Effect of laser energy on the deformation behavior in microscale laser bulge forming

Microscale laser bulge forming is a high strain rate microforming method using high-amplitude shock wave pressure induced by pulsed laser irradiation. The process can serve as a rapidly established and high precision technique to impress microfeatures on thin sheet metals and holds promise of manufacturing complex miniaturized devices. The present paper investigated the forming process using both numerical and experimental methods. The effect of laser energy on microformability of pure copper was discussed in detail. A 3D measuring laser microscope was adopted to measure deformed regions under different laser energy levels. The deformation measurements showed that the experimental and numerical results were in good agreement. With the verified simulation model, the residual stress distribution at different laser energy was predicted and analyzed. The springback was found as a key factor to determine the distribution and magnitude of the compressive residual stress. In addition, the absorbent coating and the surface morphology of the formed samples were observed through the scanning electron microscope. The observation confirmed that the shock forming process was non-thermal attributed to the protection of the absorbent coating.     

Mold-free fs laser shock micro forming and its plastic deformation mechanism

Mold-free micro forming using a fs laser was investigated by producing micro pits on pure aluminum foil. The characteristics of the pit profiles, their forming mechanisms, and the influences of some important parameters on the pit profiles were investigated by measuring the profiles and the surface morphologies of the pits. The microstructures of the shocked aluminum foil were observed through transmission electron microscopy (TEM). Pits obtained through fs laser shock forming are composed of two regions: the directly impacted region and the plastically bending region. Diameters of the former strongly depend on laser beam sizes. The plastically bending region has a negative effect on forming precision. Shorter laser pulse width is beneficial for narrowing the range of the plastically bending region and enhancing the forming precision. Using a single-side clamping mode can also narrow the plastically bending region through buffering the local bending. Fs laser-induced microstructures are characteristic of fragmentary short dislocation lines and parallel slip lines, which are the results of the ultrafast and ultrahigh pressure loading. The localization of the fs laser shock forming induced by ultrafast loading can enhance the precision of mold-free forming.     

Real time NDE of laser shock processing with time-of-flight of laser induced plasma shock wave in air by acoustic emission sensor

Acoustic emission sensor is used to research the time-of-flight of the shock wave induced by laser-plasma in air for real time nondestructive evaluation (NDE) of laser shock processing. The time-of-flight of the shock wave propagating from the source to the sensor declines nonlinearly and similarly at the different distances for different laser energies. The velocity of the shock wave at the distance of 30 mm increases faster than that of the distance of 35 mm. The relationship between the laser energy and the distance is almost linearly when the signal with distortion is measured by acoustic emission sensor. Finally, Taylor solution is used to analyze the experimental results, and the empirical formula between the energy of the shock wave and the laser energy is established, which will provide a theoretical basis for real time NDE of laser shock processing.     

激光冲击对E690高强钢激光熔覆修复微观组织的影响

为研究激光冲击对E690高强钢激光熔覆修复层微观组织的影响,选用专用金属粉末对E690高强钢试样预制凹坑进行激光熔覆修复,并使用脉冲激光对激光熔覆层进行冲击强化处理,同时采用扫描电镜、透射电镜和X射线应力分析仪分别对激光冲击前后激光熔覆层的微观组织和表面残余应力进行检测。结果表明:激光熔覆修复后,激光熔覆层组织为等轴晶,熔覆层与E690高强钢基体之间冶金结合良好,其表面残余应力为均匀分布的压应力。经激光冲击后,激光熔覆层截面晶粒得到细化,并观察到大量的形变孪晶,互相平行的孪晶界分割熔覆层粗大晶粒,在激光熔覆层的晶粒细化过程中发挥着重要作用;试样表层位错在{110}滑移面上发生交滑移,在晶界周围形成了位错缠结。经激光冲击后,激光熔覆层冲击区域表面残余压应力数值相较于冲击前提升了1.1倍。     

Experimental investigation on: Laser shock micro-forming process using the mask and flexible pad

A forming process called the mask and flexible pad laser shock forming was proposed to fabricate the micro-features on the copper foil. In this process, the mask and laser beam were used as rigid punches. Shock waves induced by plasma were used as the source of loading and plasticine was used as a flexible pad. This was a micro scale and high strain rate forming process and the traditional forming method with micro-mold was changed. In the experiment, surface morphology of formed parts was represented and it was found that the mask played a significant role in the forming process. In order to understand the forming process in the experiment, process parameters, including laser pulse energy, numbers of laser pulse and grain size, were analyzed. The experimental results showed that different parameters had different effects on formed parts. The surface quality and the thickness distribution of formed parts were investigated. It was found that formed parts could keep good surface quality after laser shocking and the reasons were explored. The thickness distribution was measured and the thickness thinning rate was calculated. There was no local tightening or rupture in the forming area. In this paper, the micro-features could be obtained on metallic foils and the method of mold-free was proved to be feasible.     

