3B, 8, 9, 13, and 13B, according to at least one embodiment, the nozzle assembly 155 includes a fastening device 164 or fastening knob configured to releasably secure the nozzle in abutting relation against the engagement portion 162. In one embodiment, the fastening device 164 and the attachment mechanism 156 (e.g., see Figures 3A, 3B, 9, 10, 13, 13A, 13B, and as described in more detail below) each have a threaded portion for tightening the nozzle in abutting relation against the engagement portion 162.

[0039] According to some embodiments, one or more nozzles available in the nozzle assembly 155 are configured to deliver gas to a surface during a material processing operation. According to some embodiments, an inert or semi-inert gas (e.g., shielding gas for welding operations) may be used, while in other embodiments, the gas can be air or other gases. In some embodiments, the handheld device 120 is configured with the capability to deliver gas to the nozzle in combination with the laser radiation. For example, the output end 124 of the handheld device 120 of FIGS. 7A-7D is configured with at least one gas port 127 for directing or supplying gas to the nozzle. Additionally, the output end 124 provides the laser radiation to the nozzle, such as via an outlet 123. In FIG. 16, a photograph of the input end 128 of the handheld device 120 is shown where gas can be introduced to the handheld device 120 and routed through the device to the gas port 127 located at the output end 124.

[0040] As shown in Figures 4, 5, and 7A-7D, according to at least one embodiment, the retaining portion 161 comprises an inner annular surface 121 or lip. In at least one embodiment, the inner annular surface 121 comprises at least one gas port 127. According to another embodiment, and as shown in Figures 7B-7D, the inner annular surface 121 further comprises an electrical contact switch 154. The contact switch 154 contacts a corresponding contact surface (e.g., a conductive pad) on the interior of the engagement portion 162, such as a conductive pad on the core member 153, which is an electronic circuit that functions as part of a safety system for the laser. For example, the electronic circuit may include the nozzle tip and may be part of a safety interlock system that controls the power to the laser when the nozzle tip is in (or is not in) contact with the workpiece surface.

[0041] In at least one other embodiment, the retaining portion 161 further comprises an identification feature (not shown) to enable the controller 150 to identify the type of nozzle attached to the engagement portion 162. For example, the retaining portion 161 (e.g., on the inner annular surface 121) may comprise a conductive surface or terminal that is connected to a resistor positioned on the engagement portion 162. When locked in place, the resistor transmits a resistance value corresponding to the nozzle type (e.g., for welding, for cleaning, for cutting, etc.) to the controller 150, which can then optionally be used to control laser parameters.

[0042] The nozzle 170 shown in Figures 2, 3A, 17A, 17B, 18, and 20 can be used for material processing operations such as welding. In some embodiments, the nozzle includes a nozzle extension 175. According to at least one embodiment, the nozzle extension 175 is configured to provide or otherwise assist in providing a laminar flow of gas to a surface of a workpiece, such as a weld puddle on the surface. In contrast, turbulent gas flow increases the likelihood that atmospheric air, including oxygen and oxides, may come into contact with the weld puddle and cause weld quality issues. According to another aspect, the nozzle extension 175 is configured to protect one or more components of the handheld device 120 and / or the nozzle from debris generated during welding. For example, as shown in Figures 6 and 13A, the nozzle can be configured with a protective window 178, and the nozzle extension 175 can be used to protect the window. Additionally, nozzle extension 175 serves to position the nozzle tip 157 from an optical element, such as a focusing lens.

[0043] In the schematic diagram of FIG. 19, a cross section of nozzle extension 175 is shown. According to one embodiment, nozzle extension 175 has an inlet 171, an outlet 179, and a central aperture 712, which allows laser radiation and gas to enter central aperture 172 through inlet 171 and exit through outlet 179. Nozzle extension 175 can be constructed from a metallic material, such as steel. At least a portion of the interior surface of central aperture 172 is configured with a debris shield 176 that prevents the passage of debris generated during material processing operations. The debris shield 176 prevents material processing debris, such as welding debris, from reaching window 178 and other optical elements and components positioned upstream.

