Development of a System for Additive Manufacturing of Ceramic Matrix Composite Structures Using Laser Technology.

Ceramic matrix composites (CMCs) are refractory ceramic materials with damage-tolerant behavior. Coming from the space industry, this class of materials is increasingly being used in other applications, such as automotive construction for high-performance brake discs, furnace technology, heat coatings for pipe systems and landing flaps on reusable rocket sections. In order to produce CMC faster and more cost-efficiently for the increasing demand, a new additive manufacturing process is being tested, which in the future should also be able to realize material joints and higher component wall thicknesses than conventional processes. The main features of the process are as follows. A ceramic fiber bundle is de-sized and infiltrated with ceramic suspension. The bundle infiltrated with matrix material is dried and then applied to a body form. During application, the matrix material is melted by laser radiation without damaging the fiber material. For the initial validation of the material system, samples are pressed and analyzed for their absorption properties using integrating sphere measurement. With the results, a suitable processing laser is selected, and initial melting tests of the matrix system are carried out. After the first validation of the process, a test system is set up, and the first test specimens are produced to determine the material parameters.

Additive Manufacturing of ß-NiAl by Means of Laser Metal Deposition of Pre-Alloyed and Elemental Powders.

The additive manufacturing (AM) technique, laser metal deposition (LMD), combines the advantages of near net shape manufacturing, tailored thermal process conditions and in situ alloy modification. This makes LMD a promising approach for the processing of advanced materials, such as intermetallics. Additionally, LMD allows the composition of a powder blend to be modified in situ. Hence, alloying and material build-up can be achieved simultaneously. Within this contribution, AM processing of the promising high-temperature material ß-NiAl, by means of LMD, with elemental powder blends, as well as with pre-alloyed powders, was presented. The investigations showed that by applying a preheating temperature of 1100 °C, ß-NiAl could be processed without cracking. Additionally, by using pre-alloyed, as well as elemental powders, a single phase ß-NiAl microstructure can be achieved in multi-layer build-ups. Major differences between the approaches were found within substrate near regions. For in situ alloying of Ni and Al, these regions are characterized by an inhomogeneous elemental distribution in a layerwise manner. However, due to the remelting of preceding layers during deposition, a homogenization can be observed, leading to a single-phase structure. This shows the potential of high temperature preheating and in situ alloying to push the development of new high temperature materials for AM.

Surface conditioning of additively manufactured titanium implants and its influence on materials properties and in vitro biocompatibility.

Customized osteosynthesis materials of titanium alloy can be generated by additive manufacturing replacing the complex adaptation to the patient individual anatomy, especially to the lower jaw bone which shows a highly individual surface area. After printing further conditioning is necessary to adjust surface roughness. The aim of the present study was to analyse the effect of different grinding and polishing procedures on sample surface and composition and in vitro biocompatibility. Ti-6Al-4V ELI samples printed by laser powder bed fusion (LPBF) were post-treated by multi-level procedures to adjust surface roughness using the surface conditioning technologies sandblasting, vibratory finishing, electro polishing or plasma polishing. Topography and chemical composition of the surfaces was analysed. Furthermore, the release of metal ions in contact to cell culture medium was quantified. Human osteoblasts as well as primary human gingiva cells (fibroblasts and epithelial cells) were cultivated in extracts or directly on the surfaces to analyse cytotoxicity, cell adhesion and cell proliferation. Surface roughness of the different materials after final polishing was in between 0.2 and 0.5 µm, which is in the same range as usually found for conventional titanium materials used in maxillofacial surgery. Furthermore, the wettability was comparable for all post-processing techniques. The chemical compositions of the finished surfaces showed a remarkable impact by the applied finishing technique. Extracts of the samples showed low cytotoxicity with exception of the plasma polished samples, which were shown to release significantly higher amounts of vanadium ions. Accordingly, cells showed good adhesion and proliferation on all samples except plasma polished specimens. Customized devices for midline osseodistraction were exemplarily printed with LPBF starting with patient's 3D data. Those devices can be considered for clinical use, since the printed and finished material meets the requirements of ISO 10993-5 for medical devices.

Laser Treatment as Sintering Process for Dispenser Printed Bismuth Telluride Based Paste.

