Effect of welding speed on butt joint quality of Ti–6Al–4V alloy welded using a high-power Nd:YAG laser

Annealed Ti–6Al–4V alloy sheets with 1 and 2 mm thickness are welded using a 4 kW Nd:YAG laser system. The effects of welding speed on surface morphology and shape, welding defects, microstructure, hardness and tensile properties are investigated. Weld joints without or with minor cracks, porosity and shape defects were obtained indicating that high-power Nd:YAG laser welding is a suitable method for Ti–6Al–4V alloy. The fusion zone consists mainly of acicular α′ martensite leading to an increase of approximately 20% in hardness compared with that in the base metal. The heat-affected zone consists of a mixture of α′ martensite and primary α phases. Significant gradients of microstructures and hardness are obtained over the narrow heat-affected zone. The laser welded joints have similar or slightly higher joint strength but there is a significant decrease in ductility. The loss of ductility is related to the presence of micropores and aluminum oxide inclusions.     

Surface nitriding of Ti–6Al–4V alloy with a high power CO2 laser

Surface nitriding of a Ti–6Al–4V alloy by laser melting in a flow of nitrogen gas has been investigated, with the aim of increasing surface hardness and hence improving related properties such as wear and erosion resistance. The effect of the scanning speed, nitrogen dilution, and nitrogen flow rate on microstructure, microhardness, and cracking of the nitrided layers was studied. Optical, scanning electron microscopy, energy dispersive spectroscopy, and X-ray diffraction (XRD) were used to reveal the microstructure and to identify the phases formed. It is shown that smooth, deep, and crack-free nitride layers of a surface hardness ranging between 500 and 800 HV can be obtained by controlling the processing parameters. Cracks are present in the sample processed at slow scanning speed and high laser power. Dilution of the nitrogen gas with argon gas leads to a crack-free nitride layer at the expense of a reduction in surface hardness. Slow scanning speeds lead to the formation of a deep and hard surface layer, and increasing the nitrogen flow rate results in a rough surface with a slight increase in hardness.     

Experimental investigation and metallographic characterization of fiber laser beam welding of Ti-6Al-4V alloy using response surface method

In the present study, experimental investigations of fiber-laser-beam-welding of 5 mm thick Ti-6Al-4V alloy are carried out based on statistical design of experiments. The relationship between the process parameters such as welding power, welding speed, and defocused position of the laser beam with the output responses such as width of the fusion zone, size of the heat affected zone, and fusion zone area are established in terms of regression models. Also, the most significant process parameters and their optimum ranges are identified and their percentage contributions on output responses are calculated. It is observed that welding power and speed plays the major role for full penetration welding. Also, welding power shows direct effect whereas welding speed shows the inverse effect on the output responses. The bead geometry is influenced by the defocused position of the laser beam due to the change in power density on the workpiece surface. However, overall fusion zone area is unaffected. Mechanical characterization of the welded samples such as microstructural analysis, hardness, and tensile tests are conducted. It is noticed that the hardness value of the FZ is higher than the HAZ and BM zone due to the difference in cooling rate during welding which promotes the formation of α′ martensitic phase in the FZ. Also, an average hardness value in the FZ is compared for two different defocusing positions (i.e. 1 and 2 mm). It is found that hardness value is higher for 1 mm defocused position than 2 mm due the decrement in grain size below a critical range at 2 mm defocused position. The ultimate tensile strength and % elongation of the welded samples are degraded as compared to BM which can be further improved by post heat treatment.     

Optimisation of TA6V alloy surface laser texturing using an experimental design approach

Active surfaces of plastic injection moulds are nowadays textured using classical techniques (chemical etching or EDM). Replacement of these technologies by a laser technology introduces a big flexibility: absence of mechanical contact with the tool, decrease of the effluent's volume and a big machining precision, even in the case of the complex forms as injection moulds for example. This paper reports the experimental study of the surface laser texturing of TA6V alloy. The influence of the operating factors on the laser texturing process has been studied using two experimental approaches: Taguchi methodology and response surface methodology (RSM). Empirical models have been developed. They allowed us to determine a correlation between process operating factors and performance indicators, such as surface roughness and material removal rate. Results analysis shows that the laser pulse energy and frequency are the most important operating factors. Mathematical models, that have been developed, can be used for the selection of operating factors’ proper values in order to obtain the desired values of the objective functions.     

