Universität Stuttgart
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Item Open Access Process limits for percussion drilling of stainless steel with ultrashort laser pulses at high average powers(2022) Brinkmeier, David; Holder, Daniel; Loescher, André; Röcker, Christoph; Förster, Daniel J.; Onuseit, Volkher; Weber, Rudolf; Abdou Ahmed, Marwan; Graf, ThomasThe availability of commercial ultrafast lasers reaching into the kW power level offers promising potential for high-volume manufacturing applications. Exploiting the available average power is challenging due to process limits imposed by particle shielding, ambient atmosphere breakdown, and heat accumulation effects. We experimentally confirm the validity of a simple thermal model, which can be used for the estimation of a critical heat accumulation threshold for percussion drilling of AISI 304 steel. The limits are summarized in a processing map, which provides selection criteria for process parameters and suitable lasers. The results emphasize the need for process parallelization.Item Open Access Analytical model for the depth progress of percussion drilling with ultrashort laser pulses(2021) Holder, Daniel; Weber, Rudolf; Graf, Thomas; Onuseit, Volkher; Brinkmeier, David; Förster, Daniel J.; Feuer, AnneA simplified analytical model is presented that predicts the depth progress during and the final hole depth obtained by laser percussion drilling in metals with ultrashort laser pulses. The model is based on the assumption that drilled microholes exhibit a conical shape and that the absorbed fluence linearly increases with the depth of the hole. The depth progress is calculated recursively based on the depth changes induced by the successive pulses. The experimental validation confirms the model and its assumptions for percussion drilling in stainless steel with picosecond pulses and different pulse energies.Item Open Access Influence of pulse duration on X-ray emission during industrial ultrafast laser processing(2022) Holland, Julian; Weber, Rudolf; Sailer, Marc; Graf, ThomasSoft X-ray emissions during the processing of industrial materials with ultrafast lasers are of major interest, especially against the background of legal regulations. Potentially hazardous soft X-rays, with photon energies of >5 keV, originate from the fraction of hot electrons in plasma, the temperature of which depends on laser irradiance. The interaction of a laser with the plasma intensifies with growing plasma expansion during the laser pulse, and the fraction of hot electrons is therefore enhanced with increasing pulse duration. Hence, pulse duration is one of the dominant laser parameters that determines the soft X-ray emission. An existing analytical model, in which the fraction of hot electrons was treated as a constant, was therefore extended to include the influence of the duration of laser pulses on the fraction of hot electrons in the generated plasma. This extended model was validated with measurements of H (0.07) dose rates as a function of the pulse duration for a constant irradiance of about 3.5 × 1014 W/cm2, a laser wavelength of 800 nm, and a pulse repetition rate of 1 kHz, as well as for varying irradiance at the laser wavelength of 1030 nm and pulse repetition rates of 50 kHz and 200 kHz. The experimental data clearly verified the predictions of the model and confirmed that significantly decreased dose rates are generated with a decreasing pulse duration when the irradiance is kept constant.Item Open Access Local vaporization at the cut front at high laser cutting speeds(2020) Bocksrocker, Oliver; Berger, Peter; Kessler, Steffen; Hesse, Tim; Rominger, Volker; Graf, ThomasHigh-speed videos of the cut front and spectrometric measurements were applied to detect local vaporization on the cut front at high cutting speeds to show that with increasing feed rate, temporally short and intense flashes are generated by vaporization phenomena on the upper part of the cut front. The latter are accompanied by the emergence of an interrupted striation pattern on the surface of the cutting edge. The findings support the assumption that local vaporization at the cut front might be the cause for reduced quality of the cutting process at elevated cutting speeds. The observation of vaporization serves as a diagnostic method to anticipate a fail cut and the interrupted striation pattern.Item Open Access Sapphire-based resonant waveguide-grating mirrors : advancing their intra-cavity power density capability(2023) Bashir, Danish; Boubekraoui, Ayoub; Mourkioti, Georgia; Li, Fangfang; Karvinen, Petri; Kuittinen, Markku; Mackenzie, Jacob. I.; Graf, Thomas; Abdou Ahmed, MarwanWe report on the design, fabrication, and implementation of a single-layer resonant waveguide-grating (RWG) mirror on a sapphire substrate. Our goal is to enhance these optics capability to withstand high intra-cavity power densities by exploiting the superior thermal properties of sapphire. The RWG was implemented as an intra-cavity folding mirror in an Yb:YAG thin-disk laser to generate linearly polarized and spectrally stabilized radiation. A linearly polarized output power of 191 W with an optical efficiency of 39% was obtained in multi-mode operation. This corresponds to a power density of 52 kW/cm 2 on the RWG, for which the increase of its surface temperature was measured to be 12 K, which resulted in a 46-fold reduction of the surface temperature rise dependence on the intra-cavity power density with respect to what has been reported for a RWG on a fused silica substrate. In near fundamental-mode operation, a linearly polarized emission with an output power of 90 W, an optical efficiency of 30%, and a spectral bandwidth of 28 pm FWHM was obtained.Item Open Access Synchrotron X-ray analysis of the influence of the magnesium content on the absorptance during full-penetration laser welding of aluminum(2021) Wagner, Jonas; Hagenlocher, Christian; Hummel, Marc; Olowinsky, Alexander; Weber, Rudolf; Graf, ThomasItem Open Access First thin-disk oscillator with ceramic Yb:LuScO3 in comparison to the operation with ceramic Yb:Lu2O3(2024) Esser, Stefan; Jing, Wei; Xu, Xiaodong; Graf, Thomas; Abdou