Investigating laser rapid manufacturing for Inconel-625 components

This paper presents an investigation of laser rapid manufacturing (LRM) for Inconel-625 components. LRM is an upcoming rapid manufacturing technology, it is similar to laser cladding at process level with different end applications. In general, laser-cladding technique is used to deposit materials on the substrate either to improve the surface properties or to refurbish the worn out parts, while LRM is capable of near-net shaping the components by layer-by-layer deposition of the material directly from CAD model. In the present study, a high-power continuous wave (CW) CO₂ laser system, integrated with a co-axial powder-feeding system and a three-axis workstation were used. The effect of processing parameters during LRM of Inconel-625 was studied and the optimum set of parameters for the maximum deposition rate was established employing Orthogonal L9 array of Taguchi technique. Results indicated that the powder feed rate and the scan speed contributed about 56% and 26%, respectively to the deposition rate, while the influence of laser power was limited to 10% only. Fabricated components were subjected to non-destructive testing (like—ultrasonic testing, dye-penetrant testing), tensile testing, impact testing, metallographic examinations and micro-hardness measurement. The test results revealed defect-free material deposition with improved mechanical strength without sacrificing the ductility.     

Laser cutting of polymeric materials: An experimental investigation

The CO₂ laser cutting of three polymeric materials namely polypropylene (PP), polycarbonate (PC) and polymethyl methacrylate (PMMA) is investigated with the aim of evaluating the effect of the main input laser cutting parameters (laser power, cutting speed and compressed air pressure) on laser cutting quality of the different polymers and developing model equations relating input process parameters with the output. The output quality characteristics examined were heat affected zone (HAZ), surface roughness and dimensional accuracy. Twelve sets of tests were carried out for each of the polymer based on the central composite design. Predictive models have been developed by response surface methodology (RSM). First-order response models for HAZ and surface roughness were presented and their adequacy was tested by analysis of variance (ANOVA). It was found that the response is well modeled by a linear function of the input parameters. Response surface contours of HAZ and surface roughness were generated. Mathematical model equations have been presented that estimate HAZ and surface roughness for various input laser cutting parameters. Dimensional accuracies of laser cutting on polymers were examined by dimensional deviation of the actual value from the nominal value. From the analysis, it has been observed that PMMA has less HAZ, followed by PC and PP. For surface roughness, PMMA has better cut edge surface quality than PP and PC. The response models developed can be used for practical purposes by the manufacturing industry. However, all three polymeric materials showed similar diameter errors tendency in spite of different material properties.     

Laser induction hybrid rapid cladding of WC particles reinforced NiCrBSi composite coatings

In order to investigate the microstructure characteristics and properties of Ni-based WC composite coatings containing a relatively large amount of WC particles by laser induction hybrid rapid cladding (LIHRC) and compare to the individual laser cladding without preheating, Ni60A + 35 wt.% WC composite coatings are deposited on A3 steel plates by LIHRC and the individual laser cladding without preheating. The composite coating produced by the individual laser cladding without preheating exhibits many cracks and pores, while the smooth composite coating without cracks and pores is obtained by LIHRC. Moreover, the cast WC particles take on the similar dissolution characteristics in Ni60A + 35 wt.% WC composite coatings by LIHRC and the individual laser cladding without preheating. Namely, the completely dissolved WC particles interact with Ni-based alloy solvent to precipitate the blocky and herringbone carbides, while the partially dissolved WC particles still preserve the primary lamellar eutectic structure. A few WC particles are split at the interface of WC and W₂C, and then interact with Ni-based alloy solvent to precipitate the lamellar carbides. Compared with the individual laser cladding without preheating, LIHRC has the relatively lower temperature gradient and the relatively higher laser scanning speed. Therefore, LIHRC can produce the crack-free composite coating with relatively higher microhardness and relatively more homogeneous distribution of WC particles and is successfully applied to strengthen the corrugated roller, showing that LIHRC process has a higher efficiency and good cladding quality.     