Welded joints integrity analysis and optimization for fiber laser welding of dissimilar materials

Dissimilar materials welded joints provide many advantages in power, automotive, chemical, and spacecraft industries. The weld bead integrity which is determined by process parameters plays a significant role in the welding quality during the fiber laser welding (FLW) of dissimilar materials. In this paper, an optimization method by taking the integrity of the weld bead and weld area into consideration is proposed for FLW of dissimilar materials, the low carbon steel and stainless steel. The relationships between the weld bead integrity and process parameters are developed by the genetic algorithm optimized back propagation neural network (GA-BPNN). The particle swarm optimization (PSO) algorithm is taken for optimizing the predicted outputs from GA-BPNN for the objective. Through the optimization process, the desired weld bead with good integrity and minimum weld area are obtained and the corresponding microstructure and microhardness are excellent. The mechanical properties of the optimized joints are greatly improved compared with that of the un-optimized welded joints. Moreover, the effects of significant factors are analyzed based on the statistical approach and the laser power (LP) is identified as the most significant factor on the weld bead integrity and weld area. The results indicate that the proposed method is effective for improving the reliability and stability of welded joints in the practical production.     

Stable room-temperature multi-wavelength lasing oscillations in a Brillouin–Raman fiber ring laser

A stable room-temperature multi-wavelength Brillouin–Raman fiber laser with a ring cavity configuration was proposed and experimentally investigated. An obvious suppressant effect for unstable mode hopping of multi-wavelength lasing oscillations induced by deeply saturated effect was observed in the ring cavity configuration. Stable room-temperature multi-wavelength lasing oscillations with more than 30 lasing lines and wavelength spacing of 0.076 nm were obtained with only 250 mW Raman pump power and a section of high nonlinear fiber with a length of 1.5 km. The lasing output is so stable that the maximum power fluctuations for the foremost three Stokes lines over more than 20 min of observation were less than 0.30 dB. The lasing stability of the laser was also compared with a linear cavity configuration with the same gain components and pump conditions. While using the linear laser cavity configuration, obvious mode hopping was observed. The minimum value of the maximum power fluctuations at all lasing lines over more than 10 min of observation was more than 0.90 dB.     

Prevention of biofilm re‐development on Ti‐6Al‐4V alloy by cometary discharge with a metallic grid

The influence of a non‐thermal plasma (NTP) on the gram‐negative bacteria Escherichia coli and Pseudomonas aeruginosa, the gram‐positive bacterium Staphylococcus epidermidis, and the yeast Candida albicans grown on agar or in the biofilm form was compared. NTP was produced by a DC cometary discharge. The biofilms were grown on the surface of Ti‐6Al‐4V alloy often used in the manufacture of prosthetic implants. The exposure by NTP not only inhibited the surface growth of microorganisms in agar cultures but also significantly suppressed the viability of bacteria and yeast in biofilms and prevented its re‐developed from persistent cells remaining in the lower layers of the biofilm. An almost complete prevention of biofilm re‐development was achieved in the case of S. epidermidis; other microorganisms displayed substantial lowering of biofilm biomass and its metabolic activity.     

Characterization of Ti6Al4V implant surface treated by Nd:YAG laser and emery paper for orthopaedic applications

A more noble and biocompatible Ti alloy was achieved at fluence of 140 J cm⁻² where the implant indicated a higher degree of hardness (825HV), higher corrosion resistance (−0.21 V) and highest hydrophilicity (i.e. θ_c = 37°) compared with 70° of the control sample. These values corresponded to 58 and 39 mN m⁻¹ of surface tension respectively. The laser treated samples at 140 J cm⁻² showed higher wettability characteristics than mechanically roughened surface. Cell growth and their spreading condition in a specific area were analyzed by SEM and Image J Program software. Clearly, more cells were attached (1.2 × 10⁵) to and spread (488 μm²) over the surface at 140 J cm⁻² than in any other condition. Pathologically, the treated samples indicated no sign of infection.     

Surface glazing of concrete using a 2.5 kW high power diode laser and the effects of large beam geometry

Interaction of a 2.5 kW high power diode laser (HPDL) beam with the ordinary Portland cement (OPC) surface of concrete has been investigated, resulting in the generation of a tough, inexpensive amorphous glaze. Life assessment testing revealed that the OPC glaze had an increase in wear life of 1.3–14.8 times over an untreated OPC surface, depending upon the corrosive environment. Also, variations in the width of the HPDL beam were seen to have a considerable affect on the melt depth. Furthermore, the maximum coverage rate that it may be possible to achieve using the HPDL was calculated as being 1.94 m²/h. It is a distinct possibility that the economic and material benefits to be gained from the deployment of such an effective and efficient large area coating on OPC could be significant.     