高超声速化学非平衡流动MHD效应的数值模拟

对偶极子磁场作用下的三维钝头体高超声速黏性绕流的化学非平衡流动进行了数值模拟.计算结果表明,在偶极子磁场强度为1.353 T时,与无磁场作用时相比,激波的脱体距离增加,增幅约为50%;壁面压力系数下降,局部下降最大达37%;壁面摩擦系数减小,局部最大可减小20%.同时,计算结果与磁场作用下的冻结流进行了比较,结果显示化学非平衡流中激波脱体距离比冻结流中小50%,滞止点温度低一半.     

Micromould based laser shock embossing of thin metal sheets for MEMS applications

Laser shock forming is a new material processing technology. Micro-channel with dimension of 260 μm × 59 μm was successfully fabricated on metallic foil surface using laser-generated shock wave. The work piece has a high spatial resolution at the micron-level. A series of experiments was conducted to validate the finite element model. An analysis procedure including dynamic analysis performed by ANSYS/LS-DYNA and static analysis performed by ANSYS is presented in detail to attain the simulation of laser shock embossing to predict the surface deformation. Micromould based laser shock embossing holds promise for achieving precise, well-controlled, low-cost, high efficiency of three-dimensional metallic microstructures. In addition, this technique can fabricate complex 3D microstructures directly by single pulse.     

Laser shock forming of aluminum sheet: Finite element analysis and experimental study

Laser shock forming (LSF) is characterized in non-contact load, high pressure and high strain ratio. This new forming process using laser-induced shock pressure can shape sheet metal without complicated forming equipments. The know-how of the forming process is essential to efficiently and accurately control the deformation of sheet metal. Experiment and numerical simulation are the important approaches for forming analysis. Taken the aluminum sheets with different thickness as the specimen, the finite element (FE) analysis for LSF was performed. In the paper, Q-switch Nd:YAG Laser with a maximum power density of 4.5 GW/cm² was used. The simulation results were in good agreement with the experiment. It showed that the formed aluminum sheets were in the form of concavo-convex. Finally, the transient and static deformations of thin sheet metal under specific operation conditions were also studied.     

激光冲击690高强钢位错组态与晶粒细化的实验研究

为研究激光冲击材料内部位错组态和晶粒细化的关系,用脉冲激光对690高强钢试样进行了冲击强化处理,采用扫描电镜和透射电镜分别获得了冲击后试样的扫描电子显微像和透射电子显微像、高分辨电子显微像,并对高分辨电子显微像进行快速傅里叶逆变换,从位错组态角度建立了激光冲击690高强钢晶粒细化模型.结果表明,690高强钢试样经功率密度为5.09 GW/cm^2的激光冲击加载后,其材料内部位错增殖、表层晶粒细化,截面晶粒尺寸大小分布在80~200 nm;析出相与基体保持半共格关系,基体中分布着众多刃型位错、位错偶以及扩展位错等缺陷,其中位错偶是由带割阶的螺型位错运动形成;通过由位错、扩展位错、空位等构成的几何位错界面扩展交汇把原始大晶粒分割成细小晶粒;激光冲击690高强钢晶粒细化模型可以描述激光冲击690高强钢位错运动主导的晶粒细化过程.     

Interface microstructure and mechanical properties of laser welding copper–steel dissimilar joint

Relatively the high reflectivity of copper to CO₂ laser led to the difficulty in joining copper to steel using laser welding. In this paper, a new method was proposed to complete the copper–steel laser butt welding. The scarf joint geometry was used, i.e., the sides of the copper and steel were in obtuse and acute angles, respectively. During the welding process, the laser beam was fixed on the steel side and the dilution ratio of copper to steel was controlled by properly selecting the deviation of the laser beam. The offset of laser beam depended on the scarf angle between the copper and steel, the thickness of plate and the processing parameters used in the laser welding. The microstructure near the interface between Cu plate and the intermixing zone was investigated. Experimental results showed that for the welded joint with high dilution ratio of copper, there was a transition zone with numerous filler particles near the interface. However, if the dilution ratio of copper is low, the transition zone is only generated near the upper side of the interface. At the lower side of the interface, the turbulent bursting behavior in the welding pool led to the penetration of liquid metal into Cu. The welded joint with lower dilution ratio of copper in the fusion zone exhibited higher tensile strength. On the bases of the microstructural evaluation at the interface of the welded joint, a physical model was proposed to describe the formation mechanism of the dissimilar joint with low dilution ratio of copper.     

