James J. Morehead

1.2-kW single-mode fiber laser based on 100-W high-brightness pump diodes

We have demonstrated a monolithic (fully fused), 1.2-kW, Yb-doped fiber laser with near-single-mode beam quality. This laser employs a new generation of high-brightness, fiber-coupled pump sources based on spatially multiplexed single emitters, with each pump providing 100 W at 915 nm within 0.15 NA from a standard 105/125 μm fiber. The fiber laser is end pumped through the high-reflector FBG using a 19:1 fused-fiber pump combiner, eliminating the need for pump/signal combiners. The output wavelength is 1080 nm, with a linewidth of < 0.5 nm FWHM. A peak power of 1.5 kW was reached in modulated operation (1-ms pulse duration) with M2 < 1.2.

Intrinsic reduction of the depolarization in Nd:YAG crystals

The output power of linearly polarized Nd:YAG lasers is typically limited by thermally induced birefringence, which causes depolarization. However, this effect can be reduced either by use of some kind of depolarization compensation or by use of crystals which are cut in [110]- and [100]-direction, instead of the common [111]-direction. Investigations of the intrinsic reduction of the depolarization by use of these crystals are presented. To our knowledge, this is the first probe beam-experiment describing a comparison between [100]-, [110]- and [111]-cut Nd:YAG crystals in a pump power regime between 100 and 200 W. It is demonstrated that the depolarization can be reduced by a factor of 6 in [100]-cut crystals. The simulations reveal that a reduction of depolarization by use of a [110]-cut crystal in comparison with a [100]-cut crystal only becomes possible at pump powers in the kW region. Analysis also shows that the bifocusing for [100]-cut is slightly smaller and more asymmetrical than for [111]-cut.

Fused fiber pump and signal combiners for a 4-kW ytterbium fiber laser

We report the development of fused-fiber pump and signal combiners. These combiners are enabling components of a ytterbium fiber-laser emitting 4 kW of 1080-nm radiation. The fiber-laser system consists of seven fiber laser modules and a 7:1 signal combiner. The laser modules are end-pumped by 90 915-nm JDSU L4 diode-lasers, yielding a nominal pump power of 900 W. The diode laser radiation is coupled into the laser fiber through a 91:1 fused-fiber pump combiner. The input fibers of this pump combiner are standard 105/125-um multimode fibers with an NA of 0.22. These fibers form a hexagonally packed fused-fiber bundle, which is tapered to match the cladding diameter of the laser fiber. Eighty-six percent of the light exiting the pump-combiner is emitted within an NA of 0.32, and all measurable power is emitted within an NA of 0.45. The typical insertion loss of the pump combiners is <1%. The high-brightness radiation of seven laser modules is combined into a single output fiber using a 7:1 fused-fiber signal combiner providing a total power of >4 kW in the single output beam. The beam parameter product of the combined output was 2.5 mm-mrad. The low insertion loss of < 2% indicates that the signal combiner is suitable to handle even higher laser powers.

3-Watt blue source based on 914-nm Nd:YVO 4 passively-Q-switched laser amplified in cladding-pumped Nd:fiber

A cladding-pumped Nd:silica fiber with a fundamental-mode cut-off near 1000 nm was used to build an amplifier with gain over a range near 920 nm. Pulses from an Nd:YVO4 passively Q-switched laser were amplified and then frequency doubled in LBO to produce blue with 3-W average power.

4-kW fiber laser for metal cutting and welding

We have developed a commercial 4-kW fiber laser consisting of seven, 600-W modules whose outputs are combined with a fused-fiber combiner. The system architecture has several practical advantages, including pumping with reliable single-emitter diodes, monolithic fused-fiber construction (no free-space beams), and end pumping using a 91:1 pump combiner (eliminating the need for complex pump/signal combiners). Typical results at 4-kW output power are a beamparameter product of 2.6 mm-mrad, 8-hr power stability of < 0.5% rms, central wavelength of 1080 nm, and linewidth of 1.2 nm FWHM. These lasers have been incorporated into Amada machines used for cutting metal sheet and plate and have been used to cut aluminum, mild steel, stainless steel, brass, titanium, and copper with a thickness up to 19 mm. A world-record cutting speed of 62 m/min has been demonstrated for 1-mm aluminum sheet metal.

Nearly circular pump guides

How nearly circular can a double-clad fibers pump guide be and still have good absorption in the core? Ds and octagons have good absorption but can be hard to cleave and lose pump power or brightness through splices with circular fibers. Ray tracing cannot be trusted since the perturbations to the circle can be smaller than a transverse wavelength. Using an algorithm well suited to near-circular boundaries, we have computed statistics of core-overlap of the lowest 10,000 modes of many pump-guide shapes. Some with 3% radial modulation have nearly as good core-overlap as an octagon.

Q-switched fiber lasers with controlled pulse shape

We report on the pulse shape of an actively Q-switched fiber laser. This master oscillator power amplifier architecture generates pulses with multiple peaks due to its intrinsic dynamics. Modeling and experimental results provide us a detailed understanding of the relative importance of the different time constants on the dynamics of the laser, which allows us to define optimized design parameters that lead to smooth and controlled pulse shapes. This solution is simple and robust; operation over a broad range of repetition rate and output power is achieved without any adjustment of the laser settings, and the corresponding variation of the optical performances is minimal.

Advances in high-power harmonic generation: Q-switched lasers with electronically adjustable pulse width

We demonstrate a variable pulse width, internally-frequency-converted, near-diffraction-limited Nd:YAG laser with output power up to 40 Watts at 532 nm and pulse widths electronically adjustable over a 40-300 ns range. The variable pulse width is achieved by clipping the pulse decaying edge with the Q-switch in a laser cavity optimized for post-pulse gain insensitivity. This approach makes possible frequency converted lasers with pulse width and output power substantially independent of repetition rate.

Compensation of Laser Thermal Depolarization Using Free Space

Stress-induced birefringence in a single-transverse-mode YAG laser is well compensated simply by having the end mirror one Rayleigh range away from the gain.

Measurement techniques for laser parameters relevant to materials processing

Many micromachining operations, particularly in the electronics sector, utilize pulsed solid-state UV lasers. These processes demand high levels of stability, as the yield and quality relate directly to the repeatability of each laser pulse. Critical stability issues arise with single-pulse processes (e.g. repair), situations requiring bursts of pulses (e.g. drilling), and continuous pulsing applications (e.g. cutting). To realize optimal stability specific design choices must be made, certain transient problems must be solved, and pulse energy measurements must be standardized. Solid-state UV lasers originate as infrared lasers, and nonlinear optics converts the infrared to the UV. This conversion introduces instability. Performing the conversion within the infrared laser cavity suppresses the instability, relative to performing the conversion outside of the laser cavity. We explain this phenomenon. Ideally, a versatile and stable solid-state laser can generate pulses in many formats. Thermal effects tend to prevent this versatile ideal, resulting in transient problems (unstable pulse trains), or less than optimal performance when the laser is pulsing continuously. Many methods of measuring pulse energy exist. Each method can produce surprisingly different results. We compare various techniques, discuss their limitations, and suggest an easily implemented pulse energy stability measurement.