Effect of leakage transformer on laser power and mode pattern of CO2 laser excited by 60 Hz AC discharges

The 60 Hz AC discharges generated by a leakage transformer instead of an isolation one, which is usually used in the power supply of DC CO₂ laser, are employed as a pumping source in this experiment. The laser performance characteristics as functions of pressure and discharge current have been investigated. The maximum laser power is about 40 W at conditions of 18 Torr and 35 mA. The output power is not less than that of DC discharge at the same condition. In addition, the laser outputs of 60 Hz AC discharges obtained by different transformers such as a leakage type and an isolation one have been measured. It was found that the laser power obtained by the leakage transformer is saturated at the higher current compared with the isolation transformer.     

全密度功能性复杂金属零件的激光直接快速制造

针对具有复杂结构的全密度功能性金属零件快速制造难题,探讨了该类零件的选区激光熔化直接快速制造方法,并结合实验,重点对同步保证选区激光熔化快速制造金属零件成型密度及精度的工艺进行了研究。结果表明：同步消除球化、飞溅及气孔对成型件致密性及精度的影响是实现选区激光熔化快速制造全密度功能性复杂金属零件的难点及关键;在维持良好的抗氧化气氛条件下,可采用尽可能薄的铺粉厚度及恰当调节其它成型参数的方法,以保证对上一层有足够的重熔量来消除球化及气孔现象;同时,采用合适的扫描策略,可弱化飞溅对成型质量的影响来解决工艺难题。采用该工艺方案可快速制造全密度功能性复杂金属零件,所成型的316L不锈钢叶轮零件相对密度为99.8%,硬度为HB192,表面粗糙度约为40 μm,尺寸精度在±0.1 mm以内,稍经打磨后即可投入使用。     

Line Narrowing of a Tunable High Pressure CO2 Laser by Means of an Improved Non-Littrow Cavity

A model is reported to foresee ,for different mirror choices, the spectral properties of a high pressure, frequency tunable, CO₂ laser, operating with a non-Littrow grating mounting. The calculations show a larger frequency selectivity for not collimated plane cavities. The model is experimentally verified in a suitable high pressure laser. In particular narrowed linewidths less than 300MHz ( FWHM) are obtained.     

Laser cutting of thick ceramic tile

This paper details developments in the CO₂ laser cutting of thick ceramic tiles, that is thicknesses of 8.5 mm and 9.2 mm. These tiles were cut at a combination of different cutting speeds to determine the necessary cutting parameters for various tile geometries. Different cutting modes were used in conjunction with different cutting speeds to investigate cut quality after laser processing. The work also looked into the effects on cutting through using various shield gases. Multipass cutting and underwater cutting were performed to examine their effects on thermal load during processing.     

CO2 laser cutting of slate

Slate is a natural stone which has the characteristic that shows a well-developed defoliation plane, allowing to easily split it in plates parallel to that plane which are particularly used as tiles for roof building. At present, the manufacturing of slate is mostly manual, being noisy, powdery and unsafe for the worker. Thus, there is a need to introduce new processing methods in order to improve both the working conditions and the quality of the products made of slate.Following the previous work focused on the drilling and cutting of slate tiles using a Nd : YAG laser, we present in this paper the results of the work carried out to explore the possibilities to cut slate plates by using a CO₂ laser. A 1.5 kW CO₂ laser was used to perform different experiments in which, the influence of some processing parameters (average power, assist gas pressure) on the geometry and quality of the cut was studied. The results obtained show that the CO₂ laser is a feasible tool for a successful cutting of slate.     

New Strong MM FIR Emissions in CH2=CF2 Pumped by a Pulsed CO2 Laser

By pumping with a suitable pulsed CO₂ laser we have produced several strong MM laser lines in 1,1 difluoroethene. All the emissions are easily identified because the emission spectroscopy is simplified in pulsed optical pumping.     