[0044] According to one non-limiting embodiment, the debris shield 176 comprises threads on the inner surface of the central aperture 172. As shown in FIG. 19, in some embodiments, the portion of the inner surface of the central aperture 172 that comprises the debris shield 176 is at least partially tapered or constricted. The debris shield 176 allows the passage of laser radiation and gases entering, passing through, and exiting the nozzle extension 175, but prevents debris generated near the outlet 179 from moving back upstream. The taper toward the inner central or inner portion of the nozzle extension 175 limits the size of the opening through which debris can move, and the threads act to "trap" debris moving through this opening by creating a roughened surface or expanding the surface area. In some embodiments, and as shown in FIG. 19, the central aperture widens outward toward the outlet beyond the tapered or constricted feature.

[0045] As shown in Figures 2, 3A, 17A, 17B, and 18 (and 20), according to at least one embodiment, a nozzle tip 157 may be attached to the outlet 179 of the nozzle extension 175. As will be appreciated, the nozzle tip 157 may be configured for a number of different types of weld joints in welding applications. The nozzle tip 157 may be made of a metallic material, such as copper or aluminum. As shown in Figures 17A, 17B, and 18, in some embodiments, the nozzle 170 further includes a spacer 158, which is attached to the outlet 179 of the nozzle extension 175 and the nozzle tip 157 and is positioned between the outlet 179 and the nozzle tip 157.

[0046] As shown in Figures 3B, 9, 10, 13, and 13A, in one embodiment, the engagement portion 162 includes a mounting mechanism 156 configured to be mounted to or attached to the nozzle extension 175. The mounting mechanism 156 is mounted to the nozzle extension 175 via a compression connection and may be referred to as a collet. As such, the collet 156 utilizes clamping pressure by forming a collar around the nozzle extension. Such a mechanism provides several advantages, such as the collet providing self-centering and anti-loosening resistance. As shown in Figures 6 and 11, a core member 153 is disposed inside the engagement portion 162. A retaining member 151 (see Figure 10) is mounted to the core member 153 and retains the mounting mechanism 156 and a pair of non-conductive insulators (not shown). The retaining member 151 also retains or otherwise captures the spring 152, which, as previously described, maintains pressure against the annular collar 167 of the engagement portion 162, thereby assisting in retaining the ball 165 within the slot 168. According to some embodiments, the retaining member 151 is threadedly attached to the core member 153 to retain the non-conductive insulator and attachment mechanism 156.

[0047] Herein, the examples refer to the attachment mechanism 156 being attached to the nozzle extension 175, however, it should be understood that the attachment mechanism 156 may be used to attach to other types of nozzles or nozzle components. For example, the nozzle extension for the nozzle 180 of FIG. 21A may be attached by the attachment mechanism 156. The compression connection provided by the attachment mechanism 156 may be used for nozzles having tubular extensions or any other components that can be accommodated by the attachment mechanism 156.

[0048] The protective window 178 is attached to one end of the core member 153, and the attachment mechanism 156 is attached to the other end of the core member 153. Additionally, the engagement portion 162 is attached to the core member 153. In one embodiment, the spring 152 is configured to hold the protective window 178 in place or helps hold the protective window 178 in place (by applying a force against the window housing, forcing the window housing against the retention portion 161 (i.e., the inner annular surface 121)). However, as will be readily appreciated, other retention mechanisms, such as, for example, a threaded retention mechanism, are also within the scope of the present disclosure. The configuration of the spring 152 also allows for replacement of the protective window 178 without the use of a separate tool.

