Photonics Spectra February 2022 edition covers how manufacturers are increasingly replacing traditional mechanical machining and thermal welding systems with laser processing tools. Learn how manufacturers are increasingly replacing traditional mechanical machining and thermal welding systems with laser processing tools. How researchers have pursued dynamic beam shaping for decades to give manufacturers the tools they want and need, and thereby expand the market for laser materials processing. Read the Photonics Spectra magazine’s article on: The Dynamic Beam-Shaping methods. How Civan’s Dynamic Beam Lasers reshape materials processing applications. The revolutionary practice of the Coherent Beam Combining theory. Dynamic Beam Laser technology allows users to take advantage of powerful laser tools while avoiding some of these tools’ inherent rigidities. Dynamic beam laser systems offer the flexibility to adjust beam shape and frequency quickly and easily, as well as to create beam sequences and steer the focus of the beam — all of which make dynamic beam lasers a game-changer in materials processing. Read the full story on Photonics Spectra February 2022 Magazine. Read the Print version > Read the Web version>

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This blog was written in conjunction with Woo-Sik Chung from Fraunhofer ILT , a leading development and contract research institute for laser technology With dire predictions about climate change pouring in, it’s no wonder that many of the major OEMs have big plans to shift production fully (or mostly) to electric vehicles by 2030-2035. While this is good news for consumers who want to make the eco-conscious decision to drive an electric car, the efficient production of electric vehicles does not come without challenges. In contrast to a standard combustion engine found in traditional vehicles, electric cars require a fuel cell stack built of approximately 200 bipolar plates. These plates are stacked together, to form the fuel cell, along with membrane-electrode assembly (MEA), and must be tightly and precisely welded with no defects to function properly and maximize the space allocated to them. Currently, it takes ten times as long to weld the plates as it does for the rest of the manufacturing process. As welding is the critical path to production, cutting down this time will have a significant effect on production time and the environmental impact of the production process. The Challenge: How to Make a Bipolar Plate There are three steps in the process of producing the bipolar plates needed to make fuel cell stacks: Step One: Cut & Shape - this process is generally referred to as punching, and involves cutting the sheet metal plate out of a coil in the right shape, as well as cutting a hole in the plates if necessary. Step Two: Mold with the Flow Field - a flow field must be formed before the joining process to allow for the cooling water to flow between the welded bipolar plates. Step Three: Welding - the final step is when the two sheets are welded together. The first two steps are very fast, taking about 100-300 millisecond each. It’s the third step - which is the crux of the production process - where the challenges arise. Welding the plates together properly requires welding up to 2m of metal. Currently, the top possible speed is around 0.5m per second, which means 4 seconds per weld. Because each car needs 200 bipolar plates, this part of the process takes 800 seconds, or 13 minutes per car, slowing down the entire production process considerably. Not So Fast: Increasing Speed Creates Defects The first two steps in the production process are already as fast as possible, so the question becomes how can the final step take less time? While the obvious answer would seem to be simply to increase the speed of the weld, doing this causes significant defects . While existing technology has the capacity to go faster, bipolar plates require deep and narrow seams on 0.1mm sheets. When the feed rate increases to above 0.5m/s, the resulting melt stream leads to the well-known humping-effect. For the bipolar plate to be welded properly, it has to pass a hydrogen leakage test to make sure that the weld is tight and there are no leaks. It could pass this test, but still have humping. In which case, the plates still cannot be used because the humping changes their shape and the plates will not fit into a single stack together. Because increasing the speed is not a viable option at this time, companies incorporate alternative solutions such as using 10 lasers at once on each sheet of metal to speed the process, but this is not cost effective or eco-friendly. The Solution: Dynamic Beam Lasers More humping occurs at high speeds with high power lasers as control of the melt pool flow and vapor capillary decrease. When we can control the shape of the laser beam to a degree that influences the melt dynamic, changing the shape could change the outcome and prevent this humping. The shape of standard laser beams cannot be easily changed, especially mid-process. With Dynamic Beam Lasers, the shape can be changed - for example to an oval - which will offer less resistance and should reduce the flow velocity of the melt behind the keyhole and decrease the risk of humping. It will then be possible to use one high intensity laser at a higher speed without causing defects. Another possibility is to use a higher intensity beam combined with additional laser points at lower intensity in order to pre and post heat the material. These processes that are now achievable with Dynamic Beam Lasers will enable an increased feed rate and greatly decrease production time. Civan is currently working in partnership with Fraunhofer ILT and Smart Move on the “Eureka Project” whose aim is to find a solution for welding bipolar plates at high speed. The potential solutions described above, which rely on Civan’s technology, will be tested to create a viable solution for producing bipolar plates at scale, efficiently.

