When laser welding pushes the boundaries of scientific engineering
A recognized leader in industrial laser technologies, IREPA LASER is reinforcing its position on major international projects by contributing to a feasibility study for CERN, the world-renowned reference in particle physics.
This collaboration is part of the ambitious Future Circular Collider (FCC) program, a next-generation scientific infrastructure designed to push the frontiers of fundamental research. Ultimately, the project aims to build a circular tunnel nearly 91 km long, capable of hosting various particle colliders and reaching unprecedented energy levels.
In this environment, where technical requirements are taken to the extreme, IREPA LASER was called upon to address a key challenge: validating a laser welding process for critical vacuum chambers.
A strategic challenge: ensuring the reliability of a complex assembly
The objectives of the study were twofold:
- Validate the feasibility of laser welding,
- Design a representative demonstrator for a particularly demanding assembly.
The components involved—tubes, valves, and absorbers—play a vital role in the operation of the facilities. Their assembly must ensure absolute reliability under extreme operating conditions.
At the heart of the challenge: copper.
Copper: a material with significant welding constraints
While copper is preferred for its outstanding thermal properties, it presents major challenges for laser welding:
- High thermal conductivity, which rapidly dissipates energy,
- Complex laser–material interaction requiring finely tuned process parameters,
- Delicate control of the molten pool, essential to prevent defects.
These characteristics demand a rigorous approach and advanced expertise to achieve results that meet the project's stringent requirements.
Extremely high quality standards
The requirements defined for this project illustrate the level of excellence expected:
- Full penetration through 2 mm thickness,
- No root-side concavity,
- Zero adhering spatter,
- Helium leak tightness down to 10⁻¹⁰ mbar·l/s,
- Complete absence of cracking or through-thickness defects.
These constraints leave no room for approximation and require perfect process control from the earliest development stages.
Securing the process during the feasibility phase
Beyond technical performance, this project highlights a central industrial challenge: securing manufacturing processes under extreme conditions before deployment.
This is precisely where IREPA LASER brings its added value. Thanks to its expertise in laser welding and its tailor-made R&D capabilities, the company can:
- Overcome complex technological barriers,
- Develop robust and repeatable processes,
- Ensure successful industrial implementation in highly demanding environments.
- A concrete illustration of excellence in the laser industry
This collaboration with CERN perfectly demonstrates the role of laser technologies in cutting-edge scientific and industrial projects. It also highlights the ability of industry players such as IREPA LASER to meet some of the most demanding technical specifications.
This achievement perfectly embodies the spirit of the laser industry: innovating, collaborating, and pushing technological boundaries in the service of both industry and scientific research.
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