On optical design limitations of generalized two-mirror remote beam delivery laser systems: the case of remote welding

Remote welding opens new possibilities for the highly productive and qualitative joining of metal structures, especially in the automotive industry. This work first summarises the different types of remote welding systems (RWSs) based primarily on the different features of the laser beam scanning systems that RWSs implement. A generalised two-mirror scanning system is geometrically analyzed in order to evaluate the irradiated laser intensity on the workpiece as it changes due to the inclinations with which the laser beam impinges to the processing plane. The study discusses the limitations that a two-mirror scanning system enforces in remote welding, and sets the foundation for further theoretical and experimental investigation of this process.