A simple dye-sensitized solar cell sealing technique using a CO2 laser beam excited by 60 Hz AC discharges

Dye-sensitized solar cells (DSSCs) use two glass substrates (photo electrode and counter electrode) coated with fluorine-doped tin oxide (FTO) to harvest light into the cell and to collect electrons. The space between the photo electrode and the counter electrode are filled with a liquid type electrolyte for electron transfer into the cell. Therefore, an appropriate sealing method is required to prevent the liquid electrolyte leaking out. In this paper, a simple CO₂ laser beam with TEM₀₀ mode excited by a 60 Hz AC discharge was used to seal two glass substrates coated with FTO for the fabrication of DSSCs. The sealing technique improved the durability and stability of the DSSCs. The optimal conditions for the sealing of the DSSCs are related to the pin-hole diameter, the discharge current and the moving velocity of the target. Especially, the CO₂ laser beam is used as a heat source that is precisely controlled by the pin-hole, which plays an important role in adjusting its spot size. From these results, the maximum laser power was found to be 40 W at 18 Torr and 35 mA. In order to achieve the best sealing quality, the following parameters are required: a pin-hole diameter of 4 mm, input voltage of 10.73 kV, discharge current of 9.31 mA, moving velocity of 1 mm/s and distance from the target surface of 26.5 cm. Scanning electron microscope images show that the sealing quality obtained using the CO₂ laser beam is superior to that obtained using a hot press or soldering iron.     

Optimization of gas pressures ratio in a fast-axial-flow CO2 laser with genetic algorithm

In this paper, the laser output power of a fast-axial flow CO₂ laser was optimized with gas pressures ratio of CO₂:N₂:He using a genetic algorithm technique. The power of laser was increased from 500 W (un-optimized case) to 2200 W (simulated case), also experimentally the power has achieved the value of 700 W (optimized case).     

Simulation of the acceleration mechanism by light-propulsion for the powder particles at laser direct material deposition

The results of the numerical analysis of heat- and mass-transfer processes at powder particles' motion in a gas flow and laser beam by light-propulsion force during the laser cladding and direct material deposition are presented. Under consideration were the stainless steel particles, the radiation power range of the CO₂ laser were 1000, 3000 and 5000 W. Finally, the particles of 45 μm in diameter reach the maximum velocity of about 80, 220, 280 m/s. It is shown that as particles are heated by the laser up to the temperature approaching the boiling point, the particles' velocity in the light field by the vapor recoil pressure may increase significantly. The radius of the particles slightly varies due to the evaporation; the losses in the clad material mass are negligibly small. Comparisons of numerical results with known experimental data on light-propulsion acceleration of single particles (aluminum, aluminum oxide and graphite) under the influence of pulse laser radiation are also presented. Particle acceleration resulting from the laser evaporation depends on the particle diameter, powder material properties, focusing degree and attenuation laser beam intensity by the direction of its propagation.     

Weld-bead profile and costs optimisation of the CO2 dissimilar laser welding process of low carbon steel and austenitic steel AISI316

The dissimilar full depth laser-butt welding of low carbon steel and austenitic steel AISI 316 was investigated using CW 1.5 kW CO₂ laser. The effect of laser power (1.1–1.43 kW), welding speed (25–75 cm/min) and focal point position (?0.8 to ?0.2 mm) on the weld-bead geometry (i.e. weld-bead area, A; upper width, W_u; lower width, W_l and middle width, W_m) and on the operating cost C was investigated using response surface methodology (RSM). The experimental plan was based on Box–Behnken design; linear and quadratic polynomial equations for predicting the weld-bead widthness references were developed. The results indicate that the proposed models predict the responses adequately within the limits of welding parameters being used. The regression equations were used to find optimum welding conditions for the desired geometric criteria.     

High pulse repetition frequency RF excited waveguide CO2 laser with mechanical Q-switching

In this paper, a mechanical Q-switching is used in radio frequency (RF) excited waveguide CO₂ laser to obtain high pulse repetition frequency (PRF) laser. The Q-switching system includes two confocal ZnSe lenses and a high speed mechanical chopper, which is inserted into the cavity. The peak power is up to 730 W and the pulse width 200 ns at the highest PRF 20 kHz. The laser also has the advantages of compact, small-volume, and low-cost.     