Effect of nose shape on the shock standoff distance at nearsonic flows

This paper describes a numerical solution of the bow shock shape ahead of some blunt and sharp axisymmetric noses containing sphere, blunt cone, and sharp cone at steady transonic flow in the Mach number range of 1.01 to 1.2. For validating the results, one sphere and three blunt cones are modeled, and their shock standoff distance is compared with other experimental and numerical studies. The flow over other noses with similar geometric parameters is then solved and compared with each other. In this study, the Reynolds-averaged Navier—Stokes equations are solved using the Spalart—Allmaras turbulence model. The purpose of this study is to determine the shock standoff distance for some blunt and sharp noses at low supersonic free flight speed. The shock standoff distance is determined from the Mach number curve on the symmetry line. The present numerical simulations reach down to M8=1.01 a range where it is almost very difficult to set in experimental studies. The shock wave locations were found to agree well with previous numerical and experimental studies. Our results are closer to the experimental results compared to other numerical studies. In addition, the results for shock standoff distances over paraboloids in these speed ranges have not been previously published as far as we know.     

爆炸载荷作用下钢-混凝土-钢组合板的动态响应数值模拟

钢-混凝土组合结构的抗爆性能已成为防护工程和反恐防爆等领域的研究热点。以钢-混凝土-钢组合板为例,利用有限元软件ABAQUS对爆炸载荷作用(爆距为2.5~7.5 m,TNT炸药量为50~100 kg)下该结构的破坏形态和动力学性能进行了数值模拟。研究结果表明,组合板的破坏形态与炸药量和爆距有关。炸药量越大,爆距越小,组合板的破坏程度越明显。当TNT炸药量为100 kg、爆距为2.5 m时,组合板发生明显的翘曲,出现了塑性铰。钢板的存在有效地抑制了核心混凝土的剥落。在爆距相同的条件下,炸药量越大,组合板的变形越明显,跨中挠度和峰值速度也越大。当炸药量相同(100 kg)时,与爆距为7.5 m相比,爆距为5.0 m时组合板的跨中挠度为其1.53倍,爆距为2.5 m时组合板的跨中挠度为其5.01倍。     

Effects of laser shock processing on 00Cr12 mechanical properties in the temperature range from 25 °C to 600 °C

Laser shock processing was performed on 00Cr12 standard tensile specimens to reveal its effect on fatigue properties. Mechanical properties of the specimens were tested at the temperatures of 25 °C, 400 °C, 500 °C and 600 °C respectively. The correlations between the fatigue times and the axial strain at different temperatures were explored. The results indicate that the anti-fatigue life of material is enhanced greatly at the room temperature after laser shock processing in which residual compressive stress is mechanically produced into the surface. The yield strength and the elasticity coefficient of 00Cr12 specimens are enhanced greatly after laser shock processing; the cycle times are obviously longer at the elevated temperature, and the laser-shocked samples exhibit lower plastic strain amplitudes compared with the non-treated ones.     

Numerical modeling of laser shock peening with femtosecond laser pulses and comparisons to experiments

A physics-based model has been developed for laser shock peening (LSP) with femtosecond (fs) laser pulses (fs-LSP), which has never been reported in literature to the authors’ best knowledge. The model is tested by comparing simulations with measured plume/shock wave front transient propagations and the LSP-induced hardness enhancement layer thickness. Reasonably good agreements have been obtained. The model shows that fs-LSP can produce much higher pressure than LSP with nanosecond (ns) laser pulses (ns-LSP), and it can also generate very large compressive residual stress in the workpiece near-surface layer with a thickness up to ∼100 μm. The developed model provides a powerful guiding tool for the fundamental study and the practical applications of fs-LSP. This study, together with the recently reported work by Nakano et al. [Journal of Laser Micro/Nanoengineering 4(1) (2009) 35-38], has confirmed the feasibility of fs-LSP on both theoretical and experimental sides.     

