Effect of an absorbent overlay on the residual stress field induced by laser shock processing on aluminum samples

Laser shock processing (LSP) or laser shock peening is a new technique for strengthening metals. This process induces a compressive residual stress field, which increases fatigue crack initiation life and reduces fatigue crack growth rate. Specimens of 6061-T6 aluminum alloy are used in this investigation. A convergent lens is used to deliver 2.5 J, 8 ns laser pulses by a Q-switch Nd:YAG laser, operating at 10 Hz. The pulses are focused to a diameter of 1.5 mm onto aluminum samples. Density of 2500 pulses/cm² with infrared (1064 nm) radiation was used. The effect of an absorbent overlay on the residual stress field using this LSP setup and this energy level is evaluated. Residual stress distribution as a function of depth is assessed by the hole drilling method. It is observed that the overlay makes the compressive residual stress profile move to the surface. This effect is explained on the basis of the vaporization of the coat layer suppressing thermal effects on the metallic substrate. The effect of coating the specimen surface before LSP treatment may have advantages on improving wear and contact fatigue properties of this aluminum alloy.     

Circular and rectangular via holes formed in SiC via using ArF based UV excimer laser

Circular via holes with diameters of 10, 25, 50 and 70 μm and rectangular via holes with dimensions of 10 μm × 100 μm, 20 μm × 100 μm and 30 μm × 100 μm and drilled depths between 105 and 110 μm were formed in 300 μm thick bulk 4H-SiC substrates by Ar/F₂ based UV laser drilling (λ = 193 nm) with a pulse width of ∼30 ns and a pulse frequency of 100 Hz. The drilling rate was linearly proportional to the fluence of the laser, however, the rate decreased for the larger via holes. The laser drilling produces much higher etch rates (229-870 μm/min) than conventional dry etching (0.2-1.3 μm/min) and the via entry can be tapered to facilitate subsequent metallization.     

Application of laser ultrasonic technique for non-contact detection of drilling-induced delamination in aeronautical composite components

The detection of drilling-induced delamination in composite components is a vital and challenging task in aviation industry. Numerous key components of aircrafts are made of composite materials, and drilling is often a final operation during assembly. Drilling-induced delamination is a very serious defect that significantly reduces the structural reliability, but it is rather difficult to be detected effectively due to its special location. A novel application of laser ultrasonic technique for the detection of drilling-induced delamination in composites is presented in this paper. A carbon fiber reinforced plastic laminate with drilling holes was made as specimen. A laser ultrasonic system was constructed and experiments were performed to detect the drilling-induced delamination, based on propagation characteristic of ultrasonic waves generated by pulse laser with a wavelength of 1064 nm and pulse duration of 10 ns. A laser interferometer based on two wave mixing is used to measure ultrasonic wave signals, and the morphology features of the delamination are imaged clearly by laser ultrasonic C-scan testing. The results proved that the laser ultrasonic technique is a feasible and effective method for the detection of drilling-induced delamination in composite components.     

Crystal growth,structural, linear and nonlinear optical studies of 4-methyl-4′-N’-methylstilbazolium tosylate single crystals

Organic 4-methyl-4′-N’-methylstilbazolium tosylate, a new derivative of the stilbazolium tosylate family compound was synthesized by condensation method. The optical quality single crystals with dimension 5 mm × 4 mm × 2 mm were grown by slow evaporation technique at 40 °C. The crystal system and lattice parameters were found from single crystal X-ray diffraction studies. The optical transmittance, cut-off wavelength (402 nm) and band gap energy (3.09 eV) were estimated by UV–visible studies. The surface laser damage threshold study was carried out for MMST crystal using Nd:YAG laser. The third-order nonlinear optical susceptibility (χ³) for MMST crystal was estimated by employing Z-scan technique using 1064 nm laser.     

Surface morphology of thin lysozyme films produced by matrix-assisted pulsed laser evaporation (MAPLE)

Thin films of the protein, lysozyme, have been deposited by the matrix-assisted pulsed laser evaporation (MAPLE) technique. Frozen targets of 0.3-1.0 wt.% lysozyme dissolved in ultrapure water were irradiated by laser light at 355 nm with a fluence of 2 J/cm². The surface quality of the thin lysozyme films of different thickness deposited on 7 mm × 7 mm Si-〈1 0 0〉-wafers was investigated with scanning electron microscopy and atomic force microscopy. Already at comparatively low thickness, ∼20 nm, the substrate is covered by intact lysozyme molecules and fragments. The concentration of lysozyme in the ice matrix apparently does not play any significant role for the morphology of the film. The morphology obtained with MAPLE has been compared with results for direct laser irradiation of a pressed lysozyme sample (i.e. pulsed laser deposition (PLD)).     

