Analysis and prediction of single laser tracks geometrical characteristics in coaxial laser cladding process

Direct Laser Fabrication is a promising new manufacturing technology coming from laser cladding process. From a coaxial nozzle, powder is fed through a laser beam on a substrate. The powder melting and solidification processes lead to the fabrication of a part layer by layer. In this work 316L stainless steel powder is used to form laser tracks on a low carbon steel substrate. The layer geometry is an important process characteristic to control the final part of fabrication. This paper presents analytical relationships between the laser tracks geometrical characteristics (width, height, area, penetration depth) and the processing parameters (laser power P, scanning speed V and powder mass flow Q_m). Three values of each processing parameters are fixed and so 27 different experiments have been made and analyzed. The validity of these results is discussed studying the correlation coefficient R, the graphical analysis of the residuals and the uncertainty evaluations. Two kinds of models are studied to predict the form and the geometrical characteristics of the single laser tracks cross sections. The first one is an analytical model in which the distribution of the powder in the feed jet is supposed to govern the laser clad geometry. Three distributions are proposed: Gaussian, uniform and polynomial. In the second model the general form of the clad cross section is supposed to be a disk due to the surface tension forces. Analytical relationships are established between the radius and the center of the disk in one hand and the process parameters in the other hand. This way we show that we can reproduce the laser track geometry in all the area experimentally explored.     

Composition design and laser cladding of Ni-Zr-Al alloy coating on the magnesium surface

The cluster line criterion was used for optimized design of a Ni-Zr-Al alloy used as coating on the AZ91HP magnesium alloy by laser cladding. Results show that the coating mainly consists of an amorphous, two ternary intermetallic phases with Ni₁₀Zr₇ and Ni₂₁Zr₈ type structures resulting in high hardness, good wear resistance and corrosion resistance. The interface between the clad layer and the substrate has good metallurgical bond.     

Prediction of clad angle in laser cladding by powder using response surface methodology and scatter search

Currently, laser cladding is an important process that allows the deposition of thick protective coatings on substrates. The article presents an experimental investigation of the influence of processing parameters on clad angle in laser cladding by powder (LCP). The clad angle is determined from the mathematical expression relating to the clad height and clad width. The cladding angle model was developed in terms of laser power, scanning speed, and powder mass flow rate by means of response surface methodology. A first-order equation covering a narrow range of the variables and a second-order equation covering a wide range of the variables are presented. An optimization technique, Scatter Search, is used to determine optimal processing parameters. The adequacy of the predictive model was tested by analysis of variance and found to be adequate.     

Identification and qualification of temperature signal for monitoring and control in laser cladding

Laser cladding has been successfully introduced into industry for the use in wear and corrosion applications and in the repair work such as turbine components, moulds and dies. Through monitoring and furthermore controling the cladding process, the quality and reproducibility in the production can be ensured. Thus the economic efficiency can increase through the reduced scrap rate. The aim of this work is to identify and analyse the infrared temperature signal emitted from the melt pool, which could be used for quality control and for closed loop control. Different measure systems including a photodiode, pyrometer and CCD camera with different functional wavelengths were used to detect the temperature radiation. The detected signals show dependence on the main process parameters including laser power, powder feeding rate and scanning speed. The results of the clad such as dilution and dimension have very good correlation with the measured temperature signal. A process monitoring and control system based on the infrared temperature signal with coaxial alignment of the ancillary lenses was established and tested successfully.     

3-D finite element modeling of laser cladding by powder injection: effects of laser pulse shaping on the process

This paper introduces a 3-D transient finite element model of laser cladding by powder injection to investigate the effects of laser pulse shaping on the process. The proposed model can predict the clad geometry as a function of time and process parameters including laser pulse shaping, travel velocity, laser pulse energy, powder jet geometry, and material properties. In the proposed strategy, the interaction between powder and melt pool is assumed to be decoupled and as a result, the melt pool boundary is first obtained in the absence of powder spray. Once the melt pool boundary is obtained, it is assumed that a layer of coating material is deposited on the intersection of the melt pool and powder stream in the absence of the laser beam in which its thickness is calculated based on the powder feedrate and elapsed time. The new melt pool boundary is then calculated by thermal analysis of the deposited powder layer, substrate and laser heat flux. The process is simulated for different laser pulse frequencies and energies. The results are presented and compared with experimental data. The quality of clad bead for different parameter sets is experimentally evaluated and shown as a function of effective powder deposition density and effective energy density. The comparisons show excellent agreement between the modeling and experimental results for cases in which a high quality clad bead is expected.     