Laser sintering as a thermal post treatment method for dispenser printed p- and n-type bismuth telluride based thermoelectric paste materials was investigated. A high-power fiber laser (600 W, 1064 nm) was used in combination with a scanning system to achieve high processing speed. A Design of Experiment (DoE) approach was used to identify the most relevant processing parameters. Printed layers were laser treated with different process parameters and the achieved sheet resistance, electrical conductivity, and Seebeck coefficient are compared to tube furnace processed reference specimen. For p-type material, electrical conductivity of 22 S/cm was achieved, compared to 15 S/cm in tube furnace process. For n-type material, conductivity achieved by laser process was much lower (7 S/cm) compared to 88 S/cm in furnace process. Also, Seebeck coefficient decreases during laser processing (40-70 µV/K and -110 µV/K) compared to the oven process (251 µV/K and -142 µV/K) for p- and n-type material. DoE did not yet deliver a set of optimum processing parameters, but supports doubts about the applicability of area specific laser energy density as a single parameter to optimize laser sintering process.

Analysis of Melt Pool Characteristics and Process Parameters Using a Coaxial Monitoring System during Directed Energy Deposition in Additive Manufacturing.

The growing number of commercially available machines for laser deposition welding show the growing acceptance and importance of this technology for industrial applications. Their increasing usage in research and production requires process stability and user-friendly handling. A commercially available DMG MORI LT 65 3D hybrid machine used in combination with a CCD-based coaxial temperature measurement system was utilized in this work to investigate what information relating to the intensity distribution of melt pool surfaces could be appropriate to draw conclusions about process conditions. In this study it is shown how the minimal required specific energy for a stable process can be determined, and it is indicated that the evolution of a plasma plume depends on thermal energy within the base material. An estimated melt pool area-calculated by the number of pixels (NOP) with intensities larger than a fixed, predefined threshold-builds the main measure in analysing images from the process camera. The melt pool area and its temporal variance can also serve as an indicator for an increased working distance.

Invariance of waveguide grating mirrors to lateral displacement phase shifts.

We present a method to analyze the coupling of lateral displacements in nanoscale structures, in particular waveguide grating mirrors (WGMs), into the phase of a reflected Gaussian beam using a finite-difference time-domain simulation. Such phase noise is of interest for using WGMs in high-precision interferometry. We show that, to the precision of our simulations (10(-7) rad), waveguide mirrors do not couple lateral displacement into phase noise of a reflected beam and that WGMs are therefore not subject to the same stringent alignment requirements as previously proposed layouts using diffraction gratings.

Interferometer phase noise due to beam misalignment on diffraction gratings.

All-reflective interferometer configurations have been proposed for the next generation of gravitational wave detectors, with diffractive elements replacing transmissive optics. However, an additional phase noise creates more stringent conditions for alignment stability. A framework for alignment stability with the use of diffractive elements was required using a Gaussian model. We successfully create such a framework involving modal decomposition to replicate small displacements of the beam (or grating) and show that the modal model does not contain the phase changes seen in an otherwise geometric planewave approach. The modal decomposition description is justified by verifying experimentally that the phase of a diffracted Gaussian beam is independent of the beam shape, achieved by comparing the phase change between a zero-order and first-order mode beam. To interpret our findings we employ a rigorous time-domain simulation to demonstrate that the phase changes resulting from a modal decomposition are correct, provided that the coordinate system which measures the phase is moved simultaneously with the effective beam displacement. This indeed corresponds to the phase change observed in the geometric planewave model. The change in the coordinate system does not instinctively occur within the analytical framework, and therefore requires either a manual change in the coordinate system or an addition of the geometric planewave phase factor.

Michelson interferometer with diffractively-coupled arm resonators in second-order Littrow configuration.

Michelson-type laser-interferometric gravitational-wave (GW) observatories employ very high light powers as well as transmissively-coupled Fabry-Perot arm resonators in order to realize high measurement sensitivities. Due to the absorption in the transmissive optics, high powers lead to thermal lensing and hence to thermal distortions of the laser beam profile, which sets a limit on the maximal light power employable in GW observatories. Here, we propose and realize a Michelson-type laser interferometer with arm resonators whose coupling components are all-reflective second-order Littrow gratings. In principle such gratings allow high finesse values of the resonators but avoid bulk transmission of the laser light and thus the corresponding thermal beam distortion. The gratings used have three diffraction orders, which leads to the creation of a second signal port. We theoretically analyze the signal response of the proposed topology and show that it is equivalent to a conventional Michelson-type interferometer. In our proof-of-principle experiment we generated phase-modulation signals inside the arm resonators and detected them simultaneously at the two signal ports. The sum signal was shown to be equivalent to a single-output-port Michelson interferometer with transmissively-coupled arm cavities, taking into account optical loss. The proposed and demonstrated topology is a possible approach for future all-reflective GW observatory designs.

