Fan Yang, Xiangmeng Meng, Stephen Nugraha Putra, Antoni Artinov, Marcel Bachmann, Michael Rethmeier
The effect of the oscillating metal vapor plume on the keyhole and molten pool behavior during the laser beam welding of AlMg3 aluminum alloys is investigated by experimental and numerical methods. The real-time height of the metal vapor plume is measured by high-speed camera observation. The obtained experimental results are used to evaluate the additional heating source and laser beam attenuation caused by the scattering and absorption based on the Beer–Lambert theory. Furthermore, the dynamic behavior of the metal vapor plume is incorporated into a 3D transient heat transfer and fluid flow model, coupled with the ray tracing method, for the laser beam welding of the AlMg3 alloy. It is found that additional heating resulting from the scattered and absorbed laser beam energy by the metal vapor plume significantly expands the shape of the molten pool on the top region. Moreover, the oscillating metal vapor plume caused the fluctuation of the high-temperature region in the molten pool. The probability of keyhole collapse at the bottom increases 17% due to the oscillating laser power induced by the laser beam attenuation. The internal interplay between the metal vapor plume, molten pool shape, and keyhole collapse is obtained. The developed model has been validated by experiments, which shows a good agreement.
{"title":"Numerical analysis of the effect of an oscillating metal vapor plume on the keyhole and molten pool behavior during deep penetration laser beam welding","authors":"Fan Yang, Xiangmeng Meng, Stephen Nugraha Putra, Antoni Artinov, Marcel Bachmann, Michael Rethmeier","doi":"10.2351/7.0001094","DOIUrl":"https://doi.org/10.2351/7.0001094","url":null,"abstract":"The effect of the oscillating metal vapor plume on the keyhole and molten pool behavior during the laser beam welding of AlMg3 aluminum alloys is investigated by experimental and numerical methods. The real-time height of the metal vapor plume is measured by high-speed camera observation. The obtained experimental results are used to evaluate the additional heating source and laser beam attenuation caused by the scattering and absorption based on the Beer–Lambert theory. Furthermore, the dynamic behavior of the metal vapor plume is incorporated into a 3D transient heat transfer and fluid flow model, coupled with the ray tracing method, for the laser beam welding of the AlMg3 alloy. It is found that additional heating resulting from the scattered and absorbed laser beam energy by the metal vapor plume significantly expands the shape of the molten pool on the top region. Moreover, the oscillating metal vapor plume caused the fluctuation of the high-temperature region in the molten pool. The probability of keyhole collapse at the bottom increases 17% due to the oscillating laser power induced by the laser beam attenuation. The internal interplay between the metal vapor plume, molten pool shape, and keyhole collapse is obtained. The developed model has been validated by experiments, which shows a good agreement.","PeriodicalId":50168,"journal":{"name":"Journal of Laser Applications","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135967754","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Christyane Oliveira Leão Almeida, Odair José Pereira dos Santos, Renato Camponogara Panziera, Manoel Kolling Dutra, Milton Pereira, Marcelo dos Santos Pereira
Steel sheets are produced with increasingly smaller thicknesses, without compromising the properties of the steel, maintaining ductility, strength, and energy absorption after impact can total depth enhance vehicle energy efficiency, lower manufacturing costs, and address the springback effect. The springback effect of laser-welded DP600 two-phase steel sheets was studied in this research. Parameters such as punching speed, initial bending angle, and time were varied. Tests including tensile tests, Vickers hardness, and optical microscopy analysis were conducted to correlate results with material properties. Autogenous laser welding joined DP600 steel plates at the bending position. Controlling springback ensures better quality in vehicle manufacturing and assembly. The results revealed that increasing the punch descent speed from 4 to 12 mm/min, for an internal angle of 90°, on the first day of observation, led to higher springback values (0.58°–3.3°, respectively), while increasing the initial curvature angle (30°–90°), maintaining a constant speed of 4 mm/min on the first day of observation, and impacting the elastic return (6.74°–0.58°, respectively). Furthermore, the observation time demonstrated a continuous increase in the springback variation during 6 days after the flexural test before stabilization (6.89°– 8.7°), maintaining a constant value of 8 mm/min and the internal angle of doubles of 30°.