A study of Ni-based WC composite coatings by laser induction hybrid rapid cladding with elliptical spot

Ni-based WC composite coatings by laser induction hybrid rapid cladding (LIHRC) with elliptical spot were investigated. Results indicate that the efficiency using the elliptical spot of 6 mm × 4 mm (the major and minor axis of laser beam are 6 mm and 4 mm, respectively, the major axis is parallel to the direction of laser scanning) is higher than that using the elliptical spot of 4 mm × 6 mm (the major axis is perpendicular to the direction of laser scanning). The precipitated carbides with the blocky and bar-like shape indicate that WC particles suffer from the heat damage of “the disintegration pattern + the growth pattern”, whichever elliptical spot is used at low laser scanning speed. However, at high laser scanning speed, the blocky carbides are only formed if the elliptical spot of 6 mm × 4 mm is adopted, showing that WC particles present the heat damage of “the disintegration pattern”, whereas the fine carbides are precipitated when the elliptical spot of 4 mm × 6 mm is used, showing that WC particles take on the heat damage of “the radiation pattern”. Especially, the efficiency of LIHRC is increased much four times higher than that of the general laser cladding and crack-free ceramic-metal coatings can be obtained.     

Fiber laser annealing of nanocrystalline PZT thick film prepared by aerosol deposition

Nanocrystalline PZT thick films (1 mm square and over 10 μm thick) directly deposited onto stainless-steel substrates (PZT/SUS) by aerosol deposition (AD) technique and then annealed using focused laser beam with a fiber laser to suppress thermal damage to the back sides of the PZT/SUS and substrate near the film edge and to retain the dielectric and/or ferroelectric properties of the PZT/SUS. Compared with CO₂ laser annealing, fiber laser annealing suppressed thermal damage to the substrate. Compared with PZT/SUS annealed at 600 °C using an electric furnace, PZT/SUS annealed at 600 °C using a fiber laser showed superior properties, namely, dielectric constant ? > 1200 at a frequency of 100 Hz, remanent polarization P_r > 30 μC/cm², and coercive field strength E_c < 50 kV/cm at a frequency of 10 Hz. Furthermore, the grain growth for the PZT/SUS formed by AD technique and annealed by fiber laser irradiation was occurred within the laser spot size.     

Ceramic components manufacturing by selective laser sintering

In the present paper, technology of selective laser sintering/melting is applied to manufacture net shaped objects from pure yttria-zirconia powders. Experiments are carried out on Phenix Systems PM100 machine with 50 W fibre laser. Powder is spread by a roller over the surface of 100 mm diameter alumina cylinder. Design of experiments is applied to identify influent process parameters (powder characteristics, powder layering and laser manufacturing strategy) to obtain high-quality ceramic components (density and micro-structure).The influence of the yttria-zirconia particle size and morphology onto powder layering process is analysed. The influence of the powder layer thickness on laser sintering/melting is studied for different laser beam velocity V (V = 1250-2000 mm/s), defocalisation (−6 to 12 mm), distance between two neighbour melted lines (so-called “vectors”) (20-40 μm), vector length and temperature in the furnace. The powder bed density before laser sintering/melting also has significant influence on the manufactured samples density.Different manufacturing strategies are applied and compared: (a) different laser beam scanning paths to fill the sliced surfaces of the manufactured object, (b) variation of vector length (c) different strategies of powder layering, (d) temperature in the furnace and (e) post heat treatment in conventional furnace. Performance and limitations of different strategies are analysed applying the following criteria: geometrical accuracy of the manufactured samples, porosity. The process stability is proved by fabrication of 1 cm³ volume cube.     

An experimental investigation of underwater pulsed laser forming

Laser forming is a new forming technology, which deforms a metal sheet using laser-induced thermal stresses. This paper presents an experimental investigation of pulsed laser forming of stainless steel in water and air. The effects of cooling conditions on bending angle and morphology of the heat affected zone (HAZ) are studied. It is shown that the case of the top surface in air and the bottom surface immersed in water has the greatest bending angle based on the forming mechanism of TGM. The water layer above the sample decreases the coupling energy, leading to a small bending angle. For a thin water thickness (1 mm), the water effects on the HAZ are limited. As water layer thickness increases (5 mm), the concave shape of the HAZ is more remarkable and irregular because the shock waves by high laser energy heating water are fully developed. However, the area and the depth of the HAZ become less significant when water thickness is 10 mm due to the long pathway that laser undergoes.     

