Pub­li­ca­tions

Sci­en­tif­ic publications

Research paper on CFD modeling of imperfections in laser welding and additive manufacturing of aluminum alloys

Ana­lyz­ing Mul­ti­spec­tral Emis­sion and Syn­chro­tron Data to Eval­u­ate the Qual­i­ty of Laser Welds on Copper

Jan Brüggen­jür­gen, Christoph Spurk, Marc Hum­mel, Christoph Franz, Andrè Häusler, Alexan­der Olowin­sky, Felix Beck­mann, Julian Moos­mann; J. Laser Appl. 1 August 2024; 36 (3): 032032.

Descrip­tion
The val­i­da­tion of laser weld­ing of metal­lic mate­ri­als is a chal­leng­ing task due to the high­ly dynam­ic process­es and the lim­it­ed acces­si­bil­i­ty of the weld seam. Mea­sur­ing the process emis­sions and the laser beam being processed is one way of record­ing high­ly dynam­ic process phenomena. 

Part­ners
> Fraun­hofer Insti­tute for Laser Tech­nol­o­gy ILT
> RWTH Aachen University

> Insti­tute of Mate­ri­als Physics

Research paper on multispectral process monitoring and X-ray videography during laser welding of hairpins

Mul­ti-spec­tral Mon­i­tor­ing Data in Cor­re­la­tion with X‑ray Videog­ra­phy dur­ing Laser Weld­ing of Hairpins

Christoph Franz, Sören Hol­latz, Oliv­er Bruch­wald, Christoph Spurk, Marc Hum­mel, Alexan­der Olowin­sky, Eve­line Rein­heimer, Chris­t­ian Hagen­locher, Felix Beck­mann, Julian Moos­mann; 13th CIRP Con­fer­ence on Pho­ton­ic Tech­nolo­gies [LANE 2024]

Descrip­tion
In today’s pro­duc­tion of high-per­for­mance elec­tric engines, the hair­pin tech­nol­o­gy is used to increase the effi­cien­cy. Instead of a sta­tor made of wind­ed round wire, thick­er cop­per pins are assem­bled and weld­ed. Typ­i­cal weld fail­ures such as spat­ters, pores or insuf­fi­cient con­nec­tion occur due to sur­face con­t­a­m­i­na­tion, insuf­fi­cient clamp­ing, posi­tion­ing or pre­vi­ous cut­ting process­es. For pro­duc­tion facil­i­ties, it is not suf­fi­cient to iden­ti­fy defec­tive welds; a clas­si­fi­ca­tion is also required in order to deter­mine the caus­es of the fault and rec­ti­fy them as soon as pos­si­ble. The capa­bil­i­ty of a mul­ti-spec­tral mon­i­tor­ing sys­tem is eval­u­at­ed in this study with the help of in-situ X‑ray videog­ra­phy. The data show a cor­re­la­tion with the sta­bil­i­ty of the vapour cap­il­lary, the weld­ing posi­tion and spat­ter formation.

Part­ners
>
Fraun­hofer Insti­tute for Laser Tech­nol­o­gy ILT

> RWTH Aachen University

> Uni­ver­si­ty of Stuttgart, Insti­tut für Strahlw­erkzeuge (IFSW)

> Insti­tute of Mate­ri­als Physics

Research paper on CFD modeling of imperfections in laser welding and additive manufacturing of aluminum alloys

Process Mon­i­tor­ing in E‑Mobility Applications

Christoph Franz, Oliv­er Bruch­wald; Pho­ton­icsViews, 17: 64–68. https://doi.org/10.1002/phvs.202000029

Descrip­tion
Copi­lot said: The arti­cle focus­es on opti­cal process mon­i­tor­ing dur­ing laser weld­ing in e‑mobility. It explores meth­ods for the reli­able acqui­si­tion and eval­u­a­tion of weld­ing process­es, par­tic­u­lar­ly in demand­ing appli­ca­tions such as the man­u­fac­tur­ing of elec­tric dri­ves and batteries.

