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Experiments using high average power (HAP) diode-pumped solid state lasers (DPSSL), reveal cross-section welds appearing more like an electron beam weld than traditional kilowatt class CO2 or fiber-delivered, lamp-pumped Nd:YAG welds. Because of the high beam quality, focus lenses were utilized with unusually large F# values and working distances while maintaining a sufficiently small spot size required to exceed the 1,000,000 watts/cm2 key-holing threshold power density.Weld experiments were conducted on 20mm and 65mm structural steel plates with a TRW HAP laser. Since the resultant welds were very narrow and deep, a method of weaving was implemented to widen the fusion zone. With only 4500 watts of average power delivered to the workpiece, full penetration, 65mm butt welds were completed in a single pass.Experiments using high average power (HAP) diode-pumped solid state lasers (DPSSL), reveal cross-section welds appearing more like an electron beam weld than traditional kilowatt class CO2 or fiber-delivered, lamp-pumped Nd:YAG welds. Because of the high beam quality, focus lenses were utilized with unusually large F# values and working distances while maintaining a sufficiently small spot size required to exceed the 1,000,000 watts/cm2 key-holing threshold power density.Weld experiments were conducted on 20mm and 65mm structural steel plates with a TRW HAP laser. Since the resultant welds were very narrow and deep, a method of weaving was implemented to widen the fusion zone. With only 4500 watts of average power delivered to the workpiece, full penetration, 65mm butt welds were completed in a single pass.

Rapid prototyping and rapid manufacturing processes are being employed to decrease the time required to develop new products. Laser cladding can be used to produce metal parts directly from CAD drawings. To apply this technology, multiple layers of metal clad are first deposited on a substrate. The clad is then tempered or annealed at periodic stages throughout the buildup process and also prior to machining. The component is then hardened and tempered by conventional heat treating procedures and ground or machined to final size. This investigation considers the response of the clad and base metal to this series of processing variables. H13, an air hardening die steel, was selected for the clads and the base metal. This alloy is commonly used for hot working dies. The response of the clad and substrate to the various heat treatments was evaluated.