Micro scale laser shock forming of pure copper and titanium sheet with forming/blanking compound die

A new process fabricating micro parts of thin metal foils by laser shock waves with forming/blanking compound die is reported in this article, in which flexible rubber material was used as the soft punch to act on the thin metal sheet. Systematic studies were carried out experimentally on the process with different laser energies and materials. The formed parts were examined in terms of their morphology, surface roughness, forming depth and mechanical properties (including nanohardness, plasticity and elastic modulus) characterized by nanoindentation test. According to the results, the ablation states of confinement medium and the surface roughness of the different regions change with energies. Additionally, the proper energies are necessary to form complex parts and the forming process can be applied to manufacture parts with good surface quality. What׳s more, the nanoindentation test results showed that the nanohardness, plasticity and elastic modulus of material were increased after impact. The increase in nanohardness and plasticity can attribute to higher stiffness of the parts. The enhanced elastic modulus indicates an increased stiffness of the parts, providing an evidence for the reduced spring back of copper during laser shocking.     

The influence of laser pulse waveform on laser-TIG hybrid welding of AZ31B magnesium alloy

By dividing laser pulse duration into two parts, three kinds of laser waveforms are designed, including a high power density pulse (HPDP) laser in a short duration set at the beginning of the laser waveform. This paper aims to find out the laser pulse waveform and idiographic critical values of HPDP, which can affect the magnesium penetration in laser-tungsten inert gas (TIG) hybrid welding. Results show that when the laser pulse duration of HPDP is not more than 0.4 ms, the welding penetration values of lasers with HPDP are larger than otherwise. Also, the welding penetration values of laser with HPDP have increased by up to 26.1%. It has been found that with HPDP, the laser can form the keyhole more easily because the interaction between laser and the plate is changed, when the TIG arc preheats the plate. Besides, the laser with high power density and short duration strikes on the plates so heavily that the corresponding background power can penetrate into the bottom of the keyhole and maintain the keyhole open, which facilitates the final welding penetration.     

冲击波在空气和熔石英元件界面传播的超快诊断

基于球面波在弹性介质界面上的反射和折射特性的基本理论,采用超快时间分辨的光学诊断技术,研究了532nm纳秒激光辐照熔石英元件表面产生的冲击波在空气和样品界面的传播特性,获得了冲击波在材料内部传输以及在空气与样品界面反射的时间分辨图像。结果表明:激光脉冲与材料作用在前后表面产生了向体内传输的冲击波,且产生的冲击波在玻璃与空气界面处反射为两个波,即反射波和反射剪切波;反射波和反射剪切波的强度与入射冲击波的入射角有关。     

Research on air tightness of image intensifier tube during laser sealing北大核心CSCD

采用高功率YAG激光焊接机对高性能三代像管管壳后端(4J34可伐合金)与荧光屏屏环(4J49可伐合金)进行封接试验。研究了激光功率、脉冲宽度对焊接接头成型及表面热扩散的影响规律。研究表明:4J34合金与4J49合金表面成型质量在设备最大工作电流100 A,激光功率195 W及脉宽1.7 ms时最好,相对于激光功率,脉冲宽度对焊缝熔宽和熔深的影响更加显著,接头焊接中心区硬化最为严重,其硬度最大,热影响区次之。     

Microstructure and corrosion properties of diode laser melted friction stir weld of aluminum alloy 2024 T351

Friction stir welding is a promising solid state joining process for high strength aluminum alloys. Though friction stir welding eliminates the problems of fusion welding as it is performed below melting temperature (T_m), it creates severe plastic deformation. Friction stir welds of some aluminum alloys exhibit relatively poor corrosion resistance. This research enhanced the corrosion properties of such welds through diode laser surface melting.A friction stir weld of aluminum alloy 2024 T351 was laser melted using a 1 kW diode laser. The melt-depth and microstructure were investigated using optical and scanning electron microscopy. The melt zone exhibited epitaxially grown columnar grains. At the interface between the melted and the un-melted zone, a thick planar boundary was observed. Energy dispersive spectroscopy analyzed the redistribution of elemental composition. The corrosion properties of the laser melted and native welds were studied in aqueous 0.5 M sodium chloride solution using open circuit potential and cyclic potentiodynamic polarization. The results show noticeable increase in the pit nucleation resistance (390 mV) after the laser surface treatment. The repassivation potential was nobler to the corrosion potential after the laser treatment, which confirmed that the resistance to pit growth was improved.     

Laser peening of aluminum alloy 7050 with fastener holes

The fatigue properties of laser peened aluminum alloy 7050 specimens with fastener holes were investigated.The surface profile and residual stress induced in the shock affected zone were characterized.Then,the fatigue specimens with notch were treated by laser peening(LP),and the fatigue lifes of LP-treated specimens were measured and compared with base materials without LP.The results indicated that LP improved the fatigue lifes of all tested specimens.The average fatigue lifes of specimens treated by LP before hole-drilling were 173% longer than those of untreated samples and had better effects than those specimens treated by LP after hole-drilling.