Impact of Beam Shape and Frequency on Weld Seam Geometry and Penetration Depth Using a Coherent Beam Combining Laser

The geometry and quality of a weld seam are critical factors in laser beam welding, influencing mechanical performance and structural integrity. Dynamically modulated laser beams provide a precise means of tailoring energy input in high-power laser welding processes. This study investigates the influence of beam shape and modulated frequency on weld seam geometry, penetration depth, and capillary behaviour using a coherent beam combining (CBC) laser system from Civan Lasers. Three beam intensity distributions—single point, line–point–line (LPL), and boomerang—were applied across a modulation frequency range of 1, 10, and 100 kHz during the welding of duplex and austenitic stainless steels. High-speed imaging captured real-time capillary dynamics, and the data were analysed to assess capillary stability, measure capillary diameter, and determine the capillary front angle as a function of frequency and beam shape. Transverse cross-sections of the welds were prepared to evaluate seam geometry and microstructure. The results show that beam shape significantly affects energy distribution and weld profile, while modulation frequency critically influences capillary behaviour and penetration characteristics. These findings highlight the critical role of dynamic beam shaping and frequency modulation in optimizing laser welding processes for material-specific performance, offering a versatile platform for advancing precision manufacturing using CBC technology.