A master thesis from Aalborg University
Optimization of Gap Bridging Performance in Laser Butt Welding Using Beam Shaping Technology: Exploring the Application of Beam Shaping in Mass-Production
[Optimization of Gap Bridging Performance in Laser Butt Welding Using Beam Shaping Technology]
Author(s)
Term
4. term
Education
Publication year
2025
Submitted on
2025-05-30
Pages
63 pages
Abstract
Autogenous laser butt welding is widely used for its high precision, low heat input, and efficiency. However, variations in joint gaps can degrade weld quality. The conventional solution—using high-precision fixtures—is costly, time-consuming, and limits production flexibility. Beam shaping offers an alternative solution and can be classified into Dynamic Beam Shaping and Static Beam Shaping. Dynamic beam shaping, using High-Speed Scanning systems, provides high flexibility but is expensive and may cause melt pool instability at low frequencies. Static beam shaping, using Diffractive Optical Elements (DOEs), is cost-effective for large-scale production and easy to maintain but lacks adaptability for different tasks. This study, for the first time, applies Quasi-Static Beam Shaping using a Civan laser to design customized beam patterns for welding. The impact of these patterns on weld quality will be compared to conventional Gaussian beams, with melt pool behavior analyzed using high-speed and thermal imaging where possible. The goal is to determine an optimal beam shaping pattern and provide design insights for static beam shaping methods, particularly DOEs.
Keywords
Documents
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