DYNAMIC BEAM SHAPING FOR LASER WELDING Dr. Shekel is the founder and CEO of Civan Lasers – the first company to develop industrial lasers based on Coherent Beam Combining. Prior to Civan, Dr. Shekel founded Cielo, a leading company in the manufacture of Fiber Optical Gyros and navigation systems and Founder and general manager of Chiaro Networks which developed the largest optical switch in the world. Dr. Shekel received his PhD in physics at NYU. ENHANCING KEYHOLE STABILITY BY BEAM SHAPING Florian Hugger studied mechanical engineering at the Technical University of Munich and afterwards worked as research assistant at the Bayerisches Laserzentrum GmbH from 2011 to 2017. His research focused on keyhole phenomena like evaporation of volatile elements and high-speed keyhole dynamics. Since 2017 he is Head of R&D at BBW Lasertechnik GmbH and addresses problems of laser welding.

It’s hard to imagine actual life on other planets, but scientists are more determined than ever to prove that life does exist beyond Planet Earth. Over 60 years ago, Philip Morrison and Giuseppe Cocconi proved for the first time that alien life could possibly broadcast their presence via radiowaves detectable by searching astronomers. More recently, NASA sent a rover to Mars to search for signs of life, in addition to the efforts of various scientists exploring new planets and areas of the galaxy. In parallel to NASA’s efforts, there are also a number of privately-funded quests including Breakthrough’s Starshot Initiative , which aims to use laser beams to push ultra-light nanocrafts to explore Promixa Centauri b, a planet in the Alpha Centauri system that is believed to be inhabitable. As a company built to pioneer new technologies in general, and laser beams in particular, Civan was an obvious choice to become part of a team that will help to develop the laser technology necessary to make the Starshot Initiative a success. What is the Starshot Initiative? The Breakthrough Initiatives comprise several space-related programs that seek to answer the most pressing question - are we Earthlings alone in the universe or are there others like us? And, if there are, can we reach them? Starshot was launched in 2016 by Yuri Milner and Stephen Hawking who believe that it makes the most sense to first look for life in Alpha Centauri, our closest neighbor at four light years away. Breakthrough ultimately intends to send camera-equipped spacecraft to take pictures of the life that may or may not exist on Proxima b. The current goal of the Starshot Initiative is a proof of concept for advanced technology using laser beams to enable ultra-light unmanned spacecraft to reach 20% of the speed of light. This proof of concept will lay the groundwork for a future flyby mission to Alpha Centauri, during which pictures will be taken that will reveal once and for all whether life exists there. The limitations of current technology mean that it would take thousands of years to actually reach Alpha Centauri. By the time any pictures would return to earth, generations of scientists would already be gone! Civan is developing new technological advances that may be used to increase the speed of space travel to 100 million miles an hour, allowing a spacecraft to reach Alpha Centauri in just over 20 years. So what exactly is this technological breakthrough that will get us to distant galaxies? Photon Sails are the Ticket When you see a spaceship blast off from Cape Canaveral, you are watching a rocket-powered launch. Its trajectory and the distance it can go is limited by the power of the rocket that will eventually run out. Photon sails (also known as solar sails) are another way of propelling a spaceship through the sky by using the momentum created when light bounces off a reflective surface. In contrast to rocket-fuel, a spacecraft powered by photon sails will continue accelerating as long as there is light to push it forward. By using photon sails, a spacecraft can travel at higher speeds (⅕-⅓ the speed of light) for longer distances- exactly what is needed to reach Alpha Centauri within a reasonable amount of time. (Credit: BREAKTHROUGH INITIATIVES) How To Power the Photon Sails While a photon sail-powered spacecraft will keep accelerating as long as there is light to power it, how can we harness photonic energy and point the spacecraft in our desired direction? The answer lies in laser beams. Lasers can direct beams of light to the photon sails and push them to the coordinates of Promixa Centauri b. Not only does this sound like science fiction, but it was actually first proposed in a science fiction novel called Rocheworld by Robert Forward. When the book was published in the 1970’s, it’s unlikely that anyone ever believed this method could actually work. Today, we are getting closer, but two critical challenges still remain: Laser strength - Civan has produced the