Investigation into CO2 laser cleaning of titanium alloys for gas-turbine component manufacture

This paper reports results of the investigation into the feasibility of using a CO₂ laser technology to perform critical cleaning of gas-turbine aero-engine components for manufacture. It reports the results of recent trials and relates these to a thermal model of the cleaning mechanisms, and describes resultant component integrity. The paper defines the experimental conditions for the laser cleaning of various aerospace-grade contaminated titanium alloys, using a continuous wave CO₂ laser. Laser cleaning of Ti64 proved successful for electron beam welding, but not for the more sensitive Ti6246. For diffusion bonding the trials produced a defective standard of joint. Effects of oxide formation is modelled and examined experimentally.     

Inert gas cutting of titanium sheet with pulsed mode CO2 laser

The present work aimed at studying the dynamic behavior of melt ejection in laser cutting of 1 mm thick titanium sheet and to obtain dross-free cuts with minimum heat affected zone (HAZ). CO₂ laser cutting of titanium sheet was carried out with continuous wave (CW) and pulsed mode laser operation with different shear gases namely argon, helium and nitrogen. Laser cutting with high frequency and low-duty cycle pulse mode operation produced dross-free cuts with no noticeable HAZ. Helium, because of its high heat convection and ability to generate high shear stress, produced laser-cuts with narrow HAZ and low dross, as compared to those produced with argon as the shear gas. Microscopic features of laser cut surfaces were analyzed and correlated with dynamic mechanism involved in laser cutting process. Process parameters for laser piercing, required for the initiation of fusion cut within the sheet, were also studied. Laser piercing requires either CW or high-duty cycle (>80%) pulse mode operation.     

Bioactive coating on titanium implants modified by Nd:YVO4 laser

Apatite coating was applied on titanium surfaces modified by Nd:YVO₄ laser ablations with different energy densities (fluency) at ambient pressure and atmosphere. The apatites were deposited by biomimetic method using a simulated body fluid solution that simulates the salt concentration of bodily fluids. The titanium surfaces submitted to the fast melting and solidification processes (ablation) were immersed in the simulated body fluid solution for four days. The samples were divided into two groups, one underwent heat treatment at 600 °C and the other dried at 37 °C. For the samples treated thermally the diffractograms showed the formation of a phase mixture, with the presence of the hydroxyapatite, tricalcium phosphate, calcium deficient hydroxyapatite, carbonated hydroxyapatite and octacalcium phosphate phases. For the samples dried only the formation of the octacalcium phosphate and hydroxyapatite phases was verified. The infrared spectra show bands relative to chemical bonds confirmed by the diffraction analyses. The coating of both the samples with and without heat treatment present dense morphology and made up of a clustering of spherical particles ranging from 5 to 20 μm. Based on the results we infer that the modification of implant surfaces employing laser ablations leads to the formation of oxides that help the formation of hydroxyapatite without the need of a heat treatment.     

Modelling of CO2 laser welding of magnesium alloys

Laser welding is an important joining process for magnesium alloys. These materials are being increasingly used in different applications such as in aerospace, aircraft, automotive, electronics, etc. To date, carbon dioxide (CO₂) neodymium-doped yttrium aluminum garnet (Nd:YAG) and the high power diode laser have been extensively used to investigate the weldability of magnesium alloys. The present work describes an analytical thermal model for the weldability of magnesium alloys (WE43) using an industrial (CO₂) laser source. The main target of the project is to present to the industrial community a simple and rapid tool for the determination of the penetration depth and the bead width as a function of both the incident laser power and welding speed. The proposed model is based on the Davis thermal approach, largely considered for the characterization of the average radius of the liquid zone, aiming at predicting the joint shape. Moreover, since during the welding process considered in this study, a protecting gas is used to avoid joint oxidation, both thermal convection and radiation phenomena in the welding area have been estimated and introduced in our model for a better characterization of the welding process. The obtained results have been compared to the experimental ones and a satisfactory correlation has been observed, indicating the reliability of the model developed in this study.     

The influence of laser power and repetition rate on oxygen and nitrogen insertion into titanium using pulsed Nd:YAG laser irradiation

Oxygen and nitrogen insertion in a titanium substrate is performed in air using a Q-switched Nd-YAG laser. This process modifies the surface by the formation of specific layers on the substrate. These layers show different properties, largely influenced by the insertion of elements in the layers. The treatment conditions, especially the laser parameters (fluence and repetition rate), must be known and controlled. Using nuclear analysis, we demonstrate that oxygen insertion is mainly influenced by repetition rate, and that nitrogen insertion is controlled by laser fluence. The physical phenomena involved in the oxygen and nitrogen insertion are discussed.     

