Single-Pass Pure Laser Welding of Thick Sections (up to 25 mm) with a 28 kW Dynamic Beam Laser: Process Stability and Mechanical

Rachel Assa; Nina Armon; Tom Shalev; Alexey Skupov; Ami Spira; Eyal Shekel

doi:10.1117/12.3077609

Single-Pass Pure Laser Welding of Thick Sections (up to 25 mm) with a 28 kW Dynamic Beam Laser: Process Stability and Mechanical

Rachel Assa
, Nina Armon
, Tom Shalev
, Alexey Skupov
, Ami Spira
, Eyal Shekel

Civan Lasers

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

Abstract

Single-pass laser welding of thick steel sections offers significant advantages over conventional multi-pass arc and hybrid welding processes, including reduced heat input, minimal distortion, and simplified joint preparation. However, achieving stable deep-penetration welds at high power remains challenging due to keyhole instabilities and melt pool dynamics. This paper presents experimental and numerical results demonstrating single-pass pure laser welding of steel plates up to 25 mm thickness using a 28 kW Dynamic Beam Laser (DBL). By employing dynamic beam shaping and optimized beamshape sequencing, stable keyhole behavior and defect-free welds were achieved. Bead-on-plate and butt-joint welds were evaluated through metallographic inspection, non-destructive testing, and mechanical qualification.

Original language	English
Title of host publication	High-Power Laser Materials Processing
Subtitle of host publication	Applications, Diagnostics, and Systems XV
Editors	Stefan Kaierle, Klaus R. Kleine
Publisher	SPIE
ISBN (Electronic)	9781510696860
DOIs	https://doi.org/10.1117/12.3077609
State	Published - 5 Mar 2026
Externally published	Yes
Event	15th High-Power Laser Materials Processing: Applications, Diagnostics, and Systems - San Francisco, United States Duration: 21 Jan 2026 → 22 Jan 2026

Publication series

Name	Proceedings of SPIE - The International Society for Optical Engineering
Volume	13886
ISSN (Print)	0277-786X
ISSN (Electronic)	1996-756X

Conference

Conference	15th High-Power Laser Materials Processing: Applications, Diagnostics, and Systems
Country/Territory	United States
City	San Francisco
Period	21/01/26 → 22/01/26

Bibliographical note

Publisher Copyright:
© 2026 SPIE. All rights reserved.

Keywords

beam shaping
dynamic beam laser
keyhole stability
laser welding
mechanical testing
single-pass welding
stainless steel
thick-section welding

Access to Document

10.1117/12.3077609

Cite this

Assa, R., Armon, N., Shalev, T., Skupov, A., Spira, A., & Shekel, E. (2026). Single-Pass Pure Laser Welding of Thick Sections (up to 25 mm) with a 28 kW Dynamic Beam Laser: Process Stability and Mechanical. In S. Kaierle, & K. R. Kleine (Eds.), High-Power Laser Materials Processing: Applications, Diagnostics, and Systems XV Article 138860C (Proceedings of SPIE - The International Society for Optical Engineering; Vol. 13886). SPIE. https://doi.org/10.1117/12.3077609

Assa, Rachel ; Armon, Nina ; Shalev, Tom et al. / Single-Pass Pure Laser Welding of Thick Sections (up to 25 mm) with a 28 kW Dynamic Beam Laser : Process Stability and Mechanical. High-Power Laser Materials Processing: Applications, Diagnostics, and Systems XV. editor / Stefan Kaierle ; Klaus R. Kleine. SPIE, 2026. (Proceedings of SPIE - The International Society for Optical Engineering).

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title = "Single-Pass Pure Laser Welding of Thick Sections (up to 25 mm) with a 28 kW Dynamic Beam Laser: Process Stability and Mechanical",

abstract = "Single-pass laser welding of thick steel sections offers significant advantages over conventional multi-pass arc and hybrid welding processes, including reduced heat input, minimal distortion, and simplified joint preparation. However, achieving stable deep-penetration welds at high power remains challenging due to keyhole instabilities and melt pool dynamics. This paper presents experimental and numerical results demonstrating single-pass pure laser welding of steel plates up to 25 mm thickness using a 28 kW Dynamic Beam Laser (DBL). By employing dynamic beam shaping and optimized beamshape sequencing, stable keyhole behavior and defect-free welds were achieved. Bead-on-plate and butt-joint welds were evaluated through metallographic inspection, non-destructive testing, and mechanical qualification.",

keywords = "beam shaping, dynamic beam laser, keyhole stability, laser welding, mechanical testing, single-pass welding, stainless steel, thick-section welding",

author = "Rachel Assa and Nina Armon and Tom Shalev and Alexey Skupov and Ami Spira and Eyal Shekel",

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Assa, R, Armon, N, Shalev, T, Skupov, A, Spira, A & Shekel, E 2026, Single-Pass Pure Laser Welding of Thick Sections (up to 25 mm) with a 28 kW Dynamic Beam Laser: Process Stability and Mechanical. in S Kaierle & KR Kleine (eds), High-Power Laser Materials Processing: Applications, Diagnostics, and Systems XV., 138860C, Proceedings of SPIE - The International Society for Optical Engineering, vol. 13886, SPIE, 15th High-Power Laser Materials Processing: Applications, Diagnostics, and Systems, San Francisco, United States, 21/01/26. https://doi.org/10.1117/12.3077609

Single-Pass Pure Laser Welding of Thick Sections (up to 25 mm) with a 28 kW Dynamic Beam Laser: Process Stability and Mechanical. / Assa, Rachel; Armon, Nina; Shalev, Tom et al.
High-Power Laser Materials Processing: Applications, Diagnostics, and Systems XV. ed. / Stefan Kaierle; Klaus R. Kleine. SPIE, 2026. 138860C (Proceedings of SPIE - The International Society for Optical Engineering; Vol. 13886).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

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AB - Single-pass laser welding of thick steel sections offers significant advantages over conventional multi-pass arc and hybrid welding processes, including reduced heat input, minimal distortion, and simplified joint preparation. However, achieving stable deep-penetration welds at high power remains challenging due to keyhole instabilities and melt pool dynamics. This paper presents experimental and numerical results demonstrating single-pass pure laser welding of steel plates up to 25 mm thickness using a 28 kW Dynamic Beam Laser (DBL). By employing dynamic beam shaping and optimized beamshape sequencing, stable keyhole behavior and defect-free welds were achieved. Bead-on-plate and butt-joint welds were evaluated through metallographic inspection, non-destructive testing, and mechanical qualification.

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Assa R, Armon N, Shalev T, Skupov A, Spira A, Shekel E. Single-Pass Pure Laser Welding of Thick Sections (up to 25 mm) with a 28 kW Dynamic Beam Laser: Process Stability and Mechanical. In Kaierle S, Kleine KR, editors, High-Power Laser Materials Processing: Applications, Diagnostics, and Systems XV. SPIE. 2026. 138860C. (Proceedings of SPIE - The International Society for Optical Engineering). doi: 10.1117/12.3077609

Single-Pass Pure Laser Welding of Thick Sections (up to 25 mm) with a 28 kW Dynamic Beam Laser: Process Stability and Mechanical

Abstract

Publication series

Conference

Bibliographical note

Keywords

Access to Document

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Cite this