world’s first 100kw SM OPA laser , which is currently one of it’s kind. However, it’s a 100 GW laser that is needed in order to propel a spacecraft fast enough and far enough to get to Alpha Centauri. Laser focus - in addition to strength, the laser must also be able to be focused on the photon sail with extreme accuracy while factoring in distortion from the Earth’s atmosphere. (Civan Laser's OPA 12 100kW Single Mode Laser based on CBC) Can Such a Laser be Built? As a result of Civan’s unique experience in the development of coherent beam combining (CBC) lasers, we were chosen to be part of a team that will help design the concept for the 100 GW lasers needed for the Starshot Initiative. The laser will be made up of billions of smaller lasers working together using coherent beam combining to focus on the photon sails, sending the unmanned spacecraft on their way. (Coherent Beam Combining diagram) We invite you to follow along on this journey as we help power the search for extraterrestrial life around distant stars.

The introduction of lasers revolutionized the nature of materials processing (MP) in the automotive and aerospace industries. Lasers have replaced traditional tools and have brought new levels of quality, reliability and efficiency to the field. The industry, however, has continued to evolve with new materials and faster processes and it is important for the lasers to keep up. At the moment, it seems as if materials processing needs may be changing faster than new laser capabilities can be developed. For example, auto parts are now made from an assortment of alloys and often require the welding of asymmetric parts or dissimilar metals. This creates challenges , and it is particularly difficult to overcome issues of cracking and porosity when welding at high speeds. One of the ways to improve results is by tailoring the beam shape for the process. While there are a number of solutions that exist for beam shaping, none of them offer a complete fix, rendering it impossible to maximize the use of lasers both in terms of cost and productivity. For example, you can use Diffractive Optical Elements(DOE) to change beam shapes, but once a new shape is designed and implemented, it can’t be changed on the fly. Or, mechanical scanners can solve keyhole instability issues, but they are limited by the maximum speed at which they can operate, which is often not fast enough. The reality is that laser technology must evolve alongside the materials processing industry. Standard lasers do not offer the flexibility needed in order for lasers to be optimized and used to their full potential in MP. This flexibility can be found in Dynamic Beam Lasers (DBL), which allow you to customize any beam element property quickly. Read on to discover how Dynamic Beam Lasers will take materials processing to the next level. Revolutionizing MP with Flexibility Since the problem is inflexibility, the most effective solution is Optical-Phased Array (OPA). OPA is a type of coherent beam combining (CBC) that combines many single-mode laser beams into one larger beam. As each laser emits its own light, there is overlap in the far field, creating a diffraction pattern. In simple terms, this process unlocks the flexibility to easily manipulate the beam shape in real-time. Basically, you use the laser like a pencil and draw whatever beam shape you want. It’s not just the shape of the beam that is flexible. There are 4 main features in which the high flexibility of DBL comes in handy: Beam shaping Shape frequency Beam sequencing Focus steering Let’s look at how flexibility in each of these areas impacts the quality of a weld. Beam Shaping The shape of the laser beam has a direct effect on the material being processed, with each different shape resulting in a specific weld geometry and micro-structure. The exact shape that you need depends on the result you are trying to achieve, and sometimes a small adjustment might make a big difference. Existing solutions do not give you the flexibility of choosing such a wide range of different shapes, let alone design the exact one that you need. With DBL, it is easy to design the relevant shape, upload it to the laser and then see the effect on the weld using cross-section analysis within a relatively short period of time. The simplicity and speed of this process makes it possible to test multiple shapes in order to optimize the best shape for the specific weld. For example, when welding dissimilar metals, DBL would allow for the use of 2 laser spots moving at the same time (imagine the movement of a kitchen mixer) to provide the homogenous weld needed. The above scenario is impossible with standard lasers and is just one example of how the accessibility of DBL will improve the capabilities of so many types of materials processing. Shape Frequency Once you’ve designed the shape of the beam, you can set the laser