An in-process method for the inverse estimation of the powder catchment efficiency during laser cladding

An estimation of the heat loss by conduction can be obtained from measurements of the surface temperature and an overall heat balance at the clad laser interaction zone. Through an inverse calculation of the boundary temperature from observed surface temperatures the powder catchment efficiency can be estimated along with the variation in the clad height expected during laser cladding. This method shows a possible way to monitor and control the clad height and profile as required by near net shape manufacturing methods based on laser cladding.     

Microstructure and interface interaction in laser induction hybrid cladding of Ni-based coating

Based on the powder feeding laser induction hybrid cladding experiments by means of three different laser and induction energy, the microstructure of Ni-based coating and interface characteristics between the Ni-based coating and steel substrate were investigated. The results show that the hybrid cladding energy including laser and induction energy has an important influence on the formation of the interface and the microstructure of the Ni-based coating characterized by the dendrite. In addition, the laser and induction energy can complement each other. For high hybrid cladding energy, the single phase Fe-Ni-Cr solid solution is formed at the interface between the coating and substrate, while the microhardness of the Ni-based coating decreases. For low hybrid cladding energy, the solid solution phases of Fe-Ni-Cr and Ni-Fe-Cr are respectively obtained on both sides of the interface and microhardness of the Ni-based coating is relatively high. During laser induction hybrid cladding, the metallurgical bond characterized by the white light layer is achieved between the coating and substrate, and the extent of metallurgical reaction can be controlled by adjusting the laser energy and induction energy appropriately.     

激光法红外热像镜组中心偏测量与调校研究

论述了多镜片成像光学镜组中心偏的理论表征 ,以及自准反射旋转法测量中心偏的原理。设计了用于红外光学镜组的中心偏检测系统。系统包括用于 8～ 14 μm红外光学系统中心偏测量的CO2 激光 ;可调焦望远镜 ;采用TGS热释电热像仪与计算机配合的数据读出及处理系统 ;径向跳动≤ 1μm ,轴向晃动≤ 1″的高精密基准轴工作台。系统测量中心偏精度为 :角度≤ 2″ ,线度≤ 0 .0 2mm。给出了中心偏数据处理程序。系统也可用于在线装校 ,更换光源 (用He Ne激光代替CO2 激光 )系统可用于 3～ 5 μm红外光学系统的测量。进一步改进并利用激光的相干特性 ,系统可实现中心偏测量精度≤ 1μm。     

水下垂向运动目标的海底多基站声定位方法及精度分析

针对水下垂向运动目标具有瞬变运动特性、难以对其轨迹进行高精度和高帧率测量的问题,提出一种有水声信标的海底多基站声定位模型,基于高斯-牛顿法给出求解算法,证明了算法满足局部线性收敛条件。数值仿真和精度分析表明,基站站址误差、声速误差和信号时延估计误差通过测量斜距传播到目标位置参数,误差传播过程受接收基阵几何构型、目标相对位置及水声学约束条件等因素影响。在多个海底基站共面条件下,补充海面基站可改进垂向测量能力。利用该方法对全区域进行精度估计,获取了定位性能在空间分布上的细节特征。以水平范围1 km×1 km、水深60 m的海区计算,对于由13个海底基站和1个海面基站构成的14元测量阵,目标运动深度范围为35~60 m,在x,y,z三个方向的均方根误差(RMSE)平均值分别为0.30 m,1.47 m,0.34 m。本文工作为水下垂向运动目标定位提供了一种技术途径,可为测量系统的论证设计提供参考。     

千瓦级双包层光纤激光器冷却方案设计理论和实验研究

尽管双包层光纤激光器的散热性能好于传统的固体激光器的散热性能,光纤激光器中的热沉积仍然是限制提高其输出功率的重要因素.以双端抽运的400 W双包层光纤激光器为实例,定量分析了光纤内的热沉积分布.根据所建立的散热模型,为了确保千瓦级双包层光纤激光器安全稳定的运行,抽运端附近的对流换热系数应大于2.8×10^-2W·cm^-2K^-1.据此设计出高功率双包层光纤激光器抽运端冷却装置并成功应用在激光系统中,获得了千瓦级的激光输出. 关键词： 热沉积 散热 双包层光纤激光器     