{"title":"Analysis of the springback effect of laser welded DP600 high-strength steel thin sheets","authors":"Christyane Oliveira Leão Almeida, Odair José Pereira dos Santos, Renato Camponogara Panziera, Manoel Kolling Dutra, Milton Pereira, Marcelo dos Santos Pereira","doi":"10.2351/7.0001100","DOIUrl":"https://doi.org/10.2351/7.0001100","url":null,"abstract":"Steel sheets are produced with increasingly smaller thicknesses, without compromising the properties of the steel, maintaining ductility, strength, and energy absorption after impact can total depth enhance vehicle energy efficiency, lower manufacturing costs, and address the springback effect. The springback effect of laser-welded DP600 two-phase steel sheets was studied in this research. Parameters such as punching speed, initial bending angle, and time were varied. Tests including tensile tests, Vickers hardness, and optical microscopy analysis were conducted to correlate results with material properties. Autogenous laser welding joined DP600 steel plates at the bending position. Controlling springback ensures better quality in vehicle manufacturing and assembly. The results revealed that increasing the punch descent speed from 4 to 12 mm/min, for an internal angle of 90°, on the first day of observation, led to higher springback values (0.58°–3.3°, respectively), while increasing the initial curvature angle (30°–90°), maintaining a constant speed of 4 mm/min on the first day of observation, and impacting the elastic return (6.74°–0.58°, respectively). Furthermore, the observation time demonstrated a continuous increase in the springback variation during 6 days after the flexural test before stabilization (6.89°– 8.7°), maintaining a constant value of 8 mm/min and the internal angle of doubles of 30°.","PeriodicalId":50168,"journal":{"name":"Journal of Laser Applications","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136012851","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Sharhid Jabar, Tianzhu Sun, Pasquale Franciosa, Hiren R. Kotadia, Darek Ceglarek, Bryan Paolini, Richard Faulhaber
Advances in laser beam shaping technologies are being studied and are considered beneficial in many aspects of dissimilar metal joining, which include reducing intermetallic compounds (IMCs), optimizing weld pool profiles, and controlling porosity and spatters. This paper utilizes a coaxial ring and core dual beam laser and aims to study the impact of the power ratios between core and ring beams on the weldability of 1100 aluminum alloy to hilumin (steel). High-resolution electron microscopy was performed in the cross sections of the weld pools to quantify the melt pool composition and subsequent IMC formation and weld defects (cracking and cavitation). Lap-shear mechanical testing and electrical resistivity testing were also carried out. Results showed that the optimal power ratio for lap-shear strength was 0.4 (intermediate core and ring) due to the reduction in the Fe-rich liquid into the upper weld region. As a result, this produced a smaller interface between the Fe-rich region and Al, thus reducing the formation of the most detrimental IMC (e.g., Fe2Al5). Conversely, a power ratio of 0.2 (core-dominant) was found beneficial for reducing electrical resistance due to a reduced total IMC volume.
