Abstract: Standard laser welding practices are limited by the intensity profile of the beam and spot size. The introduction of Diffractive Optical Elements (DOE) to the welding process allows for new beam shapes that are better suited to the welding process. A particular problem in laser welding is the joining of dissimilar materials. Because these materials have different material properties including different melting temperatures, it is difficult to synchronize the welding process using a single spot. Additionally, significant thermal stresses are introduced by the welding process because of the keyhole weld shape formed by a gaussian beam. By using a power splitting DOE, two spots of unequal intensity distributions may be projected onto each side of the weld joint. This paper discusses the use of DOEs in laser welding and joining of dissimilar materials. Results are presented from the testing of several candidate aerospace materials.!1
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