Laser cleaning of particle and grease contaminations on the surface of optics

In the high power laser facility, surface contaminations on the optics will worsen the laser beam quality and damage the optics. Particle and grease contaminations are two of the usual contaminations on the surface of optics. In this work, the 1064-nm laser induced plasma shockwave cleaning is utilized to remove SiO₂ particle contaminations on the K9 glass surface. The results indicate the removal ratio can reach above 95%. The effects of parameters (particle position, laser gap distance and laser energy) on the cleaning efficiency have been studied in the case of single pulse laser cleaning. In addition, CO₂ laser (10.6 μm) is utilized to remove the dimethylsilicone oil contaminations on the gold-coated K9 glass surface. The results show that CO₂ laser can effectively remove the dimethylsilicone oil by properly controlling the laser parameters. The cleaned area increases with the increased laser power or irradiation time when the other parameters are constant.     

Investigation of optimum condition in oxygen gas-assisted laser cutting

Laser cutting characteristics including power level and cutting gas pressure are investigated in order to obtain an optimum kerf width. The kerf width is investigated for a laser power range of 50–170 W and a gas pressure of 1–6 bar for steel and mild steel materials. Variation of sample thickness, material type, gas pressure and laser power on the average cut width and slot quality are investigated. Optimum conditions for the steel and mild steel materials with a thickness range of 1–2 mm are obtained. The optimum condition for the steel cutting results in a minimum average kerf width of 0.2 mm at a laser power of 67 W, cutting rate of 7.1 mm/s and an oxygen pressure of 4 bar. A similar investigation for the mild steel cutting results in a minimum average kerf width of 0.3 mm at the same laser power of 67 W, cutting rate of 9.5 mm/s, and an oxygen pressure of 1 bar. The experimental average kerf is about 0.3 mm, which is approximately equal to the estimated focused beam diameter of 0.27 mm for our focusing lens (f=4 cm and 100 W power). This beam size leads to a laser intensity of about 1.74×10⁹ W/m² at the workpiece surface. The estimated cutting rate from theoretical calculation is about 8.07 mm/s (1.0 mm thickness and 100 W power), which agrees with the experimental results that is 7.1 mm/s for 1.0 mm thickness of mild steel at the laser power of 88 W.     

Investigating the CO2 laser cutting parameters of MDF wood composite material

Laser cutting of medium density fibreboard (MDF) is a complicated process and the selection of the process parameters combinations is essential to get the highest quality cut section. This paper presents a means for selecting the process parameters for laser cutting of MDF based on the design of experiments (DOE) approach. A CO₂ laser was used to cut three thicknesses, 4, 6 and 9 mm, of MDF panels. The process factors investigated are: laser power, cutting speed, air pressure and focal point position. In this work, cutting quality was evaluated by measuring the upper kerf width, the lower kerf width, the ratio between the upper kerf width to the lower kerf width, the cut section roughness and the operating cost. The effect of each factor on the quality measures was determined. The optimal cutting combinations were presented in favours of high quality process output and in favours of low cutting cost.     

Statistical modeling of laser welding of DP/TRIP steel sheets

In this research work, a statistical analysis of the CO₂ laser beam welding of dual phase (DP600)/transformation induced plasticity (TRIP700) steel sheets was done using response surface methodology. The analysis considered the effect of laser power (2–2.2 kW), welding speed (40–50 mm/s) and focus position (?1 to 0 mm) on the heat input, the weld bead geometry, uniaxial tensile strength, formability limited dome height and welding operation cost. The experimental design was based on Box–Behnken design using linear and quadratic polynomial equations for predicting the mathematical models. The results indicate that the proposed models predict the responses adequately within the limits of welding parameters being used and the welding speed is the most significant parameter during the welding process.     

Experimental proof on two-cone axisymmetric-folded combination CO2 laser

The experimental proof of the light output on the two-cone axisymmetric-folded combination (ASFC) CO₂ laser has been performed. The output power from the centre discharge tube is 26.7 W, and that of one couple of folded discharge tubes is 40.5 W. Seventeen beams can be obtained from the device, which are from the folded cavities with axes placed in the inner and outer cones, respectively. Therefore, the ASFC CO₂ laser with more discharge tubes can be fabricated and much higher output power can be obtained.     