to create the shape at different speeds - this is what’s referred to as shape frequency. The speed impacts the characteristics of a weld, and a less than optimal speed can cause defects such as spatter. Fast frequencies, like 50MhZ for example, is so fast that it behaves as a quasi-static shape and would produce a completely different result than a KHz or Hz frequency. As with beam shaping, the frequency can be changed easily so that you would be able to test different speeds to determine which works best for the particular needs of the material being processed. In some cases, it’s just the difference in frequency that can be all the change needed to drastically improve a weld. Beam Sequencing Beam sequencing adds another layer of flexibility, giving you the ability to switch between beam shapes in as fast as a microsecond. This means you can create a series of different shapes and program the laser to run through them in order, at different speeds, at intervals of your choice. The beam sequence you choose would, of course, depend on what you aim to achieve, but you will have the ultimate flexibility. Current solutions would necessitate using the minimum properties required to suit all of the materials. This would be an inefficient use of resources as the process would not be optimized for any of the materials. With beam sequencing, you can easily program the laser to change from one beam shape to the next as it moves through the different layers and the material changes. In this way, the process is optimized at each layer. Focus Steering Standard lasers have a short depth of focus that concentrates the vast majority of its heat on one point. This causes all other areas of the beam to be significantly cooler. This results in an inconsistent weld throughout the depth of the material(s). Single mode lasers have a larger depth of focus, and Dynamic Beam lasers are single mode lasers that can also steer the focus. Meaning, you can change the focal position on the Z axis within the material at any time and any speed during the process. Focus steering is especially beneficial when welding thicker materials, allowing for a smoother more consistent weld. As well as in laser cutting where it causes less roughness and dross. The Power of Flexibility DBL takes a powerful tool like a laser and rids it of some of its inherent rigidities, resulting in an even more powerful and extremely flexible tool for materials processing. The flexibility offered by DBL offers many benefits, including: Strong welds of crack-sensitive materials by generating different beam shapes with pre and post heating. Reduced pores and spatter via keyhole-stabilizing beam shapes. Stabilized keyholes even at very high speeds. Controlling properties of dissimilar materials using unlimited steering patterns. Efficient welding of asymmetric materials by accounting for the heat capacity of the different parts. Overall, it has the flexibility to quickly and easily adjust beam shape and beam frequency, create beam sequences and conduct focus steering that is the true game changer in materials processing. Dynamic Beam lasers put the power in your hands to test what has until now been accepted limitations. Want to learn more? Contact us on info@civanlasers.com

PRESS RELEASE Flexible fiber laser for rapid material processing Fraunhofer IWS Dresden tests thousand times faster beam shaping (Dresden, 07-21-2021) Laser experts from Saxony and Israel are jointly testing a novel laser for industrial use at the Fraunhofer Institute for Material and Beam Technology IWS in Dresden. The system is based on the “Coherent Beam Combining” (CBC) method, which is still new for high-power lasers. The 13-kilowatt laser can generate different energy distribution patterns particularly quickly during operation and thus process even demanding high-tech materials very precisely and quickly. The Fraunhofer researchers intend to make the innovative laser technology from Israel available to companies worldwide in the near future. Within a European network project, Fraunhofer IWS is already investigating the beam shaping, which is accelerated by a thousand times, for the first time for additive manufacturing together with the laser manufacturer Civan Lasers and A. Kotliar Laser Welding Solutions. The “Dynamic Beam” laser from Jerusalem has by now been installed at Fraunhofer IWS in Dresden. The institute is thus the first research facility worldwide to employ such a laser solution. Together with the project partner Civan Lasers, the scientists hope that the testing in Saxony will provide new application scenarios. “This laser will push the limits of materials processing, for example in medical technology and aerospace,” predicts Dr. Andreas Wetzig, who heads the Cutting and Joining technology field at Fraunhofer IWS. He refers to the Saxon-Israeli research project “ShapeAM” within the European