Predicting the performance data for a fiber laser by measuring the emitted fluorescence power of the end-on pumped fiber

A novel method is described that enables the prediction of the main laser parameters (threshold pump power, output power, slope- and extraction efficiency) without having realized the laser itself. The emitted fluorescence power of an end-on pumped fiber is absolutely measured along the fiber. Using specific material parameters of the doped glass and the waveguide attenuation, we calculate the laser properties without taking the resonator losses into account. This approach is extremely useful for fibers with special design parameters. We have used this method to characterize a fiber with a novel design, the M-profile fiber. Combining the results with the measurements on the realized laser, the impact of resonator losses (e.g., tilted fiber endfaces, effects of butt-coupled mirrors) can be inferred and improvements can be undertaken.     

Predicting the performance data for a fiber laser by measuring the emitted fluorescence power of the end-on pumped fiber

Abstract

A novel method is described that enables the prediction of the main laser parameters (threshold pump power, output power, slope- and extraction efficiency) without having realized the laser itself. The emitted fluorescence power of an end-on pumped fiber is absolutely measured along the fiber. Using specific material parameters of the doped glass and the waveguide attenuation, we calculate the laser properties without taking the resonator losses into account. This approach is extremely useful for fibers with special design parameters. We have used this method to characterize a fiber with a novel design, the M-profile fiber. Combining the results with the measurements on the realized laser, the impact of resonator losses (e.g., tilted fiber endfaces, effects of butt-coupled mirrors) can be inferred and improvements can be undertaken.     

Photonic generation of microwave signal using a dual-wavelength single-longitudinal-mode distributed Bragg reflector fiber laser

In this paper, a novel all-optical microwave generation technique based on a dual-wavelength single-longitudinal-mode (SLM) distributed Bragg reflector (DBR) fiber laser is proposed and demonstrated. By exploiting spatial hole burning (SHB) effect, this laser could provide stable dual-wavelength SLM operation with a wavelength separation of 0.088 nm corresponding to the microwave signal at 10.484 GHz with a 3 dB bandwidth of 28 kHz. By appropriately adjusting the pump power, dual-wavelength oscillation could be maintained at different temperatures. We have theoretically analyzed the mechanism for microwave generation of the proposed DBR laser, and the calculated microwave frequency is in good agreement with our experimental results. Furthermore, experimental observation shows both of the laser wavelengths and generated microwave signals have good stability at room temperature.     

Photoacoustic monitoring of gases using a novel laser source tunable around 2.5 μm

We present the first spectroscopic measurements using a tunable solid state Cr²+:ZnSe laser emitting at wavelengths between 2.2 μm and 2.8 μm. Photoacoustic measurements on various gases such as methane, carbon monoxide, carbon dioxide, water vapour, nitrous oxide, and ambient air were carried out. In this paper, we present measurements on methane, nitrous oxide, and ambient air. The deduced detection limits are in the low ppm or sub-ppm range, e.g., 0.2 ppm for carbon dioxide, 0.8 ppm for methane and 2.7 ppm for carbon monoxide.     

Fabrication of a micro-optical lens using femtosecond laser 3D micromachining for two-photon imaging of bio-tissues

We report, for the first time to our knowledge, on the application of a micro-optical lens fabricated by three-dimensional (3D) femtosecond laser direct writing for two-photon fluorescence imaging of biological tissues. We show that the two-photon fluorescence images of a plant leaf tissue acquired with the micro-optical lens are comparable to that of a 5× objective lens. Our result represents an important step towards the application of micro-optical components fabricated by femtosecond laser micromachining in miniaturized nonlinear fluorescence microscopy applications, such as two-photon endoscopy.     

Surface modifications of a titanium implant by a picosecond Nd:YAG laser operating at 1064 and 532 nm

Interaction of an Nd:YAG laser, operating at 1064 or 532 nm wavelength and pulse duration of 40 ps, with titanium implant was studied. Surface damage thresholds were estimated to 0.9 and 0.6 J/cm² at wavelengths 1064 and 532 nm, respectively. The titanium implant surface modification was studied by the laser beam of energy density of 4.0 and 23.8 J/cm² (at 1064 nm) and 13.6 J/cm² (at 532 nm). The energy absorbed from the Nd:YAG laser beam is partially converted to thermal energy, which generates a series of effects, such as melting, vaporization of the molten material, shock waves, etc. The following titanium/implant surface morphological changes were observed: (i) both laser wavelengths cause damage of the titanium in the central zone of the irradiated area, (ii) appearance of a hydrodynamic feature in the form of resolidified droplets of the material in the surrounding outer zone with the 1064 nm laser wavelength and (iii) appearance of wave-like microstructures with the 532 nm wavelength. Generally, both laser wavelengths and the corresponding laser energy densities can efficiently enhance the titanium/implant roughness. This implant roughness is expected to improve its bio-integration. The process of the laser interaction with titanium implant was accompanied by formation of plasma.     