Laser cutting speeds for ceramic tile: a theoretical–empirical comparison

This paper presents a comparison of theoretically-predicted optimum cutting speeds for decorative ceramic tile with experimentally-derived data. Four well-established theoretical analyses are considered and applied to the laser cutting of ceramic tile, i.e. Rosenthal's moving point heat-source model and the heat balance approaches of Powell, Steen and Chryssolouris. The theoretical results are subsequently compared and contrasted with actual cutting data taken from an existing laser machining database. Empirical models developed by the author are described which have been successfully used to predict cutting speeds for various thicknesses of ceramic tile.     

Frequency Stabilization of Waveguide CO2 Laser by a Digital Technique

In this work we present a simple technique for laser frequency stabilization, based on Digital signal processing. The technique is used to stabilize a waveguide CO₂ laser of wide tunability by using three kinds of reference signals: the CO₂ laser ouptut power, an infrared absorption optoacoustic signal and the output power of a Far-Infrared optically pumped molecular laser.     

Laser clad Ni-base alloy added nano- and micron-size CeO2 composites

Micron-size Ni-base alloy (NBA) powders are mixed with both 1.5 wt% (%) micron-CeO₂ (m-CeO₂) and also 1.0–3.0% nano-CeO₂ (n-CeO₂) powders. These mixtures are coated on low carbon steel (Q235) by 2.0 kW CO₂ laser cladding. The effects on microstructures, microhardness and wear resistance of the coating by the addition of m- and n-CeO₂ powders to NBA (m- and n-CeO₂/NBA) have been investigated. Addition to the primary phases of γ-Ni, Cr₂₃C₆ and Ni₃B of NBA coating, CeNi₃ shows up both in m- and n-CeO₂/NBA coatings and CeNi₅ appears only in n-CeO₂/NBA coating. Directional dendrite and coarse equiaxed dendrite are grown in m-CeO₂/NBA coating from interface to central zone, whereas multi-oriented dendrite and fine equiaxed dendrite growth by addition of n-CeO₂. The microhardness and wear resistance of coatings are greatly improved by CeO₂ powder addition, and compared to the addition of 1.0% and 3.0%, 1.5% n-CeO₂/NBA is the best. Hardness and wear resistance of the coating improves with decreasing CeO₂ size from micron to nano.     

Trace Detection of Low Concentrations of Ozone Using a CO<Subscript>2</Subscript> Laser with Automatic Tuning over the Spectrum

A technique of detection of ozone, using a CO₂ laser with rapid automated tuning over 8–10 generation lines in the 9.4–9.6-µm spectral range, has been developed. Its experimental verification has shown a higher accuracy of detecting low concentrations of O₃ in comparison with the traditional technique of differential absorption on two lines (on-line and off-line). Using the technique suggested, the content of ozone in the vicinity of city roads with heavy traffic has been measured.__________Translated from Zhurnal Prikladnoi Spektroskopii, Vol. 72, No. 2, pp. 251–255, March–April, 2005.     

Macroscopic Isotope Separation of 13C by a CO2 Laser

By photochemical dissociation of the rare carbon isotope component of CHClF₂ by means of a CO₂ laser with an average power of 150 W, Q-switched at 10 kHz, we have demonstrated the separation of more than 1 mol of ¹³C, enriched to 50% (2 mol of total carbon). It is contained in about 1 mol (101 g) of the product C₂F₄. The total throughput of the starting material was 29 kg. The experiment was run day and night for 2 weeks, almost only controlled by a computer. We obtained production rates of 5 mmol/h, corresponding to about 0.5 kg ¹³C per year.     

Dynamics of a Loss-Modulated, Two-Wave CO2 Laser Lasing on Lines of Different Vibrational Bands

The nonlinear dynamics of a loss-modulated, two-wave CO₂ laser lasing on vibrational–rotational lines of different vibrational bands has been investigated theoretically and experimentally. It is shown that the time and energy parameters of laser radiation can be controlled within fairly wide limits by changing the depth and frequency of modulation and the ratio between the constant components of the losses.     

