Welding reflective materials such as copper and aluminum presents significant challenges due to their high reflectivity and thermal conductivity, which can lead to unstable keyhole formation, spatter, and inconsistent welds. This paper investigates a novel approach to overcoming these challenges using ultrafast dynamic beam wobble enabled by Dynamic Beam Laser technology based on Coherent Beam Combining (CBC). This advanced laser architecture allows the generation of arbitrary beam shapes and high-frequency wobble patterns at rates up to 40 MHz—far beyond the capabilities of conventional systems.

Dynamic beam shaping, including precisely tailored wobble geometries, provides enhanced control over keyhole behavior during laser welding. By dynamically adjusting the energy distribution in real time, this method expands the process window for thin reflective materials and improves weld consistency and quality for thicker sections. The ability to rapidly sequence between different beam shapes during welding adds a new layer of control, enabling real-time adaptation to changing material conditions.

This work explores how high-frequency dynamic beam shaping stabilizes the welding process, reduces defects such as porosity and spatter, and improves overall weld integrity. The results demonstrate the transformative potential of combining Coherent Beam Combining with advanced beam wobble strategies. This approach provides a robust and efficient solution for industrial laser welding of reflective metals, offering new capabilities for demanding manufacturing applications.