Scientific paper on nozzle wear detection in high-speed Directed Energy Deposition using multispectral process emissions

Detec­tion of Noz­zle Wear in High-Speed Direct­ed Ener­gy Depo­si­tion Using Mul­ti­spec­tral Process Emissions

Patrick Gajek, Milan Mari­nov, Andreas Roep­nack, Fred­erik Zanger; 14th CIRP Con­fer­ence on Pho­ton­ic Tech­nolo­gies [LANE 2026]

Descrip­tion
Mul­ti­spec­tral process mon­i­tor­ing enables the detec­tion of char­ac­ter­is­tic changes caused by noz­zle wear in High-Speed Direct­ed Ener­gy Depo­si­tion. The study reveals cor­re­la­tions between emis­sion sig­nals, noz­zle con­di­tion and track mor­phol­o­gy, demon­strat­ing the poten­tial for ear­ly wear detection.

Part­ners
> wbk Insti­tute of Pro­duc­tion Science
> USU GmbH

Scientific paper on multispectral analysis of laser hot-wire directed energy deposition using a coaxial processing head

Mul­ti­spec­tral Analy­sis of Laser Hot-Wire Direct­ed Ener­gy Depo­si­tion Using a Coax­i­al Pro­cess­ing Head

Kai Biester, Lau­ra Bud­de, Nick Schwarz, Ludger Overmy­er; 14th CIRP Con­fer­ence on Pho­ton­ic Tech­nolo­gies [LANE 2026]

Descrip­tion
The study inves­ti­gates the mul­ti­spec­tral acqui­si­tion of process emis­sions in laser-based hot-wire Direct­ed Ener­gy Depo­si­tion. The results show that the opti­cal mea­sure­ment set­up has a sig­nif­i­cant influ­ence on sig­nal inten­si­ty and must there­fore be tak­en into account dur­ing data analy­sis. Sta­tis­ti­cal emis­sion fea­tures can be used to dis­tin­guish balling from sta­ble process con­di­tions, where­as stub­bing could not be reli­ably classified.

Part­ners
> Laser Zen­trum Han­nover e.V.

> Insti­tute of Trans­port and Automa­tion Tech­nol­o­gy, Leib­niz Uni­ver­si­ty Hannover

Research paper on in-situ determination of powder-laser focus overlap in HS-DED using multispectral emission analysis

In-Situ Deter­mi­na­tion of Pow­der-Laser Focus Over­lap in High-Speed DED Using Mul­ti­spec­tral Emis­sion Analysis

Patrick Gajek; Hele­na Wex­el, Fred­erik Zanger; Sol­id Freeform Fab­ri­ca­tion 2025: Pro­ceed­ings of the 36th Annu­al Inter­na­tion­al Sol­id Freeform Fab­ri­ca­tion Sym­po­sium – An Addi­tive Man­u­fac­tur­ing Con­fer­ence Reviewed Paper

Descrip­tion
Pre­cise spa­tial align­ment between the laser and pow­der focus is crit­i­cal for achiev­ing com­plete par­ti­cle melt­ing and sta­ble process con­di­tions in high-speed Direct­ed Ener­gy Depo­si­tion (HS-DED). This work presents an in-situ diag­nos­tic approach using a pho­to­met­ric emis­sion sen­sor to iden­ti­fy and cal­i­brate the spa­tial over­lap of laser and pow­der focus dur­ing the depo­si­tion of AISI 316L.

Part­ners
> wbk Insti­tute of Pro­duc­tion Science

Research paper on dynamic coupling regimes in High-Speed Directed Energy Deposition using multispectral photometric monitoring

Iden­ti­fi­ca­tion of Coex­ist­ing Dynam­ic Cou­pling Regimes in High-speed Direct­ed Ener­gy Deposition

Patrick Gajek, Hele­na Wex­el, Fred­erik Zanger; CIRP Annals, 2026

Descrip­tion
High-speed direct­ed ener­gy depo­si­tion (HS-DED) fun­da­men­tal­ly alters laser–material inter­ac­tion dynam­ics due to coex­ist­ing fast plas­ma-relat­ed and delayed ther­mal respons­es, com­pli­cat­ing process sta­bil­i­ty in tran­si­tion regimes. This work inves­ti­gates the dynam­ic behav­ior of AISI 316 L processed on a com­mer­cial HS-DED sys­tem. It is shown that con­ven­tion­al grey-box mod­els based on spa­tial­ly inte­grat­ed pho­to­met­ric sig­nals fail to describe the process response at crit­i­cal oper­at­ing points. 