network program “M-era.Net”, in which this new laser will play a central role and which started in July 2021. A thousand times faster In use is Coherent Beam Combining, in which the “Dynamic Beam Laser” from the Israeli company Civan Lasers combines tens of individual beams into a powerful laser beam with high quality. Through small phase shifts (Optical Phased Array = OPA) of the wave troughs and peaks in the partial beams, the laser can quickly generate completely different energy distribution patterns in the resulting processing laser beam: While a classic laser releases most of its energy only in the center of the beam, the system from Israel can generate energy patterns on the workpieces for instance in the form of a ring, a figure eight or a horseshoe. In principle, this was already possible in the past with beam-deflecting optics or fast oscillating mirrors. But even the fastest oscillating mirrors still need milliseconds to realign the energy patterns in the beam. The “Dynamic Beam Laser”, on the other hand, accomplishes this a thousand times faster, within microseconds. This speed makes it possible for the first time to use dynamic beam shaping for additive manufacturing of metals. As part of “ShapeAM”, researchers are testing the new CIVAN system to achieve improved material properties. Specifically, the aim is the additive manufacturing of titanium and aluminum alloys, such as those needed for space components, implants and lightweight components for mobility. In doing so, the partners plan to use dynamic beam shaping to eliminate defects and thus achieve higher quality 3D printing results. Dr. Eyal Shekel, CEO of Civan, is excited about the project: “ShapeAM makes it possible for us to explore the benefits of dynamic beam shaping in metal additive manufacturing.” Dr. Elena Lopez, department head of Additive Manufacturing at Fraunhofer IWS, adds: “We plan to use novel beam shapes and control frequencies that are not achievable with other methods to overcome challenges in crack-sensitive materials.” Lively exchange between Dresden and Jerusalem The joint project is expected to develop into a fruitful scientific and personnel exchange between Israel and Saxony: Fraunhofer IWS will forward the test results to Jerusalem. Also, it is planned to temporarily send exchange scientists to Israel. In return, the Civan experts are expected to conduct their own tests in the laser laboratory in Dresden. The tests at the Dresden institute are intended to determine the possibilities and limits of the “Dynamic Beam Laser”. Basic tests with various beam profiles, materials and processes are initially planned. After that, the researchers will evaluate concrete applications, such as how well the system can cut, join or additively manufacture diverse workpieces from materials and material composites that are otherwise difficult to process. “Dynamic Beam” doubles working speed It is already predictable that the new laser will allow faster and more precise control of the melt pool dynamics in many additive and joining processes – and not only across the surface, but also in depth. Fraunhofer IWS also expects advantages in laser cutting in terms of burr-free cuts with high edge quality – at twice the working speed compared to conventional fiber lasers. The test phase in Dresden will show whether the new laser will also meet these expectations in practice. In any case, the quality and speed advantages that are already becoming apparent make the technology highly interesting for use in metal-working industry, medical technology and electromobility, as well as in aerospace industry. Online webinar and conference offer insights into first results In a webinar on September 14, 2021, Fraunhofer IWS will present the “Dynamic Beam Laser” to partners from industry and research who are interested in the project. It will subsequently be possible to test the use of the CBC fiber laser for their own applications at Fraunhofer IWS. First findings from their test series the Fraunhofer scientists will present to a broader expert audience at the combined online event Laser Symposium/ISAM 2021 in Dresden from December 7 to 9, 2021. The “Dynamic Beam” laser from Jerusalem has now been installed at Fraunhofer IWS in Dresden. The institute is thus the first research institution worldwide to utilize such a laser solution. © Fraunhofer IWS Dresden Currently, Fraunhofer IWS laser experts are testing the novel Israeli laser “Dynamic Beam” for industrial use. © Fraunhofer IWS Dresden Thanks to “coherent beam combining”, the 13-kilowatt laser can generate energy distribution patterns thousands of times faster during operation compared to conventional mirror-based methods. This speed makes it possible for the first time to use dynamic beam shaping for additive manufacturing of metals. © Fraunhofer IWS Dresden The international team of researchers will investigate welding applications, including how to use the new laser system to achieve advantages in terms of processing speed and quality for comparable components such as the one pictured. © Fraunhofer IWS Dresden

