Analytical modeling and characterization of ring beam profiles for high-power lasers used in industrial manufacturing

Active fibre lasers are widely used in the industry for different manufacturing applications ranging from cutting, to welding and additive manufacturing. The recent introduction of the multiple-core fibre lasers allows these sources to flexibly change the Power Density Distribution (PDD) from conventional Gaussian profiles towards ring shapes. While the advantages of the novel beam shapes over the conventional ones are still being explored, the need for modeling tools to define the PDD shapes becomes more evident. This work studies the analytical modeling of Gaussian to ring profiles with the aim to move towards standardized parameters referable to the manufacturing processes. The proposed models combine Gaussian and annular components to define the novel beam shapes. Among the different models assessed, the Torus and Multi-Gaussian approaches exhibited the best fitting quality thus enabling the definition of descriptive metrics of the PDD. The modeling framework developed was validated on an industrial Laser Powder Bed Fusion (LPBF) system with a double-core light source. The beam shape variation along the propagation axis was assessed to analyze the effect of defocusing using the developed beam parameters. Eventually, the best performing model was furtherly validated with a bead on plate experiment to explain how the model coefficients can be jointly exploited to predict the material response using a Gaussian or a ring beam profile.