Waveguide grating mirror in a fully suspended 10 meter Fabry-Perot cavity.

We report on the first demonstration of a fully suspended 10 m Fabry-Perot cavity incorporating a waveguide grating as the coupling mirror. The cavity was kept on resonance by reading out the length fluctuations via the Pound-Drever-Hall method and employing feedback to the laser frequency. From the achieved finesse of 790 the grating reflectivity was determined to exceed 99.2% at the laser wavelength of 1064 nm, which is in good agreement with rigorous simulations. Our waveguide grating design was based on tantala and fused silica and included a ≈ 20 nm thin etch stop layer made of Al2O3 that allowed us to define the grating depth accurately and preserve the waveguide thickness during the fabrication process. Demonstrating stable operation of a waveguide grating featuring high reflectivity in a suspended low-noise cavity, our work paves the way for the potential application of waveguide gratings as mirrors in high-precision interferometry, for instance in future gravitational wave observatories.

Diffractively coupled Fabry-Perot resonator with power-recycling.

We demonstrate the optical coupling of two cavities without light transmission through a substrate. As the all-reflective coupling component, we use a dielectric low-efficiency 3-port diffraction grating. In contrast to a conventional transmissive coupling component, such an all-reflective coupler avoids all thermal effects that are associated with light absorption in the substrate. An all-reflective scheme for cavity coupling is of interest in the field of gravitational wave detection. In such detectors light that is resonantly enhanced inside the so-called power-recycling cavity is coupled to (kilometre-scale) Fabry-Perot resonators representing the arms of a Michelson interferometer. We realized such an all-reflective coupling in a table-top experiment. Our findings are in qualitative agreement with the theoretical model incorporating the characteristics of the 3-port grating used, and therefore encourage the application of all-reflective cavity couplers in future gravitational wave detectors.

Reflective cavity couplers based on resonant waveguide gratings.

We report on a novel concept for reflective diffractive cavity couplers based on resonant waveguide gratings instead of multilayer coatings. The diffracting or rather beam splitting properties are induced to the subwavelength structures by a periodic parameter modulation of the ridges. Since such a perturbation of the highly reflective system also enhances transmission stacks of two and three reflectors are considered to retrieve transmittivities as low as possible. Our calculations show that transmissions of less than 10(-4) are possible for different configurations based on silicon and silica. The results of first technological tests for the realization of stacked T-shape structures are presented. With a total effective layer thickness not exceeding 1.1 µm the discussed approaches are expected to remarkably reduce the urgent problem of coating thermal noise of conventional components for high-precision metrology.

Pound-Drever-Hall error signals for the length control of three-port grating coupled cavities.

Gratings enable light coupling into an optical cavity without transmission through any substrate. This concept reduces light absorption and substrate heating and was suggested for light coupling into the arm cavities of future gravitational wave detectors. One particularly interesting approach is based on all-reflective gratings with low diffraction efficiencies and three diffraction orders (three ports). However, it was discovered that, generally, three-port grating coupled cavities show an asymmetric resonance profile that results in asymmetric and low quality Pound-Drever-Hall error signals for cavity length control. We experimentally demonstrate that this problem is solved by the detection of light at both reflection ports of the cavity and the postprocessing of the two demodulated electronic signals.

Widely tunable monolithic narrowband grating filter for near-infrared radiation.

We propose a monolithic narrowband guided-mode grating filter in fused silica that is widely tunable in the near-IR wavelength region. Based on a recently demonstrated approach for a monolithic reflector comprising an encapsulated grating, we theoretically investigate such a device by means of rigorous modeling aimed at a narrow linewidth. It is demonstrated that upon a spatial variation of the filter's grating period its resonance wavelength can be tuned in a remarkably wide range of near-IR radiation with 800 nm<λ(res)< 1600 nm by translating the laser beam relative to the grating area. The filter performance in terms of linewidth and contrast is essentially preserved over the entire tuning interval.

Enhanced angular tolerance of resonant waveguide grating reflectors.

