Laser repetitive pulse heating of tool surface

Laser heating of a cemented carbide tool is considered and the temperature field as well as phase changes in the heated region is modeled. Temperature rise, liquid layer thickness, and mushy size are predicted numerically. A control volume approach is introduced to solve the governing equations of heat transfer and phase change. Consecutive pulses with the duty cycle of 60% are accommodated in the simulations in line with the experimental conditions. An experiment is carried out to treat the cemented carbide tool surfaces using the CO₂ laser delivering consecutive pulses. The treated surfaces and their cross-sections are examined using the scanning electron microscope (SEM). It is found that the temperature gradient is high along the laser beam axis resulting in cracks at the irradiated surface. The rapid solidification of the surface causes compact structures with very fine grains in the surface region of the laser irradiated spot.     

Laser control melting of alumina surfaces and thermal stress analysis

Laser gas assisted melting of alumina surface is carried out and temperature as well as stress fields developed in the irradiated region are predicted using the finite element method (FEM). An experiment is conducted resembling the simulation conditions. Optical and scanning electron microscope (SEM) are used to examine the morphological and the metallurgical changes in the laser treated region. The X-ray diffraction (XRD) technique is used to determine the residual stress developed in the irradiated region. It is found that the residual stress predicted agreed with the measurement result. High heating and cooling rates result in high von Mises stress levels in the surface region.     

Laser bending of AISI 304 steel sheets: Thermal stress analysis

Laser induced bending of steel sheet is carried out and thermal stress developed in the heated region is examined. Temperature and stress fields are predicted using the finite element model. The microstructural changes in the melted region are investigated through scanning electron microscope, energy dispersive spectroscopy and X-ray diffraction. The residual stress developed at the surface vicinity of the laser treated region is measured using the X-ray diffraction technique, which is then compared with its counterpart predicted from the simulations. It is found that the residual stress at the surface vicinity is compressive and the prediction of the residual stress agrees well with that obtained from the X-ray diffraction technique. In addition, surface temperature predictions are in good agreement with the thermocouple data. The laser treated region is free from major cracks and large cavities.     

Analytical investigation into laser pulse heating and thermal stresses

Laser pulse heating of metallic surfaces results in rapid rise of temperature in the region irradiated by the laser beam. This in turn results in high temperature gradient in this region. The irradiated substrate material expands as a response to the temperature gradient. Consequently, high thermal stress levels are developed in the region of the high temperature gradient. In the present study, closed form solutions for temperature and stress fields due to a laser pulse decaying exponentially in time are presented. A Laplace transformation method is employed in the analysis. The resulting equations are non-dimensionalized with the appropriate parameters. It is found that temperature rises rapidly during the early heating period in the surface region. In this case, internal energy gain dominates the conduction losses from the surface vicinity. The thermal stress levels attain high values in the surface region. The stress wave developed is compressive and it propagates with a wave speed c₁ inside the substrate.     

Comparison of Cut Path Deviation Between CO2 and Diode Lasers in Float-Glass Cutting

Laser cutting of glass using the controlled fracture technique leads to cut path deviation at the leading and trailing edges of the float glass sheet. In this technique, thermal stresses are used to induce the crack, and the material is separated along the cutting path by extending the crack. We show that the cut path deviation is partly due to high magnitudes of thermal stresses generated near the sheet edges. The absorption of intense radiation from the CO₂ and diode laser beams in the glass causes local temperature increases and consequently generates different thermal fields and stress distributions due to surface and volumetric heat absorption. In this paper, we report the effect of the CO₂ and diode laser wavelength interaction with the float glass and its effect on the magnitudes of thermal stresses generated near the edges of the glass sheet. We simulate the distribution of the thermal stress and temperature using finite-element analysis software Abaqus and validate it against the experimental data. We show that the CO₂ laser produces a lower surface quality and a larger cut path deviation at the leading and trailing edges of the glass sheet as compared to the diode laser.     