[0049] Additionally, the core member 153 assists in directing gas out of the gas port 127 of the handheld device 120 and to the nozzle. The gas is directed around the protective window 178 to the inlet 171 and central aperture 172 of the nozzle extension 175. For example, according to one embodiment, the core member 153 has gas channels (e.g., perforated) that direct the gas around the protective window 178. Although the core member 153, the mounting mechanism 156, the retaining member 151, and the engagement portion 162 are each described herein as separate parts, it should be understood that two or more of these components may be constructed as a single monolithic part.

[0050] 3B, 17B, and 18, according to some embodiments, the exterior surface of the nozzle extension 175 can include a series of lines of scale markings 174. These scale markings 174 are located near the entry end of the nozzle extension where the nozzle extension 175 connects to the attachment mechanism 156 and are marked to aid a user in inserting the nozzle extension 175 into the attachment mechanism 156. For example, a user can align one of the lines of scale markings 174 with the end of the attachment mechanism 156.

[0051] In Figures 14A, 14B and 15, a second example of an engagement portion according to another embodiment is shown. According to this embodiment, the engagement portion comprises an outer ring 1062a and an inner ring 1062b. The outer ring 1062a is positioned over at least a portion of the outer peripheral surface of the inner ring 1062b. The inner peripheral surface of the outer ring 1062a has at least one groove or ridge 1064a configured to receive a corresponding ridge or groove 1064b on the outer peripheral surface of the inner ring 1062b. The inner ring 1062b is configured with an annular collar 167 having a pair of arc-shaped slots 166, 168 as described above, and the outer ring 1062a is configured with an inner surface 1052 that engages the spring 152 as described above. Thus, the twist-lock mechanism functions as described above, and for the sake of brevity, this function will not be repeated here. The engagement portion also includes an O-ring 159 positioned between the outer ring 1062a and the inner ring 1062b. The O-ring 159 seats in a groove 1063 in the inner ring 1062b. According to at least one embodiment, the outer ring 1062a applies a compressive force against the spring 152 to reduce or eliminate play after final displacement of the engagement portion. The O-ring 159 acts to create a frictional force between the inner ring 1062b and the outer ring 1062a that eliminates play and facilitates a "felt" rotation / engagement between the inner and outer rings. The O-ring 159 also acts to limit the distance that the inner ring 1062b can rotate back and forth within the outer ring 1062a and to prevent one ring from rotating out of the other.

[0052] It should be understood that while the examples of nozzles described herein are primarily used for welding (with or without wire) applications, the nozzle extension 175 and / or embodiments thereof may also be implemented with any nozzle used in debris-generating material processing operations, such as, for example, laser cutting and drilling.

[0053] 20, an example of a nozzle configured with a wire delivery function is shown. The nozzle 170 includes a nozzle extension 175 (and nozzle tip 157) attached to the handheld device 120 via a coupling mechanism, and further shown in this figure is the engagement portion 162 and the clamping device 164. Additionally, the nozzle includes an external wire delivery device 183 attached to the nozzle extension 175 configured to deliver wire material to the surface to be processed. As shown in FIG. 20, according to at least one embodiment, the external wire delivery device 183 is attached to the nozzle extension 175 by a mounting mechanism (not specifically labeled in the figure), such as a clamp. Additionally, this external wire delivery device 183 is disposed below the nozzle extension 175 and may be positioned at an angle or range of angles relative to the workpiece surface such that the wire delivery function is not detrimental to the welding process. Although not shown in FIG. 20, in some implementations, the nozzle tip 157 has a recess or other retaining feature to help hold the external wire delivery device 183 in place.