Analysis of materials modifications caused by UV laser micro drilling of via holes in AlGaN/GaN transistors on SiC

Pulsed UV laser drilling can be applied to fabricate vertical electrical interconnects (vias) for AlGaN/GaN high electron mobility transistor devices on single-crystalline silicon carbide (SiC) substrate. Through-wafer micro holes with a diameter of 50-100 μm were formed in 400 μm thick bulk 4H-SiC by a frequency-tripled solid-state laser (355 nm) with a pulse width of ≤30 ns and a focal spot size of ∼15 μm. The impact of laser machining on the material system in the vicinity of micro holes was investigated by means of micro-Raman spectroscopy and transmission electron microscopy. After removing the loosely deposited debris by etching in buffered hydrofluoric acid, a layer of <4 μm resolidified material remains at the side walls of the holes. The thickness of the resolidified layer depends on the vertical distance to the hole entry as observed by scanning electron microscopy. Micro-Raman spectra indicate a change of internal strain due to laser drilling and evidence the formation of nanocrystalline silicon (Si). Microstructure analysis of the vias’ side walls using cross sectional TEM reveals altered degree of crystallinity in SiC. Layers of heavily disturbed SiC, and nanocrystalline Si are formed by laser irradiation. The layers are separated by 50-100 nm thick interface regions. No evidence of extended defects, micro cracking or crystal damage was found beneath the resolidified layer. The precision of UV laser micro ablation of SiC using nanosecond pulses is not limited by laser-induced extended crystal defects.     

Performance of a 80 W copper vapor laser with “alignment free” unstable CAT-EYE resonator and other configurations using intra-cavity apertures

Performance of a kinetically enhanced copper vapor laser (KE-CVL) with various stable/unstable “alignment free” CAT-EYE resonator configurations are presented here in this paper. The laser used in the experiment was a 45 mm bore (∼2 l discharge volume) kinetically enhanced copper vapor laser developed in our laboratory and capable of generating maximum power of ∼80 W (at ∼9.8 kHz). The efficiency of the laser was ∼1.4% and beam divergence of ∼3.5 mrad in a plane-plane standard multimode cavity. For the first time performance of unstable CAT-EYE resonator is demonstrated with a CVL/KE-CVL. On using unstable CAT-EYE resonator the divergence of the laser beam reduced to ∼0.22 mrad (∼20-fold reduction as compared to conventional plane-plane cavity), ∼40 W output power and with excellent misalignment tolerance. The laser output power was found to be within ∼5% drift/decline with misalignment angle of about 4 mrad between the mirrors. This is a significant improvement in comparison to standard conventional unstable resonator (M ∼ 50) CVL where ∼0.5 mrad divergence is achieved with power drift/decline of about 45% at ∼4 mrad misalignment angle.Off-axis unstable CAT-EYE unstable resonator was also demonstrated for the first time with further reduction in beam divergence to ∼0.13 mrad and with output power of ∼28 W. The misalignment tolerance was found to be highest in case of off-axis unstable CAT-EYE resonator with decline/drift in laser power of only ∼10% for misalignment angle as high as ∼8 mrad. Performance with intra-cavity apertures in plane-plane type CAT-EYE resonator for transverse mode control is also presented for the first time in CVLs. It is observed that the laser beam divergence reduces significantly to 1.25 mrad (a factor of 2) on using an aperture of ∼3.5 mm at the CAT-EYE reflector as compared to its normal (R = F = d) configuration without aperture. In case of stable CAT-EYE resonator the average beam divergence reduces from 8 mrad to 4 mrad (factor of 2) on using intra-cavity aperture of about 3 mm. It was also observed that high misalignment tolerance was retained on using intra-cavity apertures in almost all the CAT-EYE resonators. Use of intra-cavity mesh was also demonstrated for the first time with stable CAT-EYE resonator for improving the beam focus-ability. Average beam divergence was reduced by a factor of 2.5 (from 8 mrad to 3 mrad) on using intra-cavity mesh. These new configurations in CAT-EYE resonators in KE-CVLs are found to be effective in improving and controlling the laser beam divergence significantly with additional characteristic of high misalignment tolerance.     

Combined laser/sol-gel synthesis of calcium silicate coating on Ti-6Al-4V substrates for improved cell integration

New studies have shown that tricalcium silicate powder is a bioactive material and can encourage bone-implant integration. This paper reports the synthesis of Ca₂SiO₄ coating on Ti-6Al-4V samples by laser irradiation under submerged conditions. The results of using a 160-1500 LDL 1.5 kW diode laser (rectangular spot = 2.5 mm × 3.5 mm, λ = 808 and 940 nm with equal intensities) is reported. A number of experiments were carried out varying laser parameters, such as scanning speed and laser power. Coatings are evaluated in terms of microstructure, elemental composition (XRD), SEM and wettability. The in vitro biocompatibility of the samples is investigated by monitoring 2T3 osteoblast cell growth on the samples.     