Laser texturing of Hastelloy C276 alloy surface for improved hydrophobicity and friction coefficient

Laser treatment of Hastelloy C276 alloy is carried out under the high pressure nitrogen assisting gas environment. Morphological and metallurgical changes in the laser treated layer are examined using the analytical tools including, scanning electron and atomic force microscopes, X-ray diffraction, energy dispersive spectroscopy, and Fourier transform infrared spectroscopy. Microhardness is measured and the residual stress formed in the laser treated surface is determined from the X-ray data. The hydrophibicity of the laser treated surface is assessed using the sessile drop method. Friction coefficient of the laser treated layer is obtained incorporating the micro-tribometer. It is found that closely spaced laser canning tracks create a self-annealing effect in the laser treated layer and lowers the thermal stress levels through modifying the cooling rates at the surface. A dense structure, consisting of fine size grains, enhances the microhardness of the surface. The residual stress formed at the surface is compressive and it is in the order of −800 MPa. Laser treatment improves the surface hydrophobicity significantly because of the formation of surface texture composing of micro/nano-pillars.     

Laser surface treatment of Inconel 718 alloy: Thermal stress analysis

Laser heating of Inconel 718 alloy is considered and the resulting temperature and stress fields are predicted using the finite element method (FEM). An experiment is carried out to treat the alloy surface by a laser beam at high pressure nitrogen environment. The metallurgical and morphological changes in the irradiated region are examined using the Scanning Electron Microscope (SEM), optical microscope, and X-ray Diffraction (XRD). It is found that the surface hardness of the alloy improves after the laser heating process, which is due to the microstructural changes and γ-phase nitride formation in the surface region. The maximum value of the residual stress predicted in the irradiated region is close to the yielding limit of the alloy.     

Laser gas-assisted processing of carbon coated and TiC embedded Ti-6Al-4V alloy surface

Laser gas-assisted treatment of Ti-6Al-4V alloy surface is carried out. The alloy surface is initially coated by a carbon layer, in which the TiC particles are embedded prior to laser processing of the surface. The carbon coating with the presence of TiC particles on the workpiece surface is expected to result in carbonitride compound in the surface vicinity after the laser treatment process. Optical and scanning electron microscopes are used to examine the morphological and the metallurgical changes in the laser treated layer. The residual stress formed in the surface region after the laser treatment process is critical for the practical applications of the resulting surface. Therefore, the residual stress formed in the laser treated region is predicted from the analytically equation. The X-ray diffraction technique is incorporated to obtain the residual stress formed in the surface region. It is found that the residual stress predicted agrees with the X-ray diffraction data. The dense structures consisting of TiC_xN_1−x, TiN_x, Ti₂N, and TiC compounds are formed in the surface region of the treated layer. This, in turn, significantly increases the microhardness at the surface.     

Laser cutting of holes in thick sheet metals: Development of stress field

Laser cutting of hole in a mild steel thick sheet metal is investigated. Temperature and stress fields developed around the cutting section are simulated using the finite element method. An experimental is carried out accommodating the simulation parameters. The residual stress developed in the cutting section is measured using the XRD technique and findings are compared with the predictions. Optical microscopy and SEM are carried out to examine the morphological changes in the cutting sections. It is found that temperature decays sharply in the region of the laser heat source, which results in high temperature gradient in this region. This causes the development of high stress levels around the cut edges. The residual stresses predicted are in agreement with the measured results.     

Laser melting of carbide tool surface: Model and experimental studies

Laser controlled melting is one of the methods to achieve structural integrity in the surface region of the carbide tools. In the present study, laser heating of carbide cutting tool and temperature distribution in the irradiated region are examined. The phase change process during the heating is modeled using the enthalpy–porosity method. The influence of laser pulse intensity distribution across the irradiated surface (β) on temperature distribution and melt formation is investigated. An experiment is carried out and the microstructural changes due to laser consecutive pulse heating is examined using the scanning electron microscope (SEM). It is found that melt depth predicted agrees with the experimental results. The maximum depth of the melt layer moves away from the symmetry axis with increasing β.     

