Ultra-short pulsed laser welding - an industrially-relevant manufacturing tool for bonding IR and visible optical materials

Lead Research Organisation: Heriot-Watt University
Department Name: Sch of Engineering and Physical Science

Abstract

Bonding optical materials (glasses, crystals) to other optical or structural materials (metals, ceramics) is a key manufacturing challenge for many optical devices, as clearly articulated by our industrial partners. Our solution is to use an ultra-short pulsed laser welding process that has shown great promise but currently requires many months or even years of detailed experiments for each new material combination and geometry. Hence applications are currently limited to components made from borosilicate glasses or quartz welded to aluminium alloys and stainless steel, of typical dimension 10 mm.

In this project our drive is to extend the process to new combinations of materials (including important IR materials) and shapes. To achieve this, the project will take a multi-pronged approach: (i) to create the modelling and sensing tools essential for rapid process optimisation; (ii) to engineer a new optimised laser source based on emerging 2 micron wavelength technologies, pioneering the welding process for IR optical materials; (iii) to research concepts for engineering the interface and weld/joint geometry to reduce the impact of differential thermal properties of the two materials; and (iv) to investigate scaleable welding approaches for larger parts e.g. continuous meander patterns and dynamic clamping. Finally, we will undertake a series of proof-of-principle experiments to determine the suitability of the process with a wide range of material combinations, directed towards our industrial partners' applications.

Our programme of manufacturing research is aligned with the interests of our industrial collaborators, together with the academic drivers of laser material interaction knowledge, process understanding and process control. Our ultimate goal is to develop this welding process into a truly flexible and generic solution for joining optical to structural materials at a range of scales.
 
Description Important results have been achieved comparing the welding process of quartz to different metals, that serve to provide a guide to material combinations that are likely to work or otherwise.
Exploitation Route They are most likely to be taken forwards by the manufacturers of complex optical systems.
Sectors Aerospace

Defence and Marine

Healthcare

Manufacturing

including Industrial Biotechology

 
Description Smart Products Made Smarter
Amount £2,670,178 (GBP)
Funding ID EP/X025365/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 09/2023 
End 09/2028
 
Description Collaboration with the Technical University of Darmstadt on Vacuum insulated Glazing 
Organisation Technical University of Darmstadt
Country Germany 
Sector Academic/University 
PI Contribution We have laser welded glass samples to simulate the welding of glass spacers between 2 sheets of window glass, to hold the glass sheets apart when the gap is evacuated.
Collaborator Contribution Testing of welded parts; technical advice; detailed knowledge of the application
Impact A paper has been submitted to a conference, Laser Precision Microfabrication (LPM) 2024. Currently awaiting on result. A journal paper is currently being drafted.
Start Year 2022
 
Description Industry collaboration to support project (Glass Technology Services) 
Organisation Glass Technology Services
Country United Kingdom 
Sector Private 
PI Contribution Access to results from the project at quarterly review meetings. Undertaking ultrashort pulsed laser welding trials on material combinations of particular interest to the company, using glass supplied by them.
Collaborator Contribution Specialist glass material that is not available commercially; modelling code from previous project; advice and guidance.
Impact Results from welding speciality glass samples provided by GTS. These results have been communicated by GTS to relevant customers.
Start Year 2021
 
Description Industry collaboration to support project (Leonardo) 
Organisation Leonardo MW Ltd.
Country United Kingdom 
Sector Private 
PI Contribution Testing the ultra-short pulsed laser welding process on material combinations of particular interest to the company.
Collaborator Contribution Provision of advice about results and potential applications
Impact Detailed information about the ultra-short pulsed laser welding process and how it could be applied to the Leonardo's manufacturing applications.
Start Year 2021
 
Description Industry collaboration to support project - Oxford Lasers 
Organisation Oxford Lasers Ltd
Country United Kingdom 
Sector Private 
PI Contribution The research team have provided access to our research results, also we have committed to testing materials of particular interest to the partner
Collaborator Contribution Detailed advice with regards to project progress; the topic of the project is similar to separate work being carried out by the partner and hence they are in a position to be able to advise on results and the scientific understanding underlying them; also to suggest potential solutions to problems.
Impact Results of welding new material combinations
Start Year 2021
 
Description RTO contribution to the project (Manufacturing Technology Centre) 
Organisation Manufacturing Technology Centre (MTC)
Country United Kingdom 
Sector Private 
PI Contribution Testing the ultra-short pulsed laser welding process on material combinations of particular interest to the MTC
Collaborator Contribution Provision of advice on project results; links to potential end-users
Impact Access to detailed results arising from the project; feedback on specific materials and their suitability for the ultra-short pulsed laser welding process.
Start Year 2021
 
Description RTO research collaboration (IWS Dresden) 
Organisation Fraunhofer Institute for Material and Beam Technology
Country Germany 
Sector Public 
PI Contribution Provision of samples for testing with DLIP patterning for subsequent laser welding
Collaborator Contribution DLIP laser patterning of our samples
Impact No outputs yet
Start Year 2023