This blog was written in conjunction with Florian Hugger from BBW Lasertechnik , the leading innovative laser material processing experts Automotive manufacturers use laser welding on a daily basis to create integral vehicle parts that must pass rigorous safety standards. Laser welding has proven to be very powerful in steelwork. However, as the automotive industry shifts to e-mobility, automotive parts use much more copper and aluminum for the required electronic components. The increased thermal conductivity and low absorption of those materials leads to distortions and defects in the final weld. Here are 5 main challenges in the automotive parts laser welding: Cracking in Metals Porosity High-Speed Welding Dissimilar Metals Asymmetric Parts Laser Welding with Dynamic Beam Lasers Cracking in Metals Especially when welding aluminium alloys and high-carbon steels, cracking is a common defect that renders parts unusable. Hot and cold cracks are formed when the laser makes the parts pull apart by thermal shrinkage, so what’s needed is a laser on either side of the weld in order to push the parts back together to counteract the shrinkage that would cause cracking. The current solution is to induce a second heat field, by using either an additional laser or via induction heating. (source Göbel, G: Erweiterung der Prozessgrenzen beim Laserstrahlschweißen heißrissgefährdeter Werkstoffe) A second laser is preferable because minimal heat is being used very locally, but a second laser is very expensive. Induction heating is more economical, but you must heat the entire part which means there is a huge amount of heat going into the material leading to high distortion. (source Göbel, G: Erweiterung der Prozessgrenzen beim Laserstrahlschweißen heißrissgefährdeter Werkstoffe) A lesser used solution are DOEs (diffractive optical elements). DOEs are inflexible and only offer one shape and movement in a single direction. To truly solve the challenge of cracking, we need a flexible laser that can provide a primary heat spot for the weld with two secondary heat spots keeping the metal pushed together. Porosity Porosity is caused by an unstable keyhole and the collapse of the vapor capillary. Different techniques are being tried in order to create a more stable keyhole and reduce porosity, but an ideal solution has yet to be found. (source Hohenberger B.: Laserstrahlschweißen mit Nd:YAG-Doppelfokustechnik) Oscillation with a scanner at a very high speed can work to stabilize the keyhole, but the shapes that can be used are inflexible. The most common shape for oscillation is a spiral, but it is not fast enough to prevent porosity and its inflexibility limits its potential. (source Fetzer et al.: Reduction of pores by means of laser beam oscillation during remote welding of AlMgSi) Another option to stabilize the keyhole is to try to open the keyhole at the top to improve degassing. This means changing the keyhole from an “I” shape to a “V” shape, which is currently done using multicore fibers. Similar to oscillation, this solution is inflexible because it can change the power of the inner and outer fiber cores, but cannot change the size or shape of the keyhole. (source Leimser, M: Strömungsinduzierte Einflüsse auf die Nahteigenschaften beim Laserstrahlschweißen von Aluminiumwerkstoffen) Finally, power modulation has also been tried as a way of stabilizing the keyhole. This solution is limited because it does not allow for varying levels of evaporation on either ends of the keyhole. Right now, we do not know what could be the best solution to prevent porosity because testing is limited by the inflexibility of the lasers. Once we can overcome this barrier and test various beam shapes and rotating heat spots, we will be able to test for an optimal solution. High-Speed Welding A higher speed of welding means a higher likelihood of defects. Usually, the weld is limited to a speed of ½ m/sec while anything above that causes humping and undercuts because the velocity of the melt is too high. 700 mm/s Single-spot (from BBW) The situation is slightly improved with double-fiber lasers because the additional heat source creates a larger melt pool which is slower and more stable. 