Infrared thermography for monitoring heat generation in a linear friction welding process of Ti6Al4V alloy

The increasing use of titanium alloys in a wider range of applications requires the development of new techniques and processes capable to decrease production costs and manufacturing times. In this regard welding and other joining techniques play an important role. Today, solid state friction joining processes, such as friction stir welding, friction spot welding, inertia friction welding, continuous-drive friction welding and linear friction welding (LFW), represent promising methods for part manufacturing. They allow for joining at temperature essentially below the melting point of the base materials being joined, without the addition of filler metal.However, the knowledge of temperature is essential to understand and model the phenomena involved in metal welding. A global measured value represents only a clue of the heat generation during the process; while, a deep understanding of welding thermal aspects requires temperature field measurement. This paper is focused on the use of infrared thermography applied to the linear friction welding process of Ti6Al4V alloy. The attention is concentrated on thermal field that develops on the outer wall of the two parts to be joined (i.e. heat generated in the friction zone), and on the maximum temperature that characterizes the process before and after the flash formation.     

Pulsed first-overtone CO laser: effective source of IR radiation in spectral range of 2.5–4.0 μm

Spectral properties of radiation of a pulsed electron-beam controlled discharge laser operating on the first-overtone transitions (Δv=2) of CO molecules have been studied both experimentally and theoretically. Various sets of dielectric mirrors with high reflectivity in the wide range of overtone spectrum have been used for the laser resonator. Multiwavelength lasing has been obtained in the wide spectral range of 2.5–4.0 μm. Efficiency of the laser operating on few vibrational transitions within a relatively narrow spectral range comes up to 5% at entirely suppressed fundamental band (Δv=1) lasing. Spectral characteristics of the overtone laser operating on a selected set of vibrational transitions have been analyzed theoretically. A comparison of the experimental and theoretical data has been made.     

The spectral measurement of a high repetition rate tunable dye laser output using Fabry–Perot fringe

We present the measurement of spectral distribution of a high repetition rate dye laser by deriving explicit relationship of the parameters with ring diameter of the Fabry–Perot fringe pattern. The output characteristics and its variation has been represented by generating a composite picture of a single line scan across the ring diameter of the Fabry–Perot fringe, captured through CCD camera and frame grabber card.     

Development of a PC interface board for true color control using an Ar–Kr white-light laser

For the optimal laser display, it is crucial to select and control color signals of proper wavelengths in order to construct a wide range of laser display colors. In traditional laser display schemes, color control has been achieved through the mechanical manipulation of red, green, and blue (RGB) laser beam intensities using color filters. To maximize the effect of a laser display and its color contents, it is desirable to generate laser beams with wide selection of wavelengths. We present an innovative laser display control technique, which generates six channel laser wavelengths from a white-light laser using a RF-controlled polychromatic acousto optical modulator (PCAOM). This technique enables us not only to control the intensity of individual channels, but also to achieve true color signals for the laser beam display including RGB, yellow, cyan, and violet (YCV), and other intermediate colors. For the optimal control of the PCAOM and galvano-mirror, we designed and fabricated a PC interface board. Using this PC control, we separated the white-light from an Ar–Kr mixed gas laser into various wavelengths and reconstructed them into different color schemes. Also we demonstrated the effective control and simultaneous display of reconstructed true color laser beams on a flat screen.     

A study on wear resistance and microcrack of the Ti3Al/TiAl + TiC ceramic layer deposited by laser cladding on Ti-6Al-4V alloy

Laser cladding of the Al + TiC alloy powder on Ti-6Al-4V alloy can form the Ti₃Al/TiAl + TiC ceramic layer. In this study, TiC particle-dispersed Ti₃Al/TiAl matrix ceramic layer on the Ti-6Al-4V alloy by laser cladding has been researched by means of X-ray diffraction, scanning electron microscope, electron probe micro-analyzer, energy dispersive spectrometer. The main difference from the earlier reports is that Ti₃Al/TiAl has been chosen as the matrix of the composite coating. The wear resistance of the Al + 30 wt.% TiC and the Al + 40 wt.% TiC cladding layer was approximately 2 times greater than that of the Ti-6Al-4V substrate due to the reinforcement of the Ti₃Al/TiAl + TiC hard phases. However, when the TiC mass percent was above 40 wt.%, the thermal stress value was greater than the materials yield strength limit in the ceramic layer, the microcrack was present and its wear resistance decreased.