[0054] 21A and 21B show another example of a nozzle, generally designated 180, configured with a wire delivery feature. FIG. 21A is a photograph of a side view of the nozzle 180, and FIG. 21B is a photograph of an end view (outlet side) of the nozzle 180. In this example, the wire delivery feature is "internal" to the nozzle such that the output of the wire is disposed within the outlet of the nozzle. The nozzle 180 comprises a central aperture 182, a first inlet 181 for allowing laser radiation and gas to enter the central aperture 182, a second inlet 185 coupled to a wire material source, and an outlet 189. The outlet 189 comprises a first outlet port 188 for allowing laser radiation and gas to exit the central aperture 182, and a second outlet port 187 configured to deliver wire material to a workpiece surface. The first inlet 181 may be coupled to the handheld device 120 via the coupling mechanism 160 described above. The nozzle 180 further comprises a debris shield, such as a debris shield 184 configured as a screen as shown in FIG. 21B. The debris shield 184 is disposed over at least a portion of the outlet 189. The nozzle 180 is configured to be mounted to the mounting mechanism / collet 156 rather than the nozzle extension 175.

[0055] 22A, 22B, and 23, another example of a nozzle configured with wire delivery is shown. In the example shown in the photographs of FIGS. 22A and 22B, the nozzle includes an external wire delivery and gas device 190 attached to a nozzle extension 175. In this example, gas exiting through an outlet 179 of the nozzle extension 175 is the primary gas source, and the external wire delivery and gas device 190 is configured to deliver wire material and a secondary gas source to the workpiece surface. In accordance with one or more embodiments, the device 190 may also be referred to or described as a gas lens device. The function of the device 190 is to provide a greater blanket of gas around the weld puddle, which is useful when gas from the nozzle alone is insufficient to adequately cover the workpiece. This latter problem may arise when the shape or geometry of the workpiece causes the gas to blow away rather than remain in the vicinity of the weld puddle. During a welding operation, the nozzle tip may be moved faster than the gas can accommodate or otherwise accommodate the ability of the gas to form a shield around the weld puddle (i.e., the welding operation precedes the gas function), and device 190 addresses this issue.

[0056] The external wire delivery and gas device 190 includes a central aperture 192 sized to fit around at least a portion of the outer circumferential wall of the nozzle extension 175, a gas inlet 194 coupled to a gas source, a gas outlet 196 configured as an annular opening surrounding the central aperture 192, a wire material inlet 195 coupled to a wire material source, and a wire material outlet 197 configured to deliver wire material to a workpiece surface. The external wire delivery and gas device 190 can be made from a metallic material, such as, for example, steel. The device 190 can be configured to be attached to the nozzle extension 175.

[0057] In FIG. 23, a schematic end view of the device 190 is shown. Generally, the nozzle outlet 199 includes a first outlet port 198 configured to allow the laser radiation and primary gas source to exit the central aperture 192, and a second outlet port 197 configured to deliver wire material to the work surface. Although the external wire delivery and gas device 190 is illustrated as configured to be attached to the nozzle extension 175, it should be understood that other configurations and designs are configured within the scope of this disclosure to integrate this functionality as a single (monolithic) nozzle device having a central aperture for the primary gas source and laser radiation. The first inlet allows the laser radiation and gas to enter the central aperture 192, and in some examples, the first inlet is coupled to a coupling mechanism (such as the coupling mechanism 160 described above) that releasably attaches the first inlet to the output end 124 of the handheld device 120. A second inlet (similar to inlet 195) is coupled to a wire material source and a third inlet (similar to inlet 194) is coupled to a gas source. An outlet, such as outlet 199 shown in FIG. 23, comprises a first outlet port 198 configured to allow the laser radiation and the primary gas source to exit the central aperture 192, a second outlet port 197 configured to supply the wire material to the surface, and a third outlet port 196 configured to supply the secondary gas source to the surface. The third outlet port 196 is configured as an annular opening surrounding the first outlet port 198. The wire material outlet or the second outlet port 197 can be disposed below each outlet port 198 for the primary gas and laser radiation and the secondary outlet 196 for the gas.