700 mm/s Multi spot (source BBW) Beam oscillation with a scanner is not possible at such high speeds as in the low frequency the spiral stretches out and cannot serve its purpose. Here again, the inflexibility of today’s technology prevents the testing of new beam shapes and frequencies to find the optimal solution. Dissimilar Metals When welding metals of different types - i.e. aluminum and copper or copper and steel - the objective is a homogenous weld, but often the scanner is too slow to make this happen. When materials are intermixed improperly, the result is brittle faces and cracking, particularly when dealing with aluminum and copper. (source BBW) It is possible to weld dissimilar metals when both are very thin (0.5 mm). In this case, less power is needed and a scanner with smaller mirrors can go fast enough to create a solid weld. But, as soon as we are dealing with metals that are even 1 mm thick, a larger scanner would be needed which cannot move fast enough. Dynamic Beam Shaping would allow the use of 2 laser spots to move at the same time (similar to the movement of a kitchen mixer) and provide the homogenous weld that is needed. Asymmetric Parts When welding two pieces of different thicknesses (such as one machined part that is thick and one thin sheet metal), an asymmetric heat field is needed. Because such a thing does not exist, the solution is to use the amount of heat required for the thick part despite the fact that it is too much for the thin piece. The problem with this is that the more heat that is used, the more distortion there will be. This is a main reason why lasers are used for welding, in order to reduce the heat input. But, when there are asymmetric parts there is currently no solution that generates the right amount of heat for each part. A second challenge related to asymmetric parts is that of gap-bridging - when there is a gap between two parts that needs to be sealed. If, for example, the gap is 50 microns and the laser beam is also 50 microns, it will go straight through the middle and will not seal the edges. The way to solve this situation is either to use a larger laser spot or beam oscillation. (source Hohenberger B.: Laserstrahlschweißen mit Nd:YAG-Doppelfokustechnik) The problem arises when the parts differ and the gap sizes may be smaller or larger - current laser heads are not flexible to adjust for varying gap sizes. Laser Welding with Dynamic Beam Lasers Right now, laser welding is limited by rigid technology. Flexible beam shapes will allow for full testing of many creative solutions that today cannot even be attempted. Dynamic Beam Lasers provide the flexibility needed to solve these challenges: Beam Shaping – Using simple software, quickly and easily design any beam shape. Shape Frequency – Control the frequency of the beam shape from 400Hz –50MHz, which opens a new set of parameters to control the keyhole and melt pool. Shape Sequence – Design a sequence of shapes to maintain the desired shape orientation relative to the feed direction. Focus Steering – In addition to the inherent large depth of focus of the SM beam, shift the focus up to 50MHz without any mechanical components. Dynamic Beam Lasers are the next generation of lasers that will help manufacturers rise above these key welding challenges and produce high quality parts.

Civan Lasers has successfully completed the production of the world’s first 100kW Single Mode (SM) Continues Wave (CW) coherent beam combining (CBC) laser. CBC is a long-time known technology, however so far, Civan is the only company to offer CBC lasers for material processing. Civan is the first to scale up this technology and offer commercial products in a wide range of power levels, proving that it keeps challenging the impossible, and succeeds in doing so. It was only in 2018 that Civan announced its 14kW laser, and now, just three years later, it already expands its groundbreaki ng capabilities to 100kW – 10 times higher than the current competition in the market. The CBC technology is based on parallel amplification of a single seed signal that allows for coherent recombination, ramping the output power to a degree unobtainable by in-series amplifiers . A high-power single mode CBC laser opens the opportunity for innovative and highly useful capabilities. It can be used for welding of thick metals that are found in ships and submarines, and for decommissioning of nuclear plants. One of Civans 100kW CBC unique features that distinguishes it from any other current solution in the market, is its Dynamic Beam Shaping capabilities. This technology provides the ability to control beam shape, frequency, sequence and focus steering, thus allowing to receive a very high quality and defect-free outcome. Civan constantly keeps progressing and developing its technology, bringing new and advanced solutions to the material processing market. The 100kW CBC laser is a revolutionary achievement that sets a very important milestone in that sphere. From now on - only the sky is the limit. About Civan Advanced Technologies: Civan Lasers. was established in 2008 and is the only company to offer industrial lasers based on Coherent Beam Combining technology. Civan's high power lasers are integrated into industrial material processing systems in the fields of cutting, welding, metal additive manufacturing and drilling.