ABSTRACT
In this study, an application of the laser-melting deposition additive manufacturing technique as a welding method has been studied for the laser welding (LW) of AISI 304 stainless steel, specifically 0.4 mm and 0.5 mm thick sheets. The welding was carried out without and with filler material. Inconel 718 powder particles were used as filler material in the second case. A series of experiments were designed by changing the process parameters to identify the effect of operating conditions on the weld width, depth, and height. The welds were examined through metallographic experiments performed at various cross-sections to identify the defects and pores. All the deposited welds were passed through a customized mini-focus X-ray system to analyze the weld uniformities. The optimal operating conditions were determined for 0.4 mm and 0.5 mm sheets for the LW with and without filler material. It was found that laser power, laser scanning speed, powder flow rate, and helium to argon gases mixture-control the weld bead dimensions and quality. X-ray analyses showed that the optimal operating conditions gave the least peak value of non-uniformity in the laser welds. This study opens a new window for laser welding via additive manufacturing with X-ray monitoring.
ABSTRACT
In the laser powder bed fusion (LPBF) process, the operating conditions are essential in determining laser-induced keyhole regimes based on the thermal distribution. These regimes, classified into shallow and deep keyholes, control the probability and defects formation intensity in the LPBF process. To study and control the keyhole in the LPBF process, mathematical and computational fluid dynamics (CFD) models are presented. For CFD, the volume of fluid method with the discrete element modeling technique was used, while a mathematical model was developed by including the laser beam absorption by the powder bed voids and surface. The dynamic melt pool behavior is explored in detail. Quantitative comparisons are made among experimental, CFD simulation and analytical computing results leading to a good correspondence. In LPBF, the temperature around the laser irradiation zone rises rapidly compared to the surroundings in the powder layer due to the high thermal resistance and the air between the powder particles, resulting in a slow travel of laser transverse heat waves. In LPBF, the keyhole can be classified into shallow and deep keyhole mode, controlled by the energy density. Increasing the energy density, the shallow keyhole mode transforms into the deep keyhole mode. The energy density in a deep keyhole is higher due to the multiple reflections and concentrations of secondary reflected beams within the keyhole, causing the material to vaporize quickly. Due to an elevated temperature distribution in deep keyhole mode, the probability of pores forming is much higher than in a shallow keyhole as the liquid material is close to the vaporization temperature. When the temperature increases rapidly, the material density drops quickly, thus, raising the fluid volume due to the specific heat and fusion latent heat. In return, this lowers the surface tension and affects the melt pool uniformity.
ABSTRACT
Heat equations can estimate the thermal distribution and phase transformation in real-time based on the operating conditions and material properties. Such wonderful features have enabled heat equations in various fields, including laser and electron beam processing. The integral transform technique (ITT) is a powerful general-purpose semi-analytical/numerical method that transforms partial differential equations into a coupled system of ordinary differential equations. Under this category, Fourier and non-Fourier heat equations can be implemented on both equilibrium and non-equilibrium thermo-dynamical processes, including a wide range of processes such as the Two-Temperature Model, ultra-fast laser irradiation, and biological processes. This review article focuses on heat equation models, including Fourier and non-Fourier heat equations. A comparison between Fourier and non-Fourier heat equations and their generalized solutions have been discussed. Various components of heat equations and their implementation in multiple processes have been illustrated. Besides, literature has been collected based on ITT implementation in various materials. Furthermore, a future outlook has been provided for Fourier and non-Fourier heat equations. It was found that the Fourier heat equation is simple to use but involves infinite speed heat propagation in comparison to the non-Fourier heat equation and can be linked with the Two-Temperature Model in a natural way. On the other hand, the non-Fourier heat equation is complex and involves various unknowns compared to the Fourier heat equation. Fourier and Non-Fourier heat equations have proved their reliability in the case of laser-metallic materials, electron beam-biological and -inorganic materials, laser-semiconducting materials, and laser-graphene material interactions. It has been identified that the material properties, electron-phonon relaxation time, and Eigen Values play an essential role in defining the precise results of Fourier and non-Fourier heat equations. In the case of laser-graphene interaction, a restriction has been identified from ITT. When computations are carried out for attosecond pulse durations, the laser wavelength approaches the nucleus-first electron separation distance, resulting in meaningless results.