[0058] According to one or more aspects, the nozzle 180 of FIGS. 21A and 21B and the external wire delivery and gas device 190 of FIGS. 22A and 22B, respectively, can also be referred to as a gas lens device. In FIGS. 24A and 24B, another non-limiting example of a gas lens device is generally indicated at 1090. According to this embodiment, the gas lens device 1090 is configured to surround at least a portion of the nozzle extension 175 and at least a portion of the nozzle tip 157 that is attached to the nozzle extension. The gas lens device 1090 has a gas outlet 196 configured as an annular opening that surrounds the nozzle tip 157. In the example shown in FIG. 24B, the nozzle tip 157, which contains an outlet port 198 for the primary gas and laser radiation, extends beyond the secondary gas outlet 196. In other embodiments, the nozzle tip 157 can be in closer alignment with or aligned to the gas outlet 196. As shown in FIG. 24B, a secondary gas source is directed into the annular space that includes a gas outlet 196 .

[0059] While the nozzles shown in Figures 2, 3A, 17A, 17B, 18, 20, 21A, 21B, 22A, and 22B are configured for welding operations, it should be understood that nozzles configured to perform other types of welding and other material processing operations, such as, for example, drilling, cutting (such as cutting nozzle 200 described below), brazing and / or soldering, cladding, ablation, heat treating, additive manufacturing, and surface cleaning and structuring, are also within the scope of this disclosure. These nozzles can be coupled to the handheld device 120 using a coupling mechanism, such as coupling mechanism 160 described herein. This allows for a modular approach that allows the handheld device to easily swap out nozzles for different applications or for different material processing operations within a single application.

[0060] According to some embodiments, the nozzle is configured as a cutting nozzle. In FIG. 25, one non-limiting example of a cutting nozzle is generally indicated at 200. The cutting nozzle 200 is attached to the handheld device 120 via the engagement portion 162 as described above (including the engagement portion having inner and outer rings as described above with reference to FIG. 14A, FIG. 14B, and FIG. 15). The cutting nozzle 200 includes an outlet 298 to allow the laser radiation and gas to exit the cutting nozzle. In some embodiments, the cutting nozzle 200 further includes a z-axis focal length adjustment mechanism 210. This adjustment mechanism allows the focus of the laser beam to be focused on the workpiece surface. For example, the cutting nozzle tip 257 may be positioned on a threaded cylindrical portion of the nozzle, which can be rotated to adjust the focus of the laser beam. The cutting nozzle 200 may also include at least one x-axis and y-axis adjustment mechanism 220 for aligning the laser beam exiting the handheld device with respect to the outlet 298, i.e., by moving a central aperture that guides the laser beam through the nozzle and to the tip. The adjustment mechanism 220 may be configured as a set point adjustment screw (e.g., two or more set point adjustment screws positioned along the periphery of the nozzle 200, etc.), although it should be understood that other mechanical alignment options are also within the scope of the present disclosure. Furthermore, according to some embodiments, the controller 150 may serve to adjust at least one of the x-axis, y-axis, and z-axis settings of the laser, and thus may be coupled to the mechanical components of the nozzle 200. A clamping device or knob 264 is configured to releasably secure the nozzle in abutment against the engagement portion 162 and functions in a similar manner as the clamping device 164 discussed above, i.e., to securely clamp the collet. Optionally, the cutting nozzle 200 may further include an inlet 294 for an additional gas source. It should be appreciated that the cutting nozzle tip 257 may have different sized outlets 298 for various applications.