We introduce an approach to enhance the angular tolerance of resonant waveguide gratings by stacking two resonant structures on top of each other. It is shown that reflectivities close to unity can be retrieved over the entire angular spectrum by a double T-shaped grating configuration. Although a combination of silicon as the high-index and diamond as the low-index material is considered, the principles of our new approach can also be used to realize monolithic silicon structures with similar properties. We illustrate that the functionality of the device can be understood by a decomposition into separated elements. Our approach might have compelling applications as new diffractive-reflective optical components with low-coating thermal noise in the field of high-precision metrology.

All-reflective coupling of two optical cavities with 3-port diffraction gratings.

The shot-noise limited sensitivity of Michelson-type laser interferometers with Fabry-Perot arm cavities can be increased by the so-called power-recycling technique. In such a scheme the power-recycling cavity is optically coupled with the interferometer's arm cavities. A problem arises because the central coupling mirror transmits a rather high laser power and may show thermal lensing, thermo-refractive noise and photo-thermo-refractive noise. Cryogenic cooling of this mirror is also challenging, and thus thermal noise becomes a general problem. Here, we theoretically investigate an all-reflective coupling scheme of two optical cavities based on a 3-port diffraction grating.We show that power-recycling of a high-finesse arm cavity is possible without transmitting any laser power through a substrate material. The power splitting ratio of the three output ports of the grating is, surprisingly, noncritical.

Realization of a monolithic high-reflectivity cavity mirror from a single silicon crystal.

We report on the first experimental realization of a high-reflectivity cavity mirror that solely consists of a single silicon crystal. Since no material was added to the crystal, the urgent problem of "coating thermal noise" that currently limits classical as well as quantum measurements is avoided. Our mirror is based on a surface nanostructure that creates a resonant surface waveguide. In full agreement with a rigorous model we realized a reflectivity of (99.79+/-0.01)% at a wavelength of 1.55 microm, and achieved a cavity finesse of 2784. We anticipate that our achievement will open the avenue to next generation high-precision experiments targeting fundamental questions of physics.

Demonstration of a cavity coupler based on a resonant waveguide grating.

Thermal noise in multilayer optical coatings may not only limit the sensitivity of future gravitational wave detectors in their most sensitive frequency band but is also a major impediment for experiments that aim to reach the standard quantum limit or to cool mechanical systems to their quantum ground state. Here, we present the experimental realization and characterization of a cavity coupler, which is based on a surface relief guided ode resonant grating. Since the required thickness of the dielectric coating is dramatically decreased compared to conventional mirrors, it is expected to provide low mechanical loss and, thus, low thermal noise. The cavity coupler was incorporated into a Fabry-Perot resonator together with a conventional high quality mirror. The finesse of this cavity was measured to be F = 657, which corresponds to a coupler reflectivity of R = 99.08 %.

Encapsulated subwavelength grating as a quasi-monolithic resonant reflector.

For a variety of laser interferometric experiments, the thermal noise of high-reflectivity multilayer dielectric coatings limits the measurement sensitivity. Recently, monolithic high-reflection waveguide mirrors with nanostructured surfaces have been proposed to reduce the thermal noise in interferometric measurements. Drawbacks of this approach are a highly complicated fabrication process and the high susceptibility of the nanostructured surfaces to damage and pollution. Here, we propose and demonstrate a novel quasi-monolithic resonant surface reflector that also avoids the thick dielectric stack of conventional mirrors but has a flat and robust surface. Our reflector is an encapsulated subwavelength grating that is based on silicon. We measured a high reflectivity of 93% for a wavelength of lambda = 1.55 microm under normal incidence. Perfect reflectivities are possible in theory.

Reflection-reduced encapsulated transmission grating.

We present the design and realization of a highly dispersive dielectric transmission grating with 97.0% diffraction efficiency. This grating is embedded in fused silica, which allows for an efficient suppression of any reflection losses. It is very easy to handle and clean, and its monolithic layout gives rise to high resistance against laser-induced damage and long-term stability comparable to conventional fused silica components.

Monolithic dielectric surfaces as new low-loss light-matter interfaces.

We propose a new mirror architecture, which is solely based upon structuring of the surface of a monolithic, possibly monocrystalline, bulk material. We found that a structure of T-shaped ridges of a subwavelength grating can theoretically provide 100% reflectivity. Since no material needs to be added to the mirror device, lowest mechanical loss can also be expected. Our approach might have compelling applications as a new light-matter interface.