ABSTRACT
Laser-induced forward transfer (LIFT) and two-photon polymerization (TPP) have proven their abilities to produce 3D complex microstructures at an extraordinary level of sophistication. Indeed, LIFT and TPP have supported the vision of providing a whole functional laboratory at a scale that can fit in the palm of a hand. This is only possible due to the developments in manufacturing at micro- and nano-scales. In a short time, LIFT and TPP have gained popularity, from being a microfabrication innovation utilized by laser experts to become a valuable instrument in the hands of researchers and technologists performing in various research and development areas, such as electronics, medicine, and micro-fluidics. In comparison with conventional micro-manufacturing methods, LIFT and TPP can produce exceptional 3D components. To gain benefits from LIFT and TPP, in-detail comprehension of the process and the manufactured parts' mechanical-chemical characteristics is required. This review article discusses the 3D printing perspectives by LIFT and TPP. In the case of the LIFT technique, the principle, classification of derivative methods, the importance of flyer velocity and shock wave formation, printed materials, and their properties, as well as various applications, have been discussed. For TPP, involved mechanisms, the difference between TPP and single-photon polymerization, proximity effect, printing resolution, printed material properties, and different applications have been analyzed. Besides this, future research directions for the 3D printing community are reviewed and summarized.
ABSTRACT
In this study, a rigorous analytical solution to the thermal nonlinear Klein-Gordon equation in the Kozlowski version is provided. The Klein-Gordon heat equation is solved via the Zhukovsky "state-of-the-art" mathematical techniques. Our study can be regarded as an initial approximation of attosecond laser-particle interaction when the prevalent phenomenon is photon-electron interaction. The electrons interact with the laser beam, which means that the nucleus does not play a significant role in temperature distribution. The particle is supposed to be homogenous with respect to thermophysical properties. This theoretical approach could prove useful for the study of metallic nano-/micro-particles interacting with attosecond laser pulses. Specific applications for Au "nano" particles with a 50 nm radius and "micro" particles with 110, 130, 150, and 1000 nm radii under 100 attosecond laser pulse irradiation are considered. First, the cross-section is supposed to be proportional to the area of the particle, which is assumed to be a perfect sphere of radius R or a rotation ellipsoid. Second, the absorption coefficient is calculated using a semiclassical approach, taking into account the number of atoms per unit volume, the classical electron radius, the laser wavelength, and the atomic scattering factor (10 in case of Au), which cover all the basic aspects for the interaction between the attosecond laser and a nanoparticle. The model is applicable within the 100-2000 nm range. The main conclusion of the model is that for a range inferior to 1000 nm, a competition between ballistic and thermal phenomena occurs. For values in excess of 1000 nm, our study suggests that the thermal phenomena are dominant. Contrastingly, during the irradiation with fs pulses, this value is of the order of 100 nm. This theoretical model's predictions could be soon confirmed with the new EU-ELI facilities in progress, which will generate pulses of 100 as at a 30 nm wavelength.
ABSTRACT
Metal matrix composites (MMCs) present extraordinary characteristics, including high wear resistance, excellent operational properties at elevated temperature, and better chemical inertness as compared to traditional alloys. These properties make them prospective candidates in the fields of aerospace, automotive, heavy goods vehicles, electrical, and biomedical industries. MMCs are challenging to process via traditional manufacturing techniques, requiring high cost and energy. The laser-melting deposition (LMD) has recently been used to manufacture MMCs via rapid prototyping, thus, solving these drawbacks. Besides the benefits mentioned above, the issues such as lower ultimate tensile strength, yield strength, weak bonding between matrix and reinforcements, and cracking are still prevalent in parts produced by LMD. In this article, a detailed analysis is made on the MMCs manufactured via LMD. An illustration is presented on the LMD working principle, its classification, and dependent and independent process parameters. Moreover, a brief comparison between the wire and powder-based LMDs has been summarized. Ex- and in-situ MMCs and their preparation techniques are discussed. Besides this, various matrices available for MMCs manufacturing, properties of MMCs after printing, possible complications and future research directions are reviewed and summarized.
ABSTRACT
We report a study on the biocompatibility vs. thickness in the case of titanium nitride (TiN) films synthesized on 410 medical grade stainless steel substrates by pulsed laser deposition. The films were grown in a nitrogen atmosphere, and their in vitro cytotoxicity was assessed according to ISO 10993-5 [1]. Extensive physical-chemical analyses have been carried out on the deposited structures with various thicknesses in order to explain the differences in biological behavior: profilometry, scanning electron microscopy, atomic force microscopy, X-ray photoelectron spectroscopy (XPS), X-ray diffraction and surface energy measurements. XPS revealed the presence of titanium oxynitride beside TiN in amounts that vary with the film thickness. The cytocompatibility of films seems to be influenced by their TiN surface content. The thinner films seem to be more suitable for medical applications, due to the combined high values of bonding strength and superior cytocompatibility.
ABSTRACT
The extraction efficiency of evanescent light from ZnO nanolayers and their thickness profiles in the range of (1-105) nm was evaluated by a new microscopy technique, differential evanescent light intensity imaging method. It is based on capturing the evanescent light scattered by the layer of the material deposited on glass substrates. The analyzed ZnO films were obtained by pulsed laser deposition at 27°C and 100°C, using a nanosecond UV laser source.
