# Numerical and Experimental Study of Laser Surface Modification Using a High-Power Fiber CW Laser

## TL;DR

This paper studies how a high-power laser can modify metal surfaces using both computer simulations and real experiments, helping optimize laser settings for precise metal treatment.

## Contribution

The paper introduces a validated 3D FEM framework combining thermal-structural simulations with experiments for laser surface modification of aluminum alloys.

## Key findings

- The FEM simulations accurately predict temperature gradients, displacement fields, and stress–strain evolution during laser processing.
- Experimental validation confirms the predictive capability of the numerical models for laser etching and engraving processes.
- The study enables precise optimization of laser parameters like power, dwell time, and scanning speed for metal surface treatment.

## Abstract

This work presents a combined numerical and experimental investigation into the laser machining of aluminum alloy Al 1050 H14 using a high-power Continuous Wave (CW) fiber laser. Advanced three-dimensional, coupled thermal–structural Finite Element Method (FEM) simulations are developed to model key laser–material interaction processes, including laser-induced plastic deformation, laser etching, and engraving. Cases for both static single-shot and dynamic linear scanning laser beams are investigated. The developed numerical models incorporate a Gaussian heat source and the Johnson–Cook constitutive model to capture elastoplastic, damage, and thermal effects. The simulation results, which provide detailed insights into temperature gradients, displacement fields, and stress–strain evolution, are rigorously validated against experimental data. The experiments are conducted on an integrated setup comprising a 2 kW TRUMPF CW fiber laser hosted on a 3-axis CNC milling machine, with diagnostics including thermal imaging, thermocouples, white-light interferometry, and strain gauges. The strong agreement between simulations and measurements confirms the predictive capability of the developed FEM framework. Overall, this research establishes a reliable computational approach for optimizing laser parameters, such as power, dwell time, and scanning speed, to achieve precise control in metal surface treatment and modification applications.