{"title":"Effect of a ring-shaped laser beam on the weldability of aluminum-to-hilumin for battery tab connectors","authors":"Sharhid Jabar, Tianzhu Sun, Pasquale Franciosa, Hiren R. Kotadia, Darek Ceglarek, Bryan Paolini, Richard Faulhaber","doi":"10.2351/7.0001156","DOIUrl":"https://doi.org/10.2351/7.0001156","url":null,"abstract":"Advances in laser beam shaping technologies are being studied and are considered beneficial in many aspects of dissimilar metal joining, which include reducing intermetallic compounds (IMCs), optimizing weld pool profiles, and controlling porosity and spatters. This paper utilizes a coaxial ring and core dual beam laser and aims to study the impact of the power ratios between core and ring beams on the weldability of 1100 aluminum alloy to hilumin (steel). High-resolution electron microscopy was performed in the cross sections of the weld pools to quantify the melt pool composition and subsequent IMC formation and weld defects (cracking and cavitation). Lap-shear mechanical testing and electrical resistivity testing were also carried out. Results showed that the optimal power ratio for lap-shear strength was 0.4 (intermediate core and ring) due to the reduction in the Fe-rich liquid into the upper weld region. As a result, this produced a smaller interface between the Fe-rich region and Al, thus reducing the formation of the most detrimental IMC (e.g., Fe2Al5). Conversely, a power ratio of 0.2 (core-dominant) was found beneficial for reducing electrical resistance due to a reduced total IMC volume.","PeriodicalId":50168,"journal":{"name":"Journal of Laser Applications","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136013143","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yongting Yang, Daniel Franz, Cemal Esen, Ralf Hellmann
We demonstrate an innovative beam stabilization concept consisting of complementary metal-oxide semiconductor cameras and piezo actuators for a six-axis articulated ultrashort pulsed laser robot system. The beam stabilization system is fixed on robot axes 4 and 5. Moving robot axis 5 in an angular range between 0° and 90°, the laser beam position coupled to the actual robot position is monitored by two cameras integrated on robot axis 5 and used for laser beam characterization and model generation. A mathematical description and models generated with machine learning methods, namely, linear regression and neural network, are compared for predicting the beam position drift as a function of robot axis motion, where the neural network model shows a low prediction tolerance of about 7 pixels. In addition, a stand-alone time-triggered beam correction algorithm is developed and implemented on the system, which shows an excellent correction performance for large beam position drifts (below 500 pixels).
{"title":"Development and comparison of algorithms for beam stabilization in ultrashort pulsed laser equipped on a six-axis robot","authors":"Yongting Yang, Daniel Franz, Cemal Esen, Ralf Hellmann","doi":"10.2351/7.0001169","DOIUrl":"https://doi.org/10.2351/7.0001169","url":null,"abstract":"We demonstrate an innovative beam stabilization concept consisting of complementary metal-oxide semiconductor cameras and piezo actuators for a six-axis articulated ultrashort pulsed laser robot system. The beam stabilization system is fixed on robot axes 4 and 5. Moving robot axis 5 in an angular range between 0° and 90°, the laser beam position coupled to the actual robot position is monitored by two cameras integrated on robot axis 5 and used for laser beam characterization and model generation. A mathematical description and models generated with machine learning methods, namely, linear regression and neural network, are compared for predicting the beam position drift as a function of robot axis motion, where the neural network model shows a low prediction tolerance of about 7 pixels. In addition, a stand-alone time-triggered beam correction algorithm is developed and implemented on the system, which shows an excellent correction performance for large beam position drifts (below 500 pixels).","PeriodicalId":50168,"journal":{"name":"Journal of Laser Applications","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136013572","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Qamar Hayat, Pasquale Franciosa, Giovanni Chianese, Anand Mohan, Dariusz Ceglarek, Alexander Griffiths, Christopher Harris
In the attempt to produce lighter battery packs at a lower cost, replacing common copper parts with aluminum components has been a popular approach in recent years. With regard to joining technologies, there is a growing interest in applying laser beam welding in battery pack manufacturing due to several advantages such as single-sided and noncontact access while maintaining a narrow heat-affected zone. Motivated by the need to control and reduce weld porosity in AA1060 battery busbar welding with the ultimate goal to enhance durability and reduce electrical resistance, this paper has been developed with the aim to studying the effect of laser beam shaping on porosity formation and, hence, generate knowledge about the underlying physics of the welding process itself. First, a multiphysics computational fluid dynamics model has been developed and calibrated to experimental data; then, the model has been deployed to study the effect of both circular and tailing beam shapes on melt pool dynamics and the evolution of porosity due to the instability of the keyhole. The study elucidated the importance of the keyhole’s necking on porosity formation. Findings showed that the tail beam shapes, compared to the circular spot, have a pronounced effect on the reduction of the necking effect of the keyhole—this helps to reduce number of collapsing events of the keyhole itself, thereby leading to the reduction of porosity formation.