[0061] Although the examples described herein refer to the nozzle assembly 155 used in combination with the handheld device 120 of a handheld laser system, according to at least one embodiment, the nozzle assembly 155 can be used with a laser head that provides a laser radiation source and gas, and thus aspects of the present invention are not limited to handheld lasers. In the schematic diagram of FIG. 26, an example of a laser system having a laser head is shown. The nozzle assembly 1055 is similar to that described above with reference to the nozzle assembly 155, but in this example, the retaining portion 161 is formed on the output end 1024 of the laser head 1020. The laser head 1020 transmits the laser radiation from the laser source 115 out the output end 1024 of the laser head 1020. The laser head 1020 may not include the laser source 115, but does include optics and beam guiding components included within the housing to transmit the laser radiation emitted from the laser source 115. Gas also exits the output end 1024 of the laser head 1020 in a manner similar to that described above with reference to the output end 124 of the handheld laser. For example, the output end 1024 of the laser head 1020 is configured with at least one gas port 127 for supplying gas to the nozzle. The nozzle assembly 1055 includes a nozzle, such as nozzle 170 (or nozzle 180, 220) as described above, and a coupling mechanism 160 as described above. The laser beam 122 emanates from the nozzle 170 and is directed to the workpiece 105. A controller 150 is also coupled to the laser head 1020 and the laser source 115 for sending control signals and, in some examples, receiving feedback and / or input signals.

[0062] As previously mentioned, the nozzle assembly 1055 is similar to that described above with reference to the nozzle assembly 155 and will not be described again here for brevity. For example, the coupling mechanism 160 comprises a retaining portion 161 formed on the output end 1024 of the laser head 1020 and an engaging portion 162 releasably mountable to the nozzle 170 and configured to engage the retaining portion 161. The retaining portion 161 is formed on an annular surface of the output end 1024 of the laser head 1020 (not labeled in FIG. 26 but configured as described above with reference to the annular surface 126). The annular surface is configured with at least one recess and a ball disposed within the at least one recess, similar to the at least one recess 163 and ball 165 described above. The engaging portion 162 may further comprise a spring (as previously described in connection with the spring 152) that engages an inner surface of the engaging portion 162 (see, e.g., FIGS. 8 and 15). The engagement portion includes an outer ring 1062a and an inner ring 1062b as described above with reference to Figures 14A, 14B, and 15, the inner ring 1062b configured with an annular collar 167 having a pair of arc-shaped slots 166, 168, and the outer ring 1062a configured with an inner surface that engages the spring 152. The nozzle assembly 1055 may further include a fastening device 164 as described above. As described above, the coupling mechanism 160 is configured as a twist lock mechanism and does not include threads. The nozzle 170 may further include a nozzle extension, such as nozzle extension 175 as described above, having a built-in debris shield 176 configured on an inner surface of the central aperture 172 (see Figure 19). The engagement portion includes an attachment mechanism 156 as discussed above that is attached to the nozzle extension 175 (or other tubular extension of other types of nozzles). The nozzle may be configured to perform at least one of welding, drilling, cutting, brazing, soldering, cladding, ablation, and heat treating material process operations.

[0063] The aspects disclosed herein according to the present invention are not limited in their application to the details of the structure and configuration of the components shown in the following description or illustrated in the accompanying drawings. These aspects can assume other embodiments and can be implemented or carried out in various ways. Examples of specific implementations are presented herein for illustrative purposes only and are not intended to be limiting. In particular, operations, components, elements, and features discussed in connection with any one or more embodiments are not intended to be excluded from a similar role in any other embodiment.

[0064] Also, the expressions and terminology used herein are for the purpose of explanation and should not be understood as limiting. Any word referring to an example, embodiment, component, element, or operation of the system and method described in the singular form herein may further include embodiments including plurals, and any word referring to any embodiment, component, element, or operation herein may further include embodiments including only singulars. The singular or plural referential terms are not intended to limit the systems or methods of the present disclosure, their components, operations, or elements. In this specification, the use of "including," "comprising," "having," "including," "including," and variations thereof are intended to include the items listed thereafter and their equivalents, as well as other items. The referential term "or" may be interpreted as non-exclusive, and thus any word described with "or" may refer to any one, more than one, and all of the described words. Furthermore, if there is a discrepancy in the use of a term between this document and a document incorporated herein by reference, the use of the term in the incorporated reference shall be supplementary to the use of the term in this document, and in the event of an irreconcilable discrepancy, the use of the term in this document shall prevail. Furthermore, headings and subheadings may be used herein for the convenience of the reader but shall have no effect on the scope of the invention.