Using mul­ti­spec­tral pho­to­met­ric mea­sure­ments, the emis­sion sig­nal is tem­po­ral­ly sep­a­rat­ed into plas­ma-relat­ed and ther­mal com­po­nents. Based on this, a time-domain met­ric termed spec­tral lag is intro­duced, pro­vid­ing an emis­siv­i­ty-inde­pen­dent indi­ca­tor that reli­ably cap­tures regime transitions. 

Part­ners
> wbk Insti­tute of Pro­duc­tion Science

Scientific paper on full penetration welding and multispectral process radiation during laser beam welding of austenitic stainless steel.

Influ­ence of Full Pen­e­tra­tion Weld­ing on the Mul­ti­spec­tral Sig­nal of the Process Radi­a­tion dur­ing Laser Beam Weld­ing of Austenitic Stain­less Steel

Patrick Mey­er, Chris­t­ian Schu­mann, Dario Spatzek, André Häusler; 13th CIRP Con­fer­ence on Pho­ton­ic Tech­nolo­gies [LANE 2024]

Descrip­tion
A 100% visu­al inspec­tion of the welds car­ried out is not always pos­si­ble for eco­nom­ic rea­sons. Dif­fer­ent meth­ods of process mon­i­tor­ing are there­fore used for non-destruc­tive test­ing of process and weld seam qual­i­ty. In the fol­low­ing, the record­ed mul­ti­spec­tral sig­nals of the reflec­tive process radi­a­tion are eval­u­at­ed using descrip­tive sta­tis­tics and char­ac­ter­is­tics of a full pen­e­tra­tion weld dur­ing laser beam weld­ing of austenitic stain­less steel are worked out. The aim is to detect and local­ize unin­ten­tion­al full pen­e­tra­tion weld­ing at an ear­ly stage and thus avoid rejects. For this pur­pose, adapt­ed sam­ple geome­tries with vary­ing mate­r­i­al thick­ness­es are pre­pared for the test series. As a result, the need to vary the weld­ing process para­me­ters to achieve the dif­fer­ent weld­ing states (full and par­tial pen­e­tra­tion weld) is avoid­ed. By eval­u­at­ing the mea­sured val­ues of the wave­length-selec­tive sig­nals, a sig­nif­i­cant influ­ence on the sig­nal inten­si­ty and the sig­nal fre­quen­cy could be confirmed.

Part­ners
> Fraun­hofer Insti­tute for Laser Tech­nol­o­gy ILT

Research paper on weld defect detection in laser beam welding using multispectral emission sensor data and machine learning

Weld Defect Detec­tion in Laser Beam Weld­ing Using Mul­ti­spec­tral Emis­sion Sen­sor Fea­tures and Machine Learning

Ame­na Dar­wish, Man­fred Pers­son, Ste­fan Eric­son, Rohol­lah Ghase­mi, Kent Salomonsson

Descrip­tion
Laser beam weld­ing is a high­ly com­plex process in which even the slight­est devi­a­tions can lead to hard-to-detect defects such as poros­i­ty. In this arti­cle, researchers from the Uni­ver­si­ty of Skövde present an inno­v­a­tive, data-dri­ven frame­work for detect­ing weld­ing defects using mul­ti­spec­tral emis­sion sen­sors and machine learn­ing. By com­bin­ing super­vised and unsu­per­vised learn­ing meth­ods, the sys­tem suc­cess­ful­ly extracts rel­e­vant fea­tures from 4D pho­to­di­ode sig­nals and cor­re­lates them with weld­ing defects – both for post-process analy­sis and real-time mon­i­tor­ing. The study demon­strates how AI-based eval­u­a­tion of sen­sor sig­nals can rev­o­lu­tion­ize qual­i­ty assur­ance in indus­tri­al manufacturing.