{"title":"Elucidating the effect of circular and tailing laser beam shapes on keyhole necking and porosity formation during laser beam welding of aluminum 1060 using a multiphysics computational fluid dynamics approach","authors":"Qamar Hayat, Pasquale Franciosa, Giovanni Chianese, Anand Mohan, Dariusz Ceglarek, Alexander Griffiths, Christopher Harris","doi":"10.2351/7.0001150","DOIUrl":"https://doi.org/10.2351/7.0001150","url":null,"abstract":"In the attempt to produce lighter battery packs at a lower cost, replacing common copper parts with aluminum components has been a popular approach in recent years. With regard to joining technologies, there is a growing interest in applying laser beam welding in battery pack manufacturing due to several advantages such as single-sided and noncontact access while maintaining a narrow heat-affected zone. Motivated by the need to control and reduce weld porosity in AA1060 battery busbar welding with the ultimate goal to enhance durability and reduce electrical resistance, this paper has been developed with the aim to studying the effect of laser beam shaping on porosity formation and, hence, generate knowledge about the underlying physics of the welding process itself. First, a multiphysics computational fluid dynamics model has been developed and calibrated to experimental data; then, the model has been deployed to study the effect of both circular and tailing beam shapes on melt pool dynamics and the evolution of porosity due to the instability of the keyhole. The study elucidated the importance of the keyhole’s necking on porosity formation. Findings showed that the tail beam shapes, compared to the circular spot, have a pronounced effect on the reduction of the necking effect of the keyhole—this helps to reduce number of collapsing events of the keyhole itself, thereby leading to the reduction of porosity formation.","PeriodicalId":50168,"journal":{"name":"Journal of Laser Applications","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135967882","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Laser structuring can be applied to composite electrodes of lithium-ion cells to enhance wetting and to facilitate the usage of thick-film electrodes by reducing the lithium-ion diffusion overpotential and the tortuosity of the electrodes or the usage of electrodes containing silicon, where additional porosity is required to compensate the volume expansion during lithium de-/insertion. To integrate the additional laser processing step in the well-established electrode manufacturing route, the laser processing speed must be significantly increased to match with the belt speed, which is dependent on the electrode thickness and the type of manufacturing route. Upscaling can be realized by increasing the average laser power, laser intensity, and/or laser repetition rate. Here, an ultrashort pulsed laser source with an average power of 300 W and a pulse duration of 600 fs was applied. For the first time, the presented research provides detailed laser ablation processing data for thick-film composite anodes associated with high repetition rates ranging from 4.9 to 48.8 MHz. The patterning results are compared depending on the widths, depths, aspect ratios, the total appearance regarding debris and cracks, and the volume ablation rate. In high repetition rate laser patterning, the subsequent laser pulses interact with the material vapor plasma generated by the previous laser pulses, resulting in lower ablation depths and higher ablation widths. The increase in laser peak intensity leads to higher achievable ablation depths. Processing strategies are identified for two different ablation scenarios focusing on the pouch cells of a Volkswagen ID.3 and the Tesla 4680 cell.
{"title":"High repetition ultrafast laser ablation of graphite and silicon/graphite composite electrodes for lithium-ion batteries","authors":"Alexandra Meyer, Yannic Sterzl, Wilhelm Pfleging","doi":"10.2351/7.0001180","DOIUrl":"https://doi.org/10.2351/7.0001180","url":null,"abstract":"Laser structuring can be applied to composite electrodes of lithium-ion cells to enhance wetting and to facilitate the usage of thick-film electrodes by reducing the lithium-ion diffusion overpotential and the tortuosity of the electrodes or the usage of electrodes containing silicon, where additional porosity is required to compensate the volume expansion during lithium de-/insertion. To integrate the additional laser processing step in the well-established electrode manufacturing route, the laser processing speed must be significantly increased to match with the belt speed, which is dependent on the electrode thickness and the type of manufacturing route. Upscaling can be realized by increasing the average laser power, laser intensity, and/or laser repetition rate. Here, an ultrashort pulsed laser source with an average power of 300 W and a pulse duration of 600 fs was applied. For the first time, the presented research provides detailed laser ablation processing data for thick-film composite anodes associated with high repetition rates ranging from 4.9 to 48.8 MHz. The patterning results are compared depending on the widths, depths, aspect ratios, the total appearance regarding debris and cracks, and the volume ablation rate. In high repetition rate laser patterning, the subsequent laser pulses interact with the material vapor plasma generated by the previous laser pulses, resulting in lower ablation depths and higher ablation widths. The increase in laser peak intensity leads to higher achievable ablation depths. Processing strategies are identified for two different ablation scenarios focusing on the pouch cells of a Volkswagen ID.3 and the Tesla 4680 cell.","PeriodicalId":50168,"journal":{"name":"Journal of Laser Applications","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136012565","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Laura Budde, Nick Schwarz, Jörg Hermsdorf, Stefan Kaierle, Ludger Overmeyer