A beam shaping design for coupling high power diode laser stack to fiber with capability of spectral narrowing and stabilizing

We applied a VHG-FAC lens in our design in this work to collimate the fast axis and lock the output spectrally. We used a beam shaping technique to improve the beam symmetry and power density of a high power diode laser stack with a stripe mirror plate, a V-Stack mirror and polarization beam combining elements. By this technique, the beam of a high power diode laser stack is effectively coupled into a standard 365 μmcore diameter and a NA = 0.22 fiber. By this technique, compactness, higher efficiency, narrower spectral line width and lower production cost of the diodes are possible.     

Damage/ablation morphology of laser conditioned sapphire under 1064 nm laser irradiation

The damage/ablation morphologies and laser induced damage threshold (LIDT) of three different sapphire samples: original, 1064 nm laser conditioned and 10.6 μm CO₂ laser polished substrates are investigated with ns pulses laser irradiation. The results indicate that the damage resistance capability cannot be enhanced by 1064 nm laser conditioning or CO₂ laser polishing. The damage/ablation morphology of 1064 nm-laser conditioned samples is same as that of the original sapphire. But it is different from the damage/ablation morphology of the CO₂ laser polished sapphire. The “gentle and strong” ablation phases are observed in this work and several phenomena are observed in the two ablation phases. Ripple is observed in the “gentle” ablation processes, while convex spots and raised rims are observed in the “strong” ablation processes. Meanwhile, stripe damage and pin-points are observed in the CO₂ laser conditioned sapphire after ns laser irradiation. The formation mechanisms of the phenomena are also discussed for the explanation of related damage/ablation morphology. The results may be helpful for the damage/ablation investigation of sapphire in high power laser systems.     

Diode-pumped doubly Q-switched Nd:Lu0.33Y0.37Gd0.3VO4 laser with an electro-optic modulator and a single-walled carbon nanotube saturable absorber

By simultaneously using an electro-optic (EO) modulator and a single-walled carbon nanotube saturable absorber (SWCNT-SA) in the cavity, a diode-pumped doubly Q-switched Nd:Lu_0.33Y_0.37Gd_0.3VO₄ (Nd:LuYGdVO₄) laser is demonstrated. At the incident pump power 11.43 W and f=2 kHz, the minimum pulse width 17.6 ns and the maximum pulse peak power 19,886 W can be obtained. The experimental results show that this doubly Q-switched Nd:LuYGdVO₄ laser can generate shorter pulse width and higher peak power compared to the singly Q-switched Nd:LuYGdVO₄ laser with only EO or SWCNT-SA.     

Stress-induced depolarization loss in a YAG zigzag slab

The stress-induced depolarization loss in a [1 1 1] orientated YAG zigzag slab was studied. The process to get correct piezo-optic tensor was given in detail. The results indicated that the relationships between losses and cut angles varied with the change in the bounce numbers of light in zigzag propagation through the slab. The loss mainly occurred in the area near the edges in width and the mean depolarization loss was less than 3%. The coupling of a laser beam with adequate bounce number and aspect ratio less than 1 on the entrance plane was found to reduce the depolarization loss.     

Measurement of the bead profile and microstructural characterization of a CO2 laser welded AISI 904 L super austenitic stainless steel

Laser welding of AISI 904 L super austenitic stainless steel using a diffusion cooled slab 3.5 kW CO₂ laser and employing two different shielding gases, namely argon and helium, was carried out. The laser weld bead profile depends on various parameters such as beam power (BP), travel speed (TS) and focal position (FP) of the laser spot. These parameters have to be selected suitably to obtain the desirable output. The cross sectioned area of the bead profiles measured using an optical microscope to determine the bead width and depth of penetration. X-ray diffraction used for phase identification confirmed that the weld structure was fully austenitic and dendritic. Hardness was observed to increase in the weld bead with respect to the parent metal and it was related to the microstructural refinement induced by a rapid cooling of the weld zone.     