[0065] Although several aspects of at least one example have been described, it will be understood that various changes, modifications, and improvements will readily occur to those skilled in the art. For example, the examples disclosed herein may be used in other contexts. Such changes, modifications, and improvements are intended to be part of this disclosure and are intended to be included within the scope of the examples discussed herein. Accordingly, the above description and drawings are by way of example only. [Explanation of symbols]

[0066] 100 Handheld Laser System 105 Workpiece 110 Laser module 115 Laser Light Source 120 Handheld equipment, handheld devices 121 Inner Annular Surface 122 Laser beam 123 Outlet 124 Output end 126 Annular Surface 127 Gas Port 128 Input End 130 Optical Fiber 140 Air Cooling System 150 Controller 151 Retaining member 152 Spring 153 Core material 154 Electrical Contact Switch 155 Nozzle Assembly 156 Mounting mechanism, collet 157 Nozzle tip 158 Spacer 159 O-ring 160 Coupling mechanism 161 Holding part 162 Engagement part 163 Recess 164 Fastening Device 165 balls, pins 166 Circular arc-shaped slot, first circular arc-shaped slot 167 Annular Collar 168 Circular arc shaped slot, second circular arc shaped slot 169 Indexing Features 169a Indexing Feature 169b Indexing feature 169c Indexing Features 169d Indexing Features 170 Nozzle 171 Entrance 172 Central Aperture 174 Scale Marks 175 Nozzle extension 176 Debris Shield 178 Protective Window 179 Outlet 180 Nozzle 181 First Entrance 182 Central Aperture 183 External Wire Delivery Device 184 Debris Shield 185 Second Entrance 187 Secondary discharge port 188 First discharge port 189 Outlet 190 External Wire Delivery and Gas Devices 192 Central Aperture 194 Gas Inlet 195 Wire material entry port 196 Gas outlet, third outlet port, secondary outlet, secondary gas outlet 197 Wire material outlet, second outlet port 198 First discharge port 199 Outlet 200 Cutting nozzle 210 z-axis focal length adjustment mechanism 220 x-axis and y-axis adjustment mechanism 257 Cutting nozzle tip 264 Nobu 294 Entrance 298 Outlet 712 Central Aperture 1020 Laser Head 1024 Output end 1052 Inner annular surface, inner surface 1055 Nozzle Assembly 1062a Outer Ring 1062b Inner ring 1063 Groove 1064a Ridge 1064b Ridge or groove 1090 Gas Lens Device

Claims

1. A nozzle assembly for performing a material processing operation on the surface of a workpiece using a hand-held laser system, the hand-held laser system comprising a laser light source configured to generate a laser emission, a hand-held device for guiding the laser emission, and an optical fiber coupling the hand-held device to the laser light source, wherein in the nozzle assembly, a nozzle configured to deliver the laser emission to the surface; a coupling mechanism, comprising a holding portion formed on an output end portion of the hand-held device, and an engaging portion removably attachable to the nozzle and configured to engage with the holding portion, the coupling mechanism; the nozzle assembly.

2. The nozzle assembly according to claim 1, wherein the holding portion is formed on an annular surface of the output end portion.

3. The nozzle assembly according to claim 2, wherein the annular surface is configured to have at least one recess and a ball disposed within the at least one recess.

4. The nozzle assembly according to claim 3, wherein the engaging portion comprises an annular collar, an inner circumferential surface of the annular collar is configured to have at least a pair of arcuate slots, and each slot is configured to receive the ball of the at least one recess and the ball.

5. The nozzle assembly according to claim 4, wherein the pair of arcuate slots comprises a first arcuate slot configured to engage with the ball and a second arcuate slot configured to lock the engaging portion to the holding portion when the engaging portion is rotated relative to the holding portion.