In this study, the application of the ABA cladding strategy in coaxial wire-based cladding processes is investigated. Individual weld seams (A) are first welded on the substrate and additional weld seams (B) are deposited into the intermediate spaces in the second step. Thereby, two different seam geometries are present in the cladding. Unidirectional AAA and ABA claddings are generated using laser hot-wire cladding and analyzed with respect to the quality criteria height, waviness, degree of dilution, and defects. Three different welding parameter sets are used to consider the effect of the contact angle on the applicability of the ABA cladding strategy. When the same process parameters and seam-to-seam offsets are used for the ABA cladding, as for the AAA cladding, the B weld seams are higher than the A weld seams and an uneven ridged cladding surface is present. Two approaches to solving this problem are considered. The cross-sectional area of the B weld seams is reduced by adjusting the welding speeds or an increase in the seam-to-seam offset. Both measures result in a significant reduction in waviness of 30%–58% compared to the AAA cladding. However, lack of fusion defects occurs more frequently at the deposition regime of the B weld seams. It was, therefore, necessary to adjust the process parameters for weld seam B.
{"title":"Application of the ABA cladding technique to a wire based laser cladding process","authors":"Laura Budde, Nick Schwarz, Jörg Hermsdorf, Stefan Kaierle, Ludger Overmeyer","doi":"10.2351/7.0001115","DOIUrl":"https://doi.org/10.2351/7.0001115","url":null,"abstract":"In this study, the application of the ABA cladding strategy in coaxial wire-based cladding processes is investigated. Individual weld seams (A) are first welded on the substrate and additional weld seams (B) are deposited into the intermediate spaces in the second step. Thereby, two different seam geometries are present in the cladding. Unidirectional AAA and ABA claddings are generated using laser hot-wire cladding and analyzed with respect to the quality criteria height, waviness, degree of dilution, and defects. Three different welding parameter sets are used to consider the effect of the contact angle on the applicability of the ABA cladding strategy. When the same process parameters and seam-to-seam offsets are used for the ABA cladding, as for the AAA cladding, the B weld seams are higher than the A weld seams and an uneven ridged cladding surface is present. Two approaches to solving this problem are considered. The cross-sectional area of the B weld seams is reduced by adjusting the welding speeds or an increase in the seam-to-seam offset. Both measures result in a significant reduction in waviness of 30%–58% compared to the AAA cladding. However, lack of fusion defects occurs more frequently at the deposition regime of the B weld seams. It was, therefore, necessary to adjust the process parameters for weld seam B.","PeriodicalId":50168,"journal":{"name":"Journal of Laser Applications","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136012733","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
The processability of pure Inconel X750 and Inconel X750 mixed with 15 vol. % of titanium carbide particulate through laser-directed energy deposition (l-DED) was evaluated. The powders used had a particle size in a range unusual to l-DED processing (0.18–24.05 μm); this case study presents difficulties in processing thin quadri-modal powder and describes possible measures to mitigate them, while also reporting, likely for the first time, on the l-DED processing of Inconel X750 and such related metal matrix composite (MMC). The choice in reinforcement particle size and composition aimed for a reduction in material density and insertion of additional reinforcement mechanisms. Both powders used were analyzed in an FT4 rheometer and compared to reference Inconel 625 powder. l-DED was made viable, but results show that the powders tested here represent a lower limit for the rheological properties accepted by usual l-DED systems. A methodology to quantify the stability of a given processing condition is presented and validated, also indicating that low powder flows are recommended when processing powders of this sort. Inconel X750 demonstrated sensibility to oxidation during processing as depletion of Al and Ti was detected in the deposits. Neither the MMC nor the pure material cracked or showed excessive porosity.