Theoretical prediction on the wavelength-temperature shift in pulsed TE CO2 lasers

The wavelength-temperature shift observed in pulsed TE CO₂ lasers is discussed theoretically by means of Six-temperature model rate equations for tunable TE CO₂ lasers. Numerical calculations of the temperature-wavelength shift in a pulsed TE CO₂ laser with a simple plano-concave stable resonator, whether excited by conventional low-inductance fast-discharge scheme or by a long-pulse Pulser/sustainer discharge scheme, show that the laser output wavelengths are within the 10P branch as the ambient temperature varies from 228 to 338 K, but will change as the ambient temperature varies. The laser output wavelengths will move to the transition lines with longer wavelengths in the 10P branch as the ambient temperature increases and vice versa. The calculated results also illustrate that near the ambient temperature of 310 K, the laser is more likely to operate on multi-transition lines. Considering this wavelength-temperature shift, the chilling device adopted in high-power high repetition rate TE CO₂ lasers is important in maintaining a stable laser output spectra as well as a stable laser output power. The numerical results also suggest that a frequency agile resonator is highly recommended if stable laser output spectra are required in TE CO₂ lasers.     

Control of the Radiation Parameters of a Two-Wave Repetitively Pulsed CO2 Laser

Generation dynamics of a two-wave CO₂ laser with excitation by a continuous electric discharge and with modulation of losses in one of the channels is investigated theoretically and experimentally. It is shown that by changing the frequency and depth of modulation of a variable component of losses and also the relationship between the constant components of losses one can control, over rather wide limits, the shape, duration, and peak power of radiation pulses in the active and passive channels.     

Surface treatment with linearly polarized laser beam at oblique incidence

An effective method for surface heat treatment with 10.6 μm linear polarized laser beam at oblique incidence is reported. A circular focused laser spot on the workpiece surface, simultaneously with 2.2–4 times increasing of the absorption are obtained in the 70–80° range of the incidence angle. The main element of the experimental setup is the astigmatic focusing head which focalize the laser beam into an elliptical spot of ellipticity >3 at normal incidence. At a proper incidence angle (obtained by the focusing head tilting) the focused laser spot on the work piece surface gets a circular form and p-state of polarization is achieved.We performed laser heat treatment (transformation hardening, surface remelting) of the uncoated surface, as well as the alloying and cladding processes by powder injection. An enhancement of the processing efficiency was obtained; in this way the investment and operation costs for surface treatment with CO₂ laser can be significantly reduced. Several technical advantages concerning the pollution of the focusing optical components, powder jet flowing and reflected radiation by the work piece surface are obtained.     

A scribing laser marking system using DSP controller

Laser marking is an important branch of laser processing technology, and has been widely used in many fields of industry. Digital signal processor (DSP) is an incredibly fast and powerful microprocessor that can deal with signals in real time. Not only it is portable but has the ability to integrate the processing signals of subsystems. In this research, it is emphasized that we designed a scribing laser marking system based on a DSP in galvanometric marking method. To control the rotating angle of the galvanometric scanning mirrors more accurately, we combine the D/A converter of the DSP with the human–machine interface successfully. The whole marking system is not only inexpensive, but also miniaturized.     

Laser cladding of in situ TiB2/Fe composite coating on steel

To enhance the wear resistance of mechanical components, laser cladding has been applied to deposit in situ TiB₂/Fe composite coating on steel using ferrotitanium and ferroboron as the coating precursor. The phase constituents and microstructure of the composite coating were investigated using X-ray diffraction (XRD), scanning electron micrograph (SEM) and electron probe microanalysis (EPMA). Microhardness tester and block-on-ring wear tester were employed to measure the microhardness and dry-sliding wear resistance of the composite coating. Results show that defect-free composite coating with metallurgical joint to the steel substrate can be obtained. Phases presented in the coating consist of TiB₂ and α-Fe. TiB₂ particles which are formed in situ via nucleation-growth mechanism are distributed uniformly in the α-Fe matrix with blocky morphology. The microhardness and wear properties of the composite coating improved significantly in comparison to the as-received steel substrate due to the presence of the hard reinforcement TiB₂.