Stability of travelling wave solutions for coupled surface and grain boundary motion

We investigate the spectral stability of the travelling wave solution for the coupled motion of a free surface and grain boundary that arises in materials science. In this problem a grain boundary, which separates two materials that are identical except for their crystalline orientation, evolves according to mean curvature. At a triple junction, this boundary meets the free surfaces of the two crystals, which move according to surface diffusion. The model is known to possess a unique travelling wave solution. We study the linearization about the wave, which necessarily includes a free boundary at the location of the triple junction. This makes the analysis more complex than that of standard travelling waves, and we discuss how existing theory applies in this context. Furthermore, we compute numerically the associated point spectrum by restricting the problem to a finite computational domain with appropriate physical boundary conditions. Numerical results strongly suggest that the two-dimensional wave is stable with respect to both two- and three-dimensional perturbations.     

Comparison of surface films formed on titanium by pulsed Nd:YAG laser irradiation at different powers and wavelengths in nitrogen atmosphere

The nitridation of titanium (Ti) caused by a Q-switched Nd:YAG laser under nitrogen gas atmosphere was investigated in situ using X-ray photoelectron spectroscopy (XPS). A laser having a wavelength of 1064 nm and 532 nm (SHG mode) was irradiated on a titanium substrate in an atmosphere-controlled chamber, and the substrate was then transported to an XPS analysis chamber without exposing it to air. The characteristics of the surface layer strongly depend on the laser power. When the power is relatively low, a titanium dioxide layer containing a small amount of nitrogen is formed on the substrate. Laser irradiation beyond a certain laser power is required to obtain a stoichiometric titanium nitride (TiN) layer. A TiN layer and an oxynitride layer with a TiO_xN_y-like structure are formed as the topmost and the lower surface layer, respectively, when the laser power exceeds this threshold value. The threshold laser power strongly depends on the wavelength of the laser, and this threshold value for the 532-nm laser is quite lower than that for the 1064-nm laser.     

The comparison of laser surface designing and pigment printing methods for the product quality

Developing new designs by using the computer and transferring the designs that are obtained to textile surfaces will not only increase and facilitate the production in a more practical manner, but also help you create identical designs. This means serial manufacturing of the products at standard quality and increasing their added values. Moreover, creating textile designs using the laser will also contribute to the value of the product as far as the consumer is concerned because it will not cause any wearing off and deformation in the texture of the fabric unlike the other methods.In the system that has been designed, the laser beam at selected wavelength and intensity was directed onto a selected textile surface and a computer-controlled laser beam source was used to change the colour substances on the textile surface.Pigment printing is also used for designing in textile and apparel sector. In this method, designs are transferred to the fabric manually by using dyestuff.In this study, the denim fabric used for the surfacing trial was 100% cotton, with a weft count per centimeter of 20 and a warp count per centimeter of 27, with fabric weight of 458 g/m².The first step was to prepare 40 pieces of denim samples, half of which were prepared manually pigment printing and the other half by using the laser beam. After this, some test applications were done. The tensile strength, tensile extension and some fastness values of designed pieces with two methods were compared according to the international standards.     

The laser polarization as control parameter in the formation of laser-induced periodic surface structures: Comparison of numerical and experimental results

Considering self-organized surface pattering upon multi-pulse femtosecond laser irradiation, in particularly the strong dependence of ripples orientation on the laser polarization, we present numerical simulations from an adopted surface erosion model and compare the result to our experimental data on laser-induced nanostructures formation. We present the surface morphologies obtained by this model for different polarizations of the incident laser electric field and show good agreement with ripple formation produced by laser ablation experiments. The correlation of ripples orientation with laser polarization can be described within a model where the polarization causes a breaking of symmetry at the surface. Further we discuss a time evolution of pattern formation. Our results support the non-linear self-organization mechanism of pattern formation on the surface of solids.     