Laser direct patterning of the T-shaped ITO electrode for high-efficiency alternative current plasma display panels

The laser direct patterning technique is one of the new methods of direct etching process to replace the conventional photolithography. In this experiment, a Q-switched diode-pumped Nd:YVO₄ (λ = 1064 nm) laser was used to produce the indium-tin oxide (ITO) patterns with a complex T-shaped structure on glass substrate. The results showed that the overlapping rate of laser beam had a major effect on the quality of the edge of the ITO electrode. When the overlapping rate was about 75%, it was possible to obtain optimum linearity in the edge of patterned ITO electrode. By using the optimum conditions of 75% overlapping rate, 500 mm/s scanning speed, and 40 kHz repetition rate, an alternative current plasma display panels (AC PDPs) with T-shaped ITO electrode was fabricated and characterized. The discharging results showed that the AC PDPs with the laser ablated T-shaped ITO electrode had a better discharging characteristics compared to the conventional sample with wet-etched stripe-type ITO electrode.     

Time-resolved transmission study of fused silica during laser-induced backside dry etching

Laser-induced backside dry etching (LIBDE) is a promising technique for micro- and nanomachining of transparent materials. Although several experiments have already proved the suitability and effectiveness of the technique, there are several open questions concerning the etching mechanism and the concomitant processes. In this paper time-resolved light transmission investigations of etching process of fused silica are presented. 125 nm thick silver coating was irradiated through the carrying 1 mm thick fused silica plate by single pulses of a nanosecond KrF excimer laser. The applied fluences were 0.38, 0.71 and 1 J/cm². During the etching process the irradiated spots were illuminated by an electronically delayed nitrogen laser pumped dye laser. The delay between the pump and probe pulses was varied in the range of 0 ns and 20 μs. It was found that the transmitted probe beam intensity strongly depends on the applied delays and fluences. Scanning electron microscopy and energy dispersive X-ray spectrometry of the etched surface showed the existence of silver droplets and fragments on the illuminated surfaces and silver atoms built into the treated surface layer influencing the transmission behavior of the studied samples.     

Semianalytical analysis of thermal effect in LD double-side-pumped rectangular laser crystal

A semianalytical method to analyze the thermal effect in a LD double-side-pumped rectangular laser crystal is put forward. Through the analysis of working characteristics of the laser crystal, a thermal model that matches actual situations of the laser crystal is established. General expressions of temperature field and thermal distortion field in the laser crystal can be obtained by a novel method to solve the heat conduction equation of orthotropic material. This semianalytical method can be used to calculate the temperature field and thermal distortion field in other LD double-side-pumped laser crystals and is applied to Nd:YVO₄ crystal in detail in this paper, and two methods of effectively reducing thermal distortion in the laser crystal are offered. Results show that a maximum temperature rise of 362.2 °C and a maximum thermal distortion of 5.55 μm are obtained in Nd:YVO₄ crystal when the output power of the two laser diodes are both 30 W. When the off-center distance is 0.6 mm, the maximum thermal distortion is reduced by 37.7%; when the thickness of the crystal is reduced from 2.0 mm to 1.4 mm, the maximum thermal distortion is reduced by 31.7%. Results in this paper can offer theoretical base for better solving thermal problems in laser system.     

Correction of small imperfections on white glazed china surfaces by laser radiation

A laser-assisted technique has been developed for correction of small diameter (1 mm) and shallow (0.5 mm) imperfections on the surface of gloss fired porcelain. To study the physics and establish the important parameters, artificially made holes in a porcelain sample have been first filled with correction material, then covered with raw glaze and treated by a pulsed, 7 kHz repetition rate CO₂ laser at 10.6 μm. The modification of the surface and the surrounding area have been quantified and studied with a large range of parameters of incident laser power (1-10 W), width of the laser pulses (10-125 μs) and duration of laser heating (60-480 s). Although the shine of the treated area, defined as the distribution of micro-droplets on the surface, is very similar to the untreated surfaces, the surroundings of the treated area usually show cracks. The measurement of both the spatial temperature distribution and the temporal cooling rate of the treated surface has revealed that a simple melting process always results in high gradient temperature distribution within the irradiated zone. Its inhomogeneous and fast cooling always generate at least micro-cracks on the surface within a few seconds after the laser was turned off. The duration and intensity of the laser irradiation have been then optimized in order to achieve the fastest possible melting of the surface, but without producing such high temperature gradients. To eliminate the cracks, more elaborated pre-heating and slowed-cooling-rate processes have been tried with prosperous results. These achievements complete our previous study, making possible to repair the most common surface imperfections and holes of gloss fired china samples.     

