Combined Laser Pulse Shaping for Versatile Workpiece Processing
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Solution Overview
Problem
Laser shock processing techniques are limited by complex, expensive, and single-mode operation of application-specific lasers, which hinder reliability, replaceability, and reparability, leading to high ownership costs and limited versatility in material processing.
Innovation Solution
A system combining multiple generic lasers to produce a combined laser beam pulse with synchronized temporal characteristics, energy adjustments, and spatial shaping, allowing for flexible processing results without the need for customized equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single customized laser is used for dedicated processing application, then processing precision and reliability are improved, but device complexity and cost increase
Solution Approach 1:
The system divides the laser processing function into multiple independent laser units (first laser, second laser, third laser, fourth laser) that can operate independently or in combination. Each laser can be a standard off-the-shelf component rather than a customized system, reducing individual complexity while maintaining overall functionality through modular arrangement.
Solution Approach 2:
Multiple standard lasers with fixed characteristics are designed to perform different functions (peening, shock processing, inspection) by varying their temporal sequencing and combination rather than requiring customization. The same set of lasers can produce different processing results by changing control parameters, making the system universally applicable to multiple processing applications.
2Manufacturing precision
If application-specific customized lasers are used, then processing precision is improved, but replaceability and reparability deteriorate
Solution Approach 1:
The system uses multiple standard, commercially available lasers that can be easily replaced if needed, rather than investing in expensive customized lasers that are difficult to repair. The redundancy of having multiple lasers allows for easy replacement without system shutdown, improving maintainability while maintaining processing precision through controlled combination of the standard lasers.
3Device complexity
If a single laser with fixed characteristics is used, then system simplicity is improved, but adaptability to different processing applications deteriorates
Solution Approach 1:
The system achieves adaptability through dynamic control of multiple lasers with fixed characteristics. By varying the temporal sequencing, energy levels, and combination of lasers, the system can produce different processing outcomes (compressive stresses, shockwaves, material removal) without changing the physical laser components, thus maintaining simplicity while gaining versatility.
Solution Approach 2:
The system varies processing outcomes by changing parameters such as laser pulse timing, energy levels, and combination sequences rather than changing the lasers themselves. This allows a single set of standard lasers to produce different processing effects (peening vs. shock processing vs. inspection) by adjusting control parameters, achieving versatility without complexity.
4Adaptability or versatility
If multiple lasers are combined to produce various processing results, then adaptability is improved, but device complexity increases
Solution Approach 1:
The system merges multiple standard lasers into a coordinated system where their outputs are combined in space and time. By using precise temporal sequencing and spatial positioning, the combined laser beams create enhanced processing effects that neither laser could achieve alone, while the modularity keeps individual components simple and manageable.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the reliability, replaceability, and reparability of laser systems, reducing costs while enabling a wide range of processing outcomes, from inducing shockwaves to modifying material microstructures, with improved precision and efficiency.
Implementation Method 1
a plurality of lasers that each produces a laser beam pulse... combines the laser beam pulses to produce a combined laser beam pulse... The combined laser beam pulse may induce a shockwave through the workpiece
Data Source
AI summary
Described herein is a system for processing a workpiece that includes a plurality of lasers that each produces a laser beam pulse. The system also includes a laser control module that sequences temporal characteristics of the laser beam pulses. Additionally, the system includes a laser beam compensation module that shapes a near field intensity profile of at least one of the laser beam pulses and adjusts a path length of at least one of the laser beam pulses. The system also includes at least one laser beam position element that combines the laser beam pulses to produce a combined laser beam pulse at a surface of the workpiece.