6. The nozzle assembly according to claim 5, wherein the first arcuate slot is sized larger than the second arcuate slot.

7. The nozzle assembly according to claim 4, wherein the annular collar is configured to have an indexing feature corresponding to an indexing feature positioned on the output end portion of the hand-held device.

8. The nozzle assembly according to claim 4, wherein the engaging portion further comprises a spring that engages an inner surface of the engaging portion.

9. The engaging portion comprises an outer ring and an inner ring, The inner ring is configured with the annular collar having the pair of arcuate slots, The outer ring is configured with the inner surface engaging the spring, the nozzle assembly of claim 8. **Claim 10** The coupling mechanism is configured as a twist lock mechanism, the nozzle assembly of claim 1. **Claim 11** The coupling mechanism is threadless, the nozzle assembly of claim 1. **Claim 12** The nozzle assembly of claim 1 further comprising a clamping device configured to removably fix the nozzle relative to the engagement portion. **Claim 13** The output end of the handheld device is configured to have at least one gas port for supplying gas to the nozzle, the nozzle assembly of claim 1. **Claim 14** The nozzle is configured as a cutting nozzle, the cutting nozzle a discharge port to allow laser radiation and the gas to exit from the cutting nozzle, a z-axis focal length adjustment mechanism, and, the nozzle assembly of claim 13. **Claim 15** The nozzle comprises a nozzle extension having an inlet, a discharge port, and a central aperture, the nozzle extension being for allowing laser radiation and the gas to enter through the inlet into the central aperture and exit through the discharge port, the nozzle assembly of claim 13. **Claim 16** At least a portion of the inner surface of the central aperture of the nozzle extension is configured to have a debris shield that prevents passage of debris generated during a material processing operation, the nozzle assembly of claim 15. **Claim 17** The debris shield has threads on the inner surface of the central aperture, the nozzle assembly of claim 16. **Claim 18** The portion of the inner surface configured with the debris shield is at least partially tapered, the nozzle assembly of claim 16. **Claim 19** The nozzle is configured to have a protective window, the debris shield preventing material processing debris from reaching the window, the nozzle assembly of claim 16. **Claim 20** The engagement portion further comprises a mounting mechanism mounted to the nozzle extension, the nozzle assembly of claim 15. **Claim 21** The nozzle further comprises an external wire delivery device mounted to the nozzle extension, the wire delivery device being configured to supply wire material to the surface, the nozzle assembly according to claim 15.

22. The gas exiting through the discharge port of the nozzle extension is a primary gas source, the nozzle further comprising an external wire delivery and gas device mounted to the nozzle extension, the external wire delivery and gas device being configured to supply wire material and a secondary gas source to the surface, the nozzle assembly according to claim 15.

23. The external wire delivery and gas device a central aperture sized to fit around at least a portion of the outer peripheral wall of the nozzle extension, a gas inlet coupled to a gas source, a gas outlet configured as an annular opening surrounding the central aperture, a wire material inlet coupled to a wire material source, a wire material outlet configured to supply the wire material to the surface, comprising the nozzle assembly according to claim 22.

24. The nozzle assembly according to claim 15 further comprising a gas lens device configured to surround at least a portion of the nozzle extension and at least a portion of a nozzle tip mounted to the nozzle extension, the gas lens device having a gas outlet configured as an annular opening surrounding the nozzle tip.

25. A method for performing a material processing operation on a surface of a workpiece using a hand-held laser system, the hand-held laser system having a laser light source configured to generate laser radiation, a hand-held device for guiding the laser radiation, and an optical fiber coupling the hand-held device to the laser light source, the method comprising: providing a coupling mechanism, the coupling mechanism comprising: a holding portion formed on an output end of the hand-held device, and an engaging portion removably mountable to the nozzle and configured to engage the holding portion, the step comprising the method.

26. The method according to claim 25 further comprising the step of providing the nozzle, the coupling mechanism being configured as a twist lock mechanism.

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