Modeling of plasma-controlled surface evaporation and condensation of Al target under pulsed laser irradiation in the nanosecond regime

Phase transition on the surface of an aluminium target and vapour plasma induced by laser irradiation in the nanosecond regime at the wavelengths of 1.06 and 0.248 μm with an intensity of 10⁸-10⁹ W/cm² in vacuum are analysed. Particular attention is paid to the wavelength dependence of the observed phenomena and the non-one-dimensional effect caused by the Gaussian laser intensity distribution. A transient two-dimensional model is used which includes conductive heat transfer in the condensed phase, radiative gas dynamics and laser radiation transfer in the plasma as well as surface evaporation and back condensation at the phase interface. It is shown that distinctions in phase transition dynamics for the 1.06 and 0.248 μm radiation result from essentially different characteristics of the laser-induced plasmas. For the 1.06 μm radiation, evaporation stops after the formation of hot optically thick plasma, can occasionally resume at a later stage of the pulse, proceeds non-uniformly in the spot area, and the major contribution to the mass removal occurs in the outer part of the irradiated region. Plasma induced by the 0.248 μm laser is much more transparent therefore evaporation does not stop but continues in the subsonic regime with the Mach number of about 0.1.     

Impact of localized surface preheating on the microstructure and crack formation in laser direct deposition of Stellite 1 on AISI 4340 steel

Crack formation in laser cladding of the hardfacing alloy Stellite 1 on AISI-SAE 4340 steel was prevented through locally preheating the substrate prior to the deposition process. Numerical analysis showed that the preheating process helps developing a relatively steadier melt temperature as well as decreasing the cooling rates and consequently the thermal stresses during the subsequent deposition process. Microstructural analysis revealed a thicker cross-section with smoother surface profile, more uniform surface hardness and even distribution of a dendritic morphology in the preheated sample. This confirmed the presence of a well-developed melt pool with a homogeneous composition at solidification. The microstructure of non-preheated sample was, however, considerably non-uniform consisting of macro-scale colonies of dendritic and lamellar (eutectic) structures. The experimental observations, as implied through the numerical results, showed that the preheated sample, in general, reveals more uniform structure and properties making it less prone to cracking during the deposition process.     

The importance of imaging conditions in scanning tunneling microscopy for the determination of surface texture and roughness

We show that the control conditions in the feedback loop of a scanning tunneling microscope (STM) affect the values of the surface texture parameters, including fractal characterization, when they are calculated from STM images of the surface. The main surface texture parameters (such as the r.m.s. roughness, kurtosis, skewness, and average wavelength) show a strong dependence on the conditions used in the feedback loop for imaging. Fractal character changes also with feedback parameters. The quality of the STM images can be measured quantitatively by using some of the surface texture parameters.     

Analysis of the correlation between plasma plume and keyhole behavior in laser metal welding for the modeling of the keyhole geometry

The process of laser metal welding is widely used in industry. Nevertheless, there is still a lack of complete process understanding and control. For analyzing the process we used two high-speed cameras. Therefore, we could image the plasma plume (which is directly accessible by a camera) and the keyhole (where most of the process instabilities occur) during laser welding isochronously. Applying different image processing steps we were able to find a correlation between those two process characteristics. Additionally we imaged the plasma plume from two directions and were able to calculate a volume with respect to the vaporized material the plasma plume carries. Due to these correlations we are able to conclude the keyhole stability from imaging the plasma plume and vice versa. We used the found correlation between the keyhole behavior and the plasma plume to explain the effect of changing laser power and feed rate on the keyhole geometry. Furthermore, we tried to outline the phenomena which have the biggest effect on the keyhole geometry during changes of feed rate and laser power.     

Control of Tisurface defect on TiO2 nanocrystal using various calcination atmospheres as the first step for surface defect creation and its application in photocatalysis

A new development to create the surface defect (Ti³⁺) on TiO₂ was reported in this paper and compared to the common methods which must prepare the crystalline TiO₂ in the first step prior, and then create the surface defect in the second step. In this work, the surface defect creation was performed in the first step coinciding with the crystalline TiO₂ preparation using the sol-gel method. The creation was performed by varying the amounts of oxygen fed during calcination. Based on the CO₂-temperature programmed desorption (CO₂-TPD) and electron spin resonance (ESR) results, the surface defect (Ti³⁺) substantially increased with the amount of oxygen fed. Moreover, the samples resulting from calcination were used as photocatalysts for ethylene decomposition. The reactivity of those samples was also discussed.