Publications

Multi-kilowatt Nd:YAG lasers provide an appealing solution for aluminum laser welding applications due to increased bulk absorption and ease of beam delivery as compared to high power CO{sub 2} laser systems. However, high numerical aperture optics are required to overcome the relatively poor beam quality associated with these lasers and to achieve a high irradiance. Several lens designs have been developed and evaluated to achieve the high irradiance values required to provide good coupling into aluminum alloys. The results of these tests demonstrate that near diffraction limited performance can be achieved for high numerical aperture elements. Additionally, an inverse-telephoto lens design has been developed and characterized to further demonstrate the feasibility of producing a high irradiance with a functional working distance from the weld surface.

To investigate the feasibility of producing a compact, efficient blue laser source, pumped-cavity second harmonic generation of diode lasers was explored. It is desirable to have such lasers to increase optical disk storage density, for color displays and for under-the-sea green-blue optical signal transmission. Based on assumed cavity losses, a cavity was designed and numerical analysis predicted an overall conversion efficiency to the second harmonic wavelength of 76% from a 75 mW diode laser. The diode laser used in these experiments had a single longitudinal and a single transverse mode output at 860 nm. The best conversion efficiency obtained (26%) was less than optimum due to the 2.5% single-pass linear losses associated with the cavity. However, calculations based on these higher losses are in good agreement with the experimentally determined values. In additions, a factor of 1.65 increase in the second harmonic output power is anticipated by reducing the input mirror reflectivity to better impedance-match the cavity. With this relatively low second harmonic conversion, the power to light conversion is 7.8%.

The high conductivity provided by solder closure joints of component housings is sometimes required to ensure electrical shielding of the components contained within. However, using a soldering iron to produce the solder joints can lead to charring of the insulating materials within the housing. To overcome this problem, the localized heating characteristics of laser soldering can be exploited. Feasibility of laser soldering Sn plated brass housings with a CW Nd:YAG laser has been investigated. It has been determined that laser soldering of these housings using a low solids solder flux is a viable technique and will minimize the amount of heat input to the enclosed electronic components. Metallographic analysis has shown good wetting of the solder on the housing components. Accelerated aging experiments indicate that no significant corrosion potential due to solder flux residues exists. Although a low solids flux was used to make the joints, initial results indicate that a fluxless technique can be developed to eliminate fluxes completely.