Research paper on multispectral data analysis during laser beam welding of stainless steel with different gap sizes

Sto­chas­tic Analy­sis of Mul­ti­spec­tral Data dur­ing Laser Beam Weld­ing of Stain­less Steel with Dif­fer­ent Gap Sizes

Patrick Mey­er, André Häusler, Alexan­der Olowin­sky; IOP Con­fer­ence Series: Mate­ri­als Sci­ence and Engi­neer­ing, Vol­ume 1332, 20th Nordic Laser Mate­ri­als Pro­cess­ing Con­fer­ence 26/08/2025 — 28/08/2025 Kon­gens Lyn­g­by, Denmark

Descrip­tion
Qual­i­ty assur­ance in laser beam weld­ing demands high lev­els of pre­ci­sion and respon­sive­ness. This paper intro­duces an inno­v­a­tive approach to process mon­i­tor­ing using pho­to­di­ode sen­sors that cap­ture reflect­ed laser radi­a­tion. The sen­sor data pro­vides valu­able insights into the weld­ing process and, when com­bined with machine learn­ing, enables reli­able detec­tion of process devi­a­tions. The goal is to mon­i­tor weld qual­i­ty in real time and iden­ti­fy poten­tial defects at an ear­ly stage – a cru­cial step toward auto­mat­ed and intel­li­gent manufacturing.

Master’s thesis on data-driven modification of face-specific material properties

Pilot Study for Data-dri­ven Mod­i­fi­ca­tion of Face Spe­cif­ic Mate­r­i­al Properties

Man­fred Persson

Descrip­tion
Pre­cise mon­i­tor­ing of laser process­es is cru­cial for ensur­ing the qual­i­ty of mod­ern man­u­fac­tur­ing. This study presents an inno­v­a­tive approach for real-time eval­u­a­tion of weld qual­i­ty in alu­minum bus­bar laser weld­ing. By uti­liz­ing mul­ti­spec­tral pho­to­di­ode sen­sors and deep learn­ing algo­rithms, rel­e­vant process data can be cap­tured and ana­lyzed instant­ly. The sys­tem detects qual­i­ty devi­a­tions ear­ly and enables auto­mat­ed process opti­miza­tion – a key step toward Indus­try 4.0 and intel­li­gent manufacturing.

Master’s thesis on real-time prediction in busbar laser welding using multispectral photodiode data

Real-time Qual­i­ty Pre­dic­tion in Bus­bar Laser Weld­ing: A Mul­ti-spec­tral Pho­to­di­ode and Con­vL­STM Framework

Dan Lönn

Descrip­tion
Pre­cise mon­i­tor­ing of laser process­es is essen­tial for the qual­i­ty of safe­ty-crit­i­cal com­po­nents, such as those used in the auto­mo­tive indus­try. This mas­ter’s the­sis presents an inno­v­a­tive sys­tem for real-time eval­u­a­tion of weld qual­i­ty in alu­minum bus­bar laser weld­ing. It com­bines mul­ti­spec­tral pho­to­di­ode sens­ing with a deep learn­ing mod­el (Con­vL­STM) to ana­lyze back-reflec­tions and spec­tral sig­nals dur­ing the weld­ing process. Light in the range of 400 nm to 700 nm pro­vides valu­able insights into mate­r­i­al changes and poten­tial defects. The result is an intel­li­gent, data-dri­ven solu­tion for ear­ly detec­tion of weld­ing flaws and opti­miza­tion of indus­tri­al man­u­fac­tur­ing processes.

Con­tact us!

If you would like to find out more about our prod­ucts and ser­vices or request a cus­tomized quote, please con­tact us. You can reach us by phone, e‑mail or via our con­tact form. We look for­ward to your inquiry!

Con­tact us!

If you would like to find out more about our prod­ucts and ser­vices or request a cus­tomized quote, please con­tact us. You can reach us by phone, e‑mail or via our con­tact form. We look for­ward to your inquiry!

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