Ahmed, MarwanWe report on the characterization and first laser operation of ceramic Yb:LuScO3 in a thin-disk oscillator. The optical performance achieved with a ceramic Yb:LuScO3 disk is compared to the one obtained with an existing ceramic Yb:Lu2O3 disk for reference. The characterization covers the measurement of the fluorescence spectra, the fluorescence lifetimes, and nomarsky imaging. The investigation on the laser operation covers the measurement of resonator losses, output powers, and thermal behavior during continuous-wave operation in a multimode thin-disk oscillator. An average output power of 149 W and a slope efficiency of 51.8% were achieved with the ceramic Yb:LuScO3 disk which reached a maximum surface temperature of about 150 °C. At the same temperature level, a disk made of the already established ceramic Yb:Lu2O3 delivered 957 W of output power with a slope efficiency of 75.7%.Item Open Access Single-crystal and ceramic Yb:Lu2O3 gain media for thin-disk oscillators(2023) Esser, Stefan; Xu, Xiaodong; Wang, Jun; Zhang, Jian; Graf, Thomas; Abdou Ahmed, MarwanWe report on the direct comparison of single-crystal and ceramic Yb3+:Lu203 gain media with respect to emission spectra, fluorescence lifetime, depolarization, and laser performance in a continuous-wave thin-disk laser oscillator. The most efficient laser operation was achieved with a single-crystal disk in multimode operation with a slope efficiency of 72.1% and an average output power of 997 W. At the same temperature level, a ceramic disk delivered 861 W with a slope efficiency of 68.6%. In fundamental-mode operation, the highest average power of 360 W and highest optical efficiency of 41.3% were obtained with a ceramic disk. For the single-crystal disk, the fundamental-mode output power was limited to 113 W at an optical efficiency of 29%, potentially due to stress within the crystal.Item Open Access Adjustment of the geometries of the cutting front and the kerf by means of beam shaping to maximize the speed of laser cutting(2023) Lind, Jannik; Hagenlocher, Christian; Weckenmann, Niklas; Blazquez-Sanchez, David; Weber, Rudolf; Graf, ThomasThe shape of the laser beam used for fusion cutting significantly influences the geometry of both the cutting front and the cutting kerf. The angle of the cutting front in turn impacts the local absorptivity, while the width of the kerf defines the amount of material, which has to be molten. The kerf’s geometry therefore determines the maximum possible cutting speed at which a successful cut is feasible with a given available laser power. The absorptivity, the width of the kerf, and the maximum possible cutting speed can be estimated from a simple model considering the conservation of energy and rough geometrical approximations. In order to verify the prediction of the model, the geometry of the cutting front and kerf resulting from different processing conditions was observed by means of online high-speed X-ray diagnostics. The geometry of the interaction zone was recorded with a framerate of 1000 Hz during fusion cutting of 10-mm-thick samples of stainless steel. Comparing the results obtained with different shapes of the laser beam, it was found that the absorptivity is increased when the beam’s longitudinal cross-section (parallel to the feed) is enlarged. Reducing the width of the beam in the transversal direction normal to the feed reduces the cross-sectional area of the cutting kerf. The findings show a good agreement with the geometric model which enabled the prediction of the absorptivity and the cross-sectional area of the cutting kerf and hence allows to reliably estimate the maximum cutting speed for different shapes of the laser beam, laser power, and sheet thicknesses.Item Open Access Uncertainties and robustness with regard to the safety of a repository for high-level radioactive waste : introduction of a research initiative(2024) Kurgyis, Kata; Achtziger-Zupančič, Peter; Bjorge, Merle; Boxberg, Marc S.; Broggi, Matteo; Buchwald, Jörg; Ernst, Oliver G.; Flügge, Judith; Ganopolski, Andrey; Graf, Thomas; Kortenbruck, Philipp; Kowalski, Julia; Kreye, Phillip; Kukla, Peter; Mayr, Sibylle; Miro, Shorash; Nagel, Thomas; Nowak, Wolfgang; Oladyshkin, Sergey; Renz, Alexander; Rienäcker-Burschil, Julia; Röhlig, Klaus-Jürgen; Sträter, Oliver; Thiedau, Jan; Wagner, Florian; Wellmann, Florian; Wengler, Marc; Wolf, Jens; Rühaak, WolframThe Federal Company for Radioactive Waste Disposal (BGE mbH) is tasked with the selection of a site for a high-level radioactive waste repository in Germany in accordance with the Repository Site Selection Act. In September 2020, 90 areas with favorable geological conditions were identified as part of step 1 in phase 1 of the Site Selection Act. Representative preliminary safety analyses are to be carried out next to support decisions on the question, which siting regions should undergo surface-based exploration. These safety analyses are supported by numerical simulations building on geoscientific and technical data. The models that are taken into account are associated with various sources of uncertainties. Addressing these uncertainties and the robustness of the decisions pertaining to sites and design choices is a central component of the site selection process. In that context, important research objectives are associated with the question of how uncertainty should be treated through the various data collection, modeling and decision-making processes of the site selection procedure, and how the robustness of the repository system should be improved. BGE, therefore, established an interdisciplinary research cluster to identify open questions and to address the gaps in knowledge in six complementary research projects. In this paper, we introduce the overall purpose and the five thematic groups that constitute this research cluster. We discuss the specific questions addressed as well as the proposed methodologies in the context of the challenges of the site selection process in Germany. Finally, some conclusions are drawn on the potential benefits of a large method-centered research cluster in terms of simulation data management.