Miniature high-repetition-rate TEA CO2 laser with surface-wire-corona preionization

In this article, an experimental study of a miniature, sealed-off, high-repetition-rate transversely excited atmospheric-pressure (TEA) CO₂ laser with a kind of surface-wire-corona preionization (SWCP) is described. We have utilized an SWCP consisting of SiO₂ dielectric tube and a fine wire strained and attached to the dielectric surface. A BN ceramic material, which has an extremely low coefficient of thermal expansion of about 5 × 10⁻⁷/°C was employed as a supporter of the resonator. A measurement on emission spectra of SWCP has been reported. By applying SWCP to the TEA CO₂ laser, efficient laser operation at an overall efficiency of 9.8% with an output energy of 150 mJ has been achieved from a small discharge volume of 25 cm³ with an active length of 230 mm. At the pulse repetition frequency of 60 Hz, the TEM₀₀ mode of laser beam with pulse width of 60 ns was obtained.     

Ultrafast laser performance of Yb3 +: Sc2SiO5 crystal with a single-walled carbon nanotube absorber

Single-walled carbon nanotube (SWCNT) absorber fabricated by vertical evaporation is used in passively mode-locked Yb^3 +:Sc₂SiO₅ (Yb:SSO) ultrafast laser for the first time. The performance of Yb:SSO ultrafast laser with pulse width as short as 880 fs is studied and the average output power is 712 mW. To our knowledge, this is the highest output power of femtosecond lasers with SWCNT-SAs reported. In addition, we firstly demonstrate a passively mode-locked picosecond Yb:SSO laser without inserting any dispersion compensation device. The pulses width is as short as 5.4 ps and the output power is 940 mW.     

Diode-pumped monolithic Er3+:Yb3+:YAl3(BO3)4 micro-laser at 1.6 μm

Efficient eye-safe 1.6 μm monolithic laser was realized in a c-cut, 0.7-mm-thick Er³⁺:Yb³⁺:YAl₃(BO₃)₄ microchip end-pumped by a quasi-continuous-wave 970 nm diode laser. At incident pump peak power of 20.4 W, a maximum output peak power of 2.6 W with a slope efficiency of 19% was obtained when the waist radius of pump laser beam was 220 μm. The spectra and profiles of output beam of the Er³⁺:Yb³⁺:YAl₃(BO₃)₄ monolithic laser were measured. The influences of the waist radius of pump laser beam on the slope efficiency and threshold of the monolithic laser were also investigated.     

Laser diode end-pumped passively Q-switched Tm,Ho:YLF laser with Cr:ZnS as a saturable absorber

Output performance of a continuous-wave (CW) laser diode end-pumped passively Q-switched Tm,Ho:YLF laser is demonstrated with a Cr:ZnS crystal as the saturable absorber. We particularly investigate the influence of saturable absorber's position in the resonator when the Cr:ZnS crystal is placed close to and far from the laser beam waist. We compare the experimental results at the two different positions, and find that the laser shows unusual output characteristics when the Cr:ZnS saturable absorber is placed close to the beam waist. The pulse width and the pulse energy almost keep constant, measured about 1.25 μs and 4 μJ respectively, when the pump power is changed in the range of 1–1.9 W. Moreover, the pulse repetition frequency can be tuned between 1.3 kHz and 2.6 kHz by changing the pump power. The output wavelength of the passively Q-switched laser shifts to 2053 nm from 2067 nm in CW operation.     

Improvement of stability and pulse energy in a diode-pumped dual-loss-modulated QML Nd:Lu0.2Y0.8VO4 laser with EO modulator and GaAs

The Q-switched and mode-locked (QML) performance in a diode-pumped Nd:Lu_0.2Y_0.8VO₄ laser with electro-optic (EO) modulator and GaAs saturaber absorber is investigated. In comparison with the solely passively QML laser with GaAs, the dual-loss-modulated QML laser with EO and GaAs can generate pulses with higher stability and shorter pulse width of Q-switched envelope, as well as higher pulse energy. At the repetition rate 1 kHz of EO, the pulse width of Q-switched pulse envelope has a compression of 89% and the pulse energy has an improvement of 24 times. The QML laser characteristics such as the pulse width, pulse peak power etc. have been measured for different small-signal transmittance (T₀) of GaAs, different reflectivity (R) of output coupler and modulation frequencies of the EO modulator (f_e). The highest peak power and the shortest pulse width of mode-locked pulses are obtained at f_e = 1 kHz, R = 90% and T₀ = 92.6%. By considering the influences of EO modulator, a developed rate equation model for the dual-loss-modulated QML laser with EO modulator and GaAs is proposed. The numerical solutions of the equations are in good agreement with the experimental results.