Manufacturing difficulties
Most laser processing failures are not power failures, but stability failures.
In deep penetration welding, the steam cavity (small hole) supports the deep penetration. This cavity is essentially located in dynamic.
As the beam interacts with the molten metal, it will open, collapse, and oscillate.
On easily processed materials, this instability can still be managed;
This is not the case for difficult to process materials.
Figure 1 — An unstable keyhole ejects spatter and produces inconsistent results
copper
copper At commonly used laser wavelengths reflectance Very high, and thermal conductivity
Extremely high. Small holes are difficult to form and prone to collapse, resulting in splashes and pores.
aluminium
aluminium Easy to generate hydrogen pores and thermal cracks, and its reflectivity makes early pores Unstable transformation.
Heterogeneous joint
Heterogeneous joints (such as copper aluminum)Forming within a narrow process window Intermetallic compounds Extremely sensitive to any fluctuations.
Thin walled heat dissipation structure
Thin walled heat dissipation components (cold plate, manifold) Require sufficient fusion to achieve sealing without deformation, channel intrusion, or burning through.
Common crux
The common crux lies in Uncontrolled flow of molten pool
When the flow is chaotic, the process window narrows and defects increase, under the same nominal parameters
The results of each component are inconsistent.
The high value of copper is precisely the reason for the rapid collapse of its small pores
One sentence definition of FRM
FRM=Flow Regulation Mode=Pool Flow Control Mode
GW FRM Laser is a GW laser Beam shaping welding product family——Real time control through independently adjustable center beam and ring beam Molten pool flow, stable lock hole, and suppression of splashing
Realize copper/aluminum, etc splash free deep penetration welding of high reactive materials.
core idea
FRM does not provide ordinary Gaussian spots. It is welded directly Single mode light source give Triple clad fiber
Provide clear and concise information Core+ring energy Distribution, forming a factory defined energy distribution rather than a fixed beam shape.
FRM is not something
Figure 2 — Beam intensity cross-sections compared: single-mode Gaussian, broad multi-mode, and FRM's factory-defined core-and-annular distribution (illustrative).
FRM does not claim that the process can achieve "zero splashing". It aims to Reduce splash risk and improve consistency
The actual results always depend on Materials, joints, parameters and testing.
FRM cannot replace Reasonable joint design, assembly control, or process validationIt expands and Stable process window
But it will not replace engineering specifications.
FRM Not limited to a single application Welding and cutting are currently the priority applications. This platform can be extended to other material processing tasks, provided that GW Laser can establish clear Process value And validate it on representative samples.
FRM (Flow Regulation Mode) It is the controlled beam profile of GW laser product platform
The design intention is Regulating the flow of small holes and molten pool Make the process on difficult to process materials Stable and reproducible.
single mode | multimodal | FRM | |
Beam quality | high | lower | high (Controlled profile) |
energy distribution | Fixed Gauss | Broad/Fixed | Factory definition; controlled |
On difficult to process materialssmall hole | instable; There is a risk of splashing | Low density;Weak control | Controlled;stable |
Core Value | Fine features | Thick plate tolerance | stable; Repeatable results |
Application Guide
FRM is applied in situations where melt pool regulation can create measurable value. Its expression varies depending on the application and is consistent with the positioning of GW laser.
Copper welding
Copper is the most typical application. Its application scenarios includeElectric vehicle battery busbarWith terminals、Card issuing and flat wire motor connector, Power electronic components, and Data center/AI infrastructure cooling hardware (cold plates, connectors).
In situations where the reflectivity and thermal conductivity of copper make small holes unstable, FRM aims to Regulating the flow of the molten pool and reducing the risk of splashing In the areas with the highest fluctuation cost - low and stable joint resistance, primary yield, and sealed heat dissipation components - its value is most prominent.
Aluminum welding
aluminum Pores and thermal cracking sensitivity Making consistency the primary challenge.
The flow regulation of FRM supports more uniform solidification and smoother melting depth, which helps to mitigate fluctuations in mass production Maintain the process window.
Cut
In terms of cutting, FRM uses Positioning based on customer achievements, rather than a general list of functions: cutting quality and edge quality, cutting speed, cutting behavior and process window width. Each material and thickness must be validated.
The contribution of FRM needs to be compared Specific cutting quality give Capacity target To evaluate.
Beyond welding and cutting
Due to FRM being a Beam profile platform Other material processing applications can also be explored, as long as there are clear process issues, value assumptions are defined, and the results can be validated on representative samples. GW Laser will not use its claimed sleeve, which is only suitable for welding, for other applications.
Stable process window
in the final analysis, The core value of FRM lie inStability and repeatability
A product that can be maintained throughout the entire batch production
A wider and more predictable process window.
For copper, aluminum, dissimilar joints, and thin-walled heat dissipation components, this stability is often Laboratory process and production line process
The difference between them.
If you wish to evaluate the applicability of FRM in your own application, it is recommended to Acceptance criteria and authentic materials
Get started -let process window tell you if FRM truly lives up to its name.
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