{"title":"Processability of thin-powdered Inconel X750 and TiC metal matrix composite by laser-directed energy deposition","authors":"Adriano de Souza Pinto Pereira, Jhonattan Gutjahr, Milton Pereira, Ulrich Tetzlaff, Márcio Celso Fredel","doi":"10.2351/7.0001134","DOIUrl":"https://doi.org/10.2351/7.0001134","url":null,"abstract":"The processability of pure Inconel X750 and Inconel X750 mixed with 15 vol. % of titanium carbide particulate through laser-directed energy deposition (l-DED) was evaluated. The powders used had a particle size in a range unusual to l-DED processing (0.18–24.05 μm); this case study presents difficulties in processing thin quadri-modal powder and describes possible measures to mitigate them, while also reporting, likely for the first time, on the l-DED processing of Inconel X750 and such related metal matrix composite (MMC). The choice in reinforcement particle size and composition aimed for a reduction in material density and insertion of additional reinforcement mechanisms. Both powders used were analyzed in an FT4 rheometer and compared to reference Inconel 625 powder. l-DED was made viable, but results show that the powders tested here represent a lower limit for the rheological properties accepted by usual l-DED systems. A methodology to quantify the stability of a given processing condition is presented and validated, also indicating that low powder flows are recommended when processing powders of this sort. Inconel X750 demonstrated sensibility to oxidation during processing as depletion of Al and Ti was detected in the deposits. Neither the MMC nor the pure material cracked or showed excessive porosity.","PeriodicalId":50168,"journal":{"name":"Journal of Laser Applications","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"136013145","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Kiran Michael, Lukas Greiner, Philip Dreizehnter, Jodok Weixler, Matthias Putzer, Timo Schudeleit, Markus Bambach, Konrad Wegener
This study investigates the feasibility of using ultra-short pulsed (USP) lasers to fabricate single crystalline diamond (SCD) tools. SCD has exceptional mechanical, tribological, and thermal properties and offers excellent performance in the precision machining of hard and brittle materials over polycrystalline diamond and diamond-coated tools. However, the anisotropic nature of the SCD makes it difficult for laser machining because the material shows susceptibility to cracking, defect growth, and breakout depending on its crystallographic orientation. Anisotropy needs to be considered while optimizing the geometry of the tool to minimize wear and improve tool performance. An advanced four-axis laser machining approach with optimized laser parameters and temporal beam shaping is used to mitigate challenges related to defect growth and orientation dependence, leading to the production of high-quality single cutting-edge SCD tools. Cylindrical diamonds and diamond crystals with top surface planes {100} and {111} are used in the study. The occurrence of defects in the diamond when laser machined and their dependence on the crystallographic orientation along the circumference of the diamond is thoroughly investigated via SEM, electron backscatter diffraction, and light microscopy images. Finally, the laser-manufactured SCD tools are tested by turning fully sintered zirconia ceramics (3Y-TZP-A). USP laser machining of SCD is demonstrated to be a viable alternative to traditional manufacturing methods for producing high-quality SCD tools with unique properties and performance. The results further emphasize the importance of understanding the crystallographic orientation dependence when laser machining crystalline materials like diamonds.
