Design of a 10 kW level diode laser optical stack with a line shape beam spot

Zhiyong Dong; Zhiyong Dong; Zhiyong Dong; Guyi Lin; Guyi Lin; Guyi Lin; Pengfei Zhao; Pengfei Zhao; Xuechun Lin; Xuechun Lin; Xuechun Lin; Xuechun Lin

doi:10.1364/AO.382484

Applied Optics
Vol. 59,
Issue 8,
pp. 2319-2324
(2020)
•https://doi.org/10.1364/AO.382484

Design of a 10 kW level diode laser optical stack with a line shape beam spot

Zhiyong Dong, Guyi Lin, Pengfei Zhao, and Xuechun Lin

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Zhiyong Dong, Guyi Lin, Pengfei Zhao, and Xuechun Lin, "Design of a 10 kW level diode laser optical stack with a line shape beam spot," Appl. Opt. 59, 2319-2324 (2020)

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Abstract

We designed and simulated a diode laser with output power of more than 10 kW and a line shape beam spot of approximately ${14 - 58}\;{\rm mm} \times {1.6}\;{\rm mm}$ (${{\rm 1/e}^2}$ width). The diode laser was assembled with high fill factor diode laser bars that can be cooled with filtered tap water. The diode laser bar was beam shaped with a tilted cylindrical lens array to twist the slow axis of individual emitters by 90 deg, and then the slow axis was collimated with a single cylindrical lens. From the simulation, 20 laser diode bars with the same wavelength formed a diode laser optical stack with an output power of more than 3.5 kW, a beam spot of ${31}\;{\rm mm} \times {12}\;{\rm mm}$ size, and full divergence angles of around 6 mrad in both the horizontal and vertical directions. Then, three laser diode optical stacks with different wavelengths were wavelength-multiplexed to obtain an output power of more than 10 kW. Finally, the diode laser optical stack was transformed by simple cylindrical lenses to form a line shape spot with a working distance longer than 250 mm. Our diode laser design is much simpler than previous devices with similar output power and can find various applications such as high-speed laser cladding.

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Parameter	Value
Output power	200 W, CW
Central wavelength	$940 n m \pm 5 n m$ at 25°C
	$980 n m \pm 5 n m$ at 25°C
	$1020 n m \pm 5 n m$ at 25°C
TE polarization	$> 94 %$
Number of emitters	25
Emitter size	200 µm
Fill factor	50%
Fast-axis full divergence angle of raw bar	$< 42 d e g$ (95% energy)
Slow-axis full divergence angle of raw bar	$< 6.5 d e g$ (95% energy) Emitter far-field intensity distribution of Gaussian

Parameter	Value
Material	S-TIH53 (Ohara)
EFL of FAC lens at 808 nm	0.365 mm
Back focal length at 808 nm	0.095 mm
Length of biconvex lens	1.65 mm
Radius of curvature of cylindrical surface	0.37 mm
Gap between the FAC lens and the biconvex lens array	0.05 mm
Pitch	0.4 mm

Mirrors	Specifications
Half-wave plate	$R < 0.25 %$ at 940 nm, 980 nm or 1020 nm (per surface)
Thin-film polarizer	45° angle incidence, Extinction $r a t i o > 1000 : 1$
HR mirror	$R > 99.8 %$ at 900–1100 nm, 45° angle of incidence
Dichroic mirror (2)	$R > 99.5 %$ at 980 nm & 1020 nm, $R < 3 %$ at 940 nm, 45° angle of incidence
Dichroic mirror (1)	$R > 99.5 %$ at 980 nm, $R < 3 %$ at 1020 nm, 45° angle of incidence
Vertical direction cylindrical telescope lenses	$R < 0.2 %$ at 900–1100 nm, 0° angle of incidence, $f = - 50 m m$ , $f = - 100 m m$ , $f = 250 m m$
Horizontal direction cylindrical lens	$R < 0.2 %$ at 900–1100 nm, 0° angle of incidence, $f = 300 m m$

Parameter	Value
Output power	200 W, CW
Central wavelength	$940 n m \pm 5 n m$ at 25°C
	$980 n m \pm 5 n m$ at 25°C
	$1020 n m \pm 5 n m$ at 25°C
TE polarization	$> 94 %$
Number of emitters	25
Emitter size	200 µm
Fill factor	50%
Fast-axis full divergence angle of raw bar	$< 42 d e g$ (95% energy)
Slow-axis full divergence angle of raw bar	$< 6.5 d e g$ (95% energy) Emitter far-field intensity distribution of Gaussian

Parameter	Value
Material	S-TIH53 (Ohara)
EFL of FAC lens at 808 nm	0.365 mm
Back focal length at 808 nm	0.095 mm
Length of biconvex lens	1.65 mm
Radius of curvature of cylindrical surface	0.37 mm
Gap between the FAC lens and the biconvex lens array	0.05 mm
Pitch	0.4 mm

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Applied Optics