Coaxial laser hotwire head

A method to perform an additive manufacturing, welding or cladding process, the method comprising:

• generating, at a preheating power source, a preheating current to flow through a preheating portion of an electrode wire advancing through a laser processing head, the preheating portion being between a first contact point and a second contact point within the laser processing head, to preheat the preheating portion of the electrode wire to a preheating temperature below a melting temperature of the electrode wire;
• generating, at an arc welding power source, arc welding power to flow through the electrode wire and a workpiece to create an arc between the electrode wire and the workpiece;
• generating, at a laser source within the laser processing head, one or more laser beams, the one or more laser beams collectively having lasing power sufficient to at least partially melt the electrode wire when the electrode wire is preheated to the preheating temperature;
• focusing, by the laser source and through first and second lenses offset from a central axis extending through the laser processing head, the first lens arranged opposite the second lens relative to the central axis, the one or more laser beams at a focal point on the workpiece at which the electrode wire makes contact with the workpiece to at least partially melt the electrode wire;
• and
• rotating the first and second lenses during welding,
• wherein the laser processing head is configured to rotate the first and second lenses consistently during welding about the central axis that is collinear with the second contact point and the electrode wire as the electrode wire moves through first and second contact points and through the laser processing head to the workpiece.

A laser welding system, comprising:

• a wire feeder to drive an electrode wire to a laser processing head, the laser processing head comprising a first contact point and a second contact point arranged along a central axis and encased within the laser processing head;
• one or more power sources connected to both of the first and second contact points, the one or more power sources configured to:
• generate a current to flow through the electrode wire between the first contact point and the second contact point to heat a portion of the electrode wire within the laser processing head;
• and
• provide power to the electrode wire to create an arc between the electrode wire and the workpiece via the first contact point or the second contact point;
• a laser source configured to generate one or more laser beams having lasing power sufficient to at least partially melt the electrode wire;
• a coaxial laser head of the laser processing head configured to focus the one or more laser beams through first and second lenses offset from the central axis to one or more focal points on the workpiece to at least partially melt the electrode wire, the first lens arranged opposite the second lens relative to the central axis, wherein the coaxial laser head is configured to consistently rotate the first and second lenses during welding about the central axis that is collinear with the first contact point, the second contact point, and the electrode wire as the electrode wire moves through the first and second contact points and through the laser processing head to the workpiece;
• and
• an arc clamp module coupled to the first contact point and the second contact point, the arc clamp module configured to provide an alternative current path to redirect at least a part of the current to flow through the alternative current path to extinguish the arc or prevent the arc from forming.