Laser carbonitriding of alumina surface

Laser carbonitriding of alumina surfaces is examined. Temperature and stress fields developed during the laser heating of the substrate surface are predicted using the finite element method in line with the experimental conditions. The formation of Al(C, N) and AlN compounds in the surface region of irradiated workpiece is examined using X-ray Photoelectron Spectroscopy (XPS) and X-ray Diffraction (XRD). The microstructural and morphological changes in the laser irradiated region are examined using Scanning Electron Microscope (SEM). The microhardness of the resulting surface is measured and compared with the base material hardness. It is found that high temperature gradient is developed in the irradiated region, which in turn, results in high residual stress levels in this region. XPS and XRD data reveal the presence of Al (C, N) and AlN compounds in the surface region. The microhardness in the surface region of the laser treated workpiece increases significantly.     

Laser hole cutting into bronze: Thermal stress analysis

Laser hole cutting in bronze is carried out and the thermal stress formed in the cutting section is examined using a finite element code. The cut geometry and microstructural changes in the cutting section are examined using optical microscope, scanning electron microscope (SEM), and energy dispersive spectroscopy (EDS). It is found that the high conductivity of bronze increases the cooling rates within the cutting section, which influences the thermal stress field in the cutting region. The residual stress predicted is in the order of 200 MPa within the vicinity of the hole circumference. The striation pattern at the kerf surface changes towards the hole exit, which is associated with the drag forces developed in this region.     

Laser cutting of Kevlar laminates and thermal stress formed at cutting sections

Laser cutting of Kevlar laminates is carried out and thermal stress field developed in the cutting region is predicted using the finite element code. Temperature predictions are validated through the thermocouple data. The morphological changes in the cutting section are examined by incorporating optical and scanning electron microscopes. It is found that temperature predictions agree well with the thermocouple data. High values of von Mises stress are observed at the cutting edges and at the mid-thickness of the Kevlar laminate due to thermal compression formed in this region. The laser cut edges are free from whiskers; however, striation formation and some small sideways burning is observed at the kerf edges.     

Thermal dynamics-based mechanism for intense laser-induced material surface vaporization

Laser material processing involving welding, ablation and cutting involves interaction of intense laser pulses of nanosecond duration with a condensed phase. Such interaction involving high brightness radiative flux causes multitude of non-linear events involving thermal phase transition at soild-liquid-gas interfaces. A theoretical perspective involving thermal dynamics of the vaporization process and consequent non-linear multiple thermal phase transitions under the action of laser plasma is the subject matter of the present work. The computational calculations were carried out where titanium (Ti) was treated as a condensed medium. The solution to the partial differential equations governing the thermal dynamics and the underlying phase transition event in the multiphase system is based on non-stationary Eulerian variables. The Mach number M depicts significant fluctuations due to thermal instabilities associated with the laser beam flux and intensity. A conclusive amalgamation has been established which relates material surface temperature profile to laser intensity, laser flux and the pressure in the plasma cloud.      

Laser cutting of rectangular geometry into alumina tiles

Laser cutting of rectangular geometry into the 5 mm thick alumina tiles is carried out. Temperature and stress fields, which are developed during the cutting process, are simulated in line with the experimental conditions. The morphological changes in the cutting sections are examined using optical and electron scanning microscopes, energy dispersive spectroscopy, and X-ray diffraction technique. The predictions of surface temperature and the residual stress are validated through the experimental data. It is found that von Mises stress attains high values in the region of the mid-thickness of the workpiece. The laser cut sections are free from major cracks and large scale sideways burning. The predictions of surface temperature and residual stress agree well with their counterparts obtained from the experiment.     