{"title":"Ultra-short pulsed laser processing of single crystalline diamonds for tooling applications","authors":"Kiran Michael, Lukas Greiner, Philip Dreizehnter, Jodok Weixler, Matthias Putzer, Timo Schudeleit, Markus Bambach, Konrad Wegener","doi":"10.2351/7.0001159","DOIUrl":"https://doi.org/10.2351/7.0001159","url":null,"abstract":"This study investigates the feasibility of using ultra-short pulsed (USP) lasers to fabricate single crystalline diamond (SCD) tools. SCD has exceptional mechanical, tribological, and thermal properties and offers excellent performance in the precision machining of hard and brittle materials over polycrystalline diamond and diamond-coated tools. However, the anisotropic nature of the SCD makes it difficult for laser machining because the material shows susceptibility to cracking, defect growth, and breakout depending on its crystallographic orientation. Anisotropy needs to be considered while optimizing the geometry of the tool to minimize wear and improve tool performance. An advanced four-axis laser machining approach with optimized laser parameters and temporal beam shaping is used to mitigate challenges related to defect growth and orientation dependence, leading to the production of high-quality single cutting-edge SCD tools. Cylindrical diamonds and diamond crystals with top surface planes {100} and {111} are used in the study. The occurrence of defects in the diamond when laser machined and their dependence on the crystallographic orientation along the circumference of the diamond is thoroughly investigated via SEM, electron backscatter diffraction, and light microscopy images. Finally, the laser-manufactured SCD tools are tested by turning fully sintered zirconia ceramics (3Y-TZP-A). USP laser machining of SCD is demonstrated to be a viable alternative to traditional manufacturing methods for producing high-quality SCD tools with unique properties and performance. The results further emphasize the importance of understanding the crystallographic orientation dependence when laser machining crystalline materials like diamonds.","PeriodicalId":50168,"journal":{"name":"Journal of Laser Applications","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135967751","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Woo-In Choo, Yoo-Eun Lee, Sungbin Im, Minsun Oh, Dongchoul Kim, Dong Hyuck Kam
Automotive lamps have not only functional roles but also highly esthetic purposes in the design of a car. As such, they use complex three-dimensional shapes to implement various designs. The main manufacturing challenge comes from the plastic bonding process of the complex components, which currently is done by thermal bonding, ultrasonic bonding, and laser welding. Laser welding processes with a narrow joint area are preferred since they require minimal joint area and produce no burr. In this study, an optimization study for simultaneous bonding of lamps is carried out using multiple light sources generated by connecting specially manufactured bundle optical fibers with a diode laser source. The diode laser beams with a wavelength of 915 nm and a power of 80 W, each, were simultaneously delivered through a 30-optical fibers bundle. The fibers were integrated within the mold that holds the lamp achieving transmission welding through the overlapped upper transparent polymer PMMA (IF850) and the lower nontransparent polymer ABS (HL121H). The process parameters investigated were the laser power, duration time, waveguide gap, and clamping pressure. We present optimized process parameters that achieved no pores and relatively uniform melting. In the shear test, the average load was approximately 1300 N, and the base sheet fractures along the welding joints were observed.
{"title":"Experimental evaluation of poly methyl methacrylate-acrylonitrile butadiene styrene transmission welding using mold-integrated simultaneous laser welding technology","authors":"Woo-In Choo, Yoo-Eun Lee, Sungbin Im, Minsun Oh, Dongchoul Kim, Dong Hyuck Kam","doi":"10.2351/7.0001144","DOIUrl":"https://doi.org/10.2351/7.0001144","url":null,"abstract":"Automotive lamps have not only functional roles but also highly esthetic purposes in the design of a car. As such, they use complex three-dimensional shapes to implement various designs. The main manufacturing challenge comes from the plastic bonding process of the complex components, which currently is done by thermal bonding, ultrasonic bonding, and laser welding. Laser welding processes with a narrow joint area are preferred since they require minimal joint area and produce no burr. In this study, an optimization study for simultaneous bonding of lamps is carried out using multiple light sources generated by connecting specially manufactured bundle optical fibers with a diode laser source. The diode laser beams with a wavelength of 915 nm and a power of 80 W, each, were simultaneously delivered through a 30-optical fibers bundle. The fibers were integrated within the mold that holds the lamp achieving transmission welding through the overlapped upper transparent polymer PMMA (IF850) and the lower nontransparent polymer ABS (HL121H). The process parameters investigated were the laser power, duration time, waveguide gap, and clamping pressure. We present optimized process parameters that achieved no pores and relatively uniform melting. In the shear test, the average load was approximately 1300 N, and the base sheet fractures along the welding joints were observed.","PeriodicalId":50168,"journal":{"name":"Journal of Laser Applications","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135591158","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
京公网安备 11010802042870号
京ICP备2023020795号-1
扫码关注我们
求助内容：
应助结果提醒方式：