Effect of plasma confinement on laser shock microforming of thin metal sheets

Laser shock forming is conceived as a non-thermal laser forming method of thin metal sheets using the shock wave induced by laser irradiation to modify the target curvature. The plastic deformation induced by the shock wave and the direct plasma pressure applied on the material generate a residual stress distribution in the material finally leading to its bending. Using water as a confinement medium for the plasma the pressure can be increased around 10 times and the final deformation has a dramatic increase.The effect can be made clearly apparent in thin specimens (up to 1 mm). In the present study thin (100 μm) stainless steel (AISI 316) strips (1 mm long and 300 μm wide) in single and double pinned configurations have been investigated.A Nd:YAG Laser (1064 nm) with 10 ns of pulse length (FWHM) and an energy of 21 mJ per pulse is focused in the strip (spot diameter of the spot = 500 μm).Experimental and numerical studies of the influence of plasma confinement in the process and number of applied pulses are presented.The study shows that the final bending of the specimens can be controlled on a relative wide range by a stable quasi-proportional relation to the number of applied pulses and, what is considered as of major importance, that plasma confinement increases the generated pressure and thus the bending in the target.Laser shock microforming in confined configuration is considered as a technique allowing the successful processing of components in a medium range of miniaturization.     

Effects of processing parameters on laser cutting of aluminium-copper alloys using off-axial supersonic nozzles

Conventional laser cutting involves the utilization of converging coaxial nozzles to inject the assist gas used to remove the molten material. This processing system prevents the utilization of this technique to cut aluminium alloys for aerospace applications. The inefficient removal of molten material by the assist gas produces cuts with poor quality; very rough cuts, with a large amount of dross, and a large heat affected zone (HAZ) are obtained. An alternative to increase the assist gas performance is the utilization of off-axial supersonic nozzles. Removal of molten material is substantially increased and cuts with high quality are obtained. On the other hand, pulsed laser cutting offers superior results during the processing of high reflectivity materials as aluminium alloys. However, there are no experimental studies which explore the pulsed laser cutting of aluminium alloys by means of a cutting head assisted by an off-axis supersonic nozzle.The present work constitutes a quantitative experimental study to determine the influence of processing parameters on the cutting speed and quality criteria during processing by means of off-axial supersonic nozzles. Cutting experiments were performed in pulsed mode and the results explained under the basis of the molten material removal mechanisms. Performed experiments indicate a reduction in cutting speed as compared to continuous wave (CW) mode processing and the existence of two processing regimes as a function of the pulse frequency. Best results are obtained under the high pulse frequency one (f > 100 Hz) because the superior capabilities of molten material removal of the supersonic jets are completely exploited in this processing regime.     

Laser ablation of metals by femtosecond pulses: Theoretical and experimental study

We have investigated ultrashort laser micromachining of metals, both from the point of view of the basic physical processes, and the technological implications. The process of hole drilling of Ni with ≈300 fs SHG (λ = 527 nm) Nd-glass and Al samples with 100 fs Ti:sapphire (λ = 800 nm) laser pulses, respectively, has been experimentally addressed by using time-gated optical emission spectroscopy of the ablated material and SEM analysis of the targets. The ablation process has also been analyzed by classical, molecular dynamics (MD) simulations, by using a Morse potential to describe the interaction between the atoms, and taking into account the electron heat diffusion contribution. The dependence of the ablation depth on laser fluence, as measured by SEM analysis, is in good agreement with the numerical simulations and is also well correlated with the optical emission yield of the expanding plume.     

Efficient 1047 nm CW laser emission of Nd:YLF under direct pumping into the emitting level

We demonstrate a 1047 nm Nd:LiYF₄ (Nd:YLF) laser by directly pumping into the upper lasing level with a tunable Ti:Sapphire laser. The results obtained for direct upper laser level pumping at 863, 872 and 880 nm of Nd:YLF were compared with traditional 806 nm pump band excitation. Highly efficient 1047 nm continuous-wave (CW) laser emission under direct pumping at 880 nm in an 8 mm thick, 1.0 at.% Nd:YLF crystal is obtained. The slope efficiency is improved from 55.6% for traditional pumping at 806 nm to 76.3% for direct pumping at 880 nm.