Theoretical and experimental analysis of high power diode laser (HPDL) hardening of AISI 1045 steel

Laser surface hardening makes use of the rapid and cooling cycles produced on metals surfaces exposed to a scanning laser beam without affecting the bulk of the sample. Mechanical and chemical properties of the surface can be enhanced through the metallurgical transformations that take place during the mentioned thermal cycles. Steels and cast irons are the usual materials to be hardened by laser and recently the high power diode lasers (HPDL) became the appropriate tool to carry out this process. In this work, some systematic experiments have been carried out to harden AISI 1045 surface samples by a cw (HPDL) working at different power levels (470, 760 W). The main processing parameters (scanning velocity and density power of the laser beam) were tuned from the prediction realized by the numerical (ANSYS) analysis of the heat conduction involved in the process. Such analysis allowed us to put in evidence the variation of the temperature and the cooling rate of the steel sample surface, affecting the uniformity of the demanding mechanical properties of the surface. In this way, a close-loop temperature control of the surface was justified in order to keep the hardness value within the range required. The formation of martensite phase in the laser treated superficial zone confirmed the hardening of the steel.     

Laser controlled melting of pre-prepared inconel 718 alloy surface

Laser treatment of Inconel 718 alloy surface is carried out. The alloy surface is coated with a carbon layer containing 7% TiC particles prior to the laser treatment. The carbon coating provides increased absorption of the incident laser beam and holds TiC particles. The microstrutural and morphological changes in the laser treated region are examined using optical and scanning electron microscopes, energy dispersive spectroscopy, and X-ray diffraction. The microhardness of the surface is measured and the residual stress formed at the surface vicinity is determined from the XRD technique. It is found that partial dissolution of carbide particles takes place at the surface. The composition of fine grains at the surface vicinity, nitride compounds formed, and dissolution of Laves phase at the surface region enhances the hardness at the treated surface. In addition, laser treated surface is free from the micro-crack network and cavities.     

Laser-induced thermal stresses on steel surface

In laser heat treatment of steels, a thin surface layer of austenite forms during heating and subsequent phase change process in the cooling period. However, thermal stress develops due to high-temperature gradient attainment in the surface vicinity which in turn results in microcrack development at the surface. The present study is carried out to compute the temperature profiles due to step input pulse laser radiation and determine the resulting thermal stresses. The study is extended to include three-step input pulses having the same energy content. This provides the comparison for the influence of the pulse length on the resulting thermal stresses. To validate the theoretical predictions, an experiment is conducted to irradiate the AISI 4142 steel surface by an Nd–YAG laser. Microphotography and EDS analysis of the heated regions are carried out. It is found that considerable thermal stress is eveloped at the workpiece surface due to attainment of high-temperature gradient in this region. In addition, microcracks are observed at the surface of the irradiated spot.     

CO2 laser gas assisted nitriding of Ti-6Al-4V alloy

Laser gas assisted nitriding of Ti-6Al-4V alloy is carried out and nitride compounds formed and their concentration in the surface vicinity are examined. SEM, XRD and XPS are accommodated to examine the nitride layer characteristics. Microhardness across the nitride layer is measured. Temperature field and nitrogen distribution due to laser irradiation pulse is predicted. It is found that the nitride layer appears like golden color; however, it becomes dark gold color once the laser power irradiation is increased. The δ-TiN and ?-TiN are dominant phases in the surface vicinity. The needle like dendrite structure replace with the feathery like structure in the surface region due to high nitrogen concentration. No porous or microcracks are observed in the nitrided layer, except at high power irradiation, in this case, elongated cracks are observed in the surface region where the nitrogen concentration is considerably high.     

Laser cutting of sharp edge: Thermal stress analysis

Laser cutting of sharp edge and thermal stress development in the cutting section is examined. The finite element method is used to predict temperature and stress fields while the X-ray diffraction (XRD) technique is used to measure the residual stress around the cut edges. A mild steel sheet with 5 mm thickness is used in the simulations and the experiment. The morphological and metallurgical changes around the edges are examined using the optical microscopy and scanning electron microscopy (SEM). It is found that temperature remains high at the sharp edge when the laser beam is located in this region. This, in turn, lowers the cooling rate and reduces von Mises stress in this region. The magnitude of the residual stress is about 90 MPa at the sharp corner while the maximum von Mises stress is in the order of 280 MPa, which occurs away from sharp corner. In addition, the residual stress predicted agrees with the experimental data.