Growth of titanium oxynitride layers by short pulsed Nd:YAG laser treatment of Ti plates: Influence of the cumulated laser fluence

Titanium oxynitride layers were formed by surface laser treatment of Ti plates in air using a Nd:YAG laser source of short pulse duration about 5 ns. The cumulated laser fluence was varied in the 100-1200 J cm⁻² range and its influence on the composition and the structure of the formed layers was studied by different characterization techniques providing physico-chemical and structural information. It was shown that the laser treatment induces the insertion of light elements as O, N and C in the formed layer with the amount increasing with the laser fluence. The in-depth composition of the layers and the co-existence of different phases were also studied.The way in which the laser parameters such as fluence affect the insertion of nitrogen and oxygen was discussed in connection with the effects of the plasma plume formed above the target.     

Comparative interaction mechanisms for different laser systems with selected materials on titanium alloys

This paper describes further research into, and modelling of, the interaction mechanisms of various laser types with materials, including synthetic oil and silicone grease. A Q-switched Nd:YAG pulsed laser, a CW CO₂ laser, and a pulsed KrF excimer laser (λ = 248 nm) were used in the study. In general, the materials studied were very absorptive in the ultraviolet, less absorptive in the infrared, and least absorptive in the near-infrared. For the excimer, photo-ablation takes place, while for the other two wavelengths thermal vapourization dominates. In the case of silicone grease, full volatilization is only obtained using the excimer. For the other two wavelengths, this is not the case, with a sticky residue remaining after treatment. Interaction with synthetic oil with its lower boiling point can be obtained for all three laser types. With the Nd:YAG the dominant heating mechanism is conduction from the substrate and a baking effect is observed with strong interaction between the contaminant and the substrate. For the two pulsed lasers, oxidation is substantially less, while for the continuous wave CO₂, the interaction time is sufficiently long for oxidation and secondary reactions to take place if care is not taken to work below the reaction threshold.     

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.     

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.     

CO2 laser beam modulating for surface texturing machining

Laser texturing is a novel technique that may be used to texture a cold roller in the process of manufacturing high quality steel sheets. With the aim of improving the quality of the textured roller by using a CO₂ laser, a new laser beam modulating device is proposed. An optical beam expander with a fast rotating chopper system is designed. The laser pulse is split into two parts by the chopper blades; one is the preheating pulse that is reflected onto optical loop mirrors; the other is the directly transmitted pulse that creates the craters at the preheated spots. The preheating beam focus spot size and position can be adjusted. The focusing characteristics and optical parameter compensation for the flying optics are investigated. The heat transfer and melt process of laser texturing are numerically simulated. The effects of the double pulses on the texturing are analyzed. The effect of preheating the sample ahead of the laser texturing pulse is examined. The surface profile and bump hardness show improvements by using this approach.     

CO2 laser cutting of MDF: 2. Estimation of power distribution

Part 2 of this paper details an experimentally-based method to evaluate the power distribution for both CW and PM cutting. Variations in power distribution with different cutting speeds, material thickness and pulse ratios are presented. The paper also provides information on both the cutting efficiency and absorptivity index for MDF, and comments on the beam dispersion characteristics after the cutting process.     

Ambient gas effects on high-power Nd:YAG laser ablation of SnO2:Sb transparent conducting thin film

Optical emission spectra of the plasma produced by 1.06 μm Nd:YAG laser ablation of SnO₂:Sb transparent conducting thin film were recorded and analyzed as functions of distance from the target surface and incident laser power density in air and in vacuum. Ambient gas effects on pulsed laser ablation of target were analyzed in detail. We also discussed how the air takes part in the plasma evolution process and confirmed that the ignition of the air plasma is by the collisions between the energetic electrons and the nitrogen atoms through a cascade avalanche process.     

Radiation effects and pulsed laser deposition of titanium by Nd:Yag laser

A study of Ti laser irradiation and thin film deposition produced by an Nd:Yag pulsed laser is presented. The laser pulse, 9?ns width, has a power density of the order of 10¹⁰?W/cm². The titanium etching rate is of the order of 1?µg/pulse, it increases with the laser fluence and shows a threshold value at about 30?J/cm² laser fluence. The angular distribution of ejected atoms (neutrals and ions) is peaked along the normal of the target surface. At high fluence, the fractional ionization of the plasma produced by the laser is of the order of 10%. Time-of-flight measurements demonstrate that the titanium ions, at high laser fluence, may reach kinetic energies of about 1?keV. Obtained results can be employed to produce energetic titanium ions, to produce coverage of thin films of titanium and to realize high adherent titanium-substrate interfaces. The obtained results can be employed to produce energetic titanium ions, to produce a coverage of thin titanium films on polymers, and to realize highly adherent titanium–substrate interfaces.     

High-power Nd:YAG planar waveguide laser with YAG and Al2O3 claddings

Thermal effects in Nd:YAG planar waveguide lasers with non-symmetrical claddings are discussed. The heat generated in the active core can be removed more efficiently by directly contacting the active core to the heat sink. Several cladding materials are compared to optimize the heat removal. Furthermore, uniform pumping is achieved with oblique edge-pumping technique. Using quasi-CW pumping at 1 KHz repetition rate, an average output power of 280 W with a slope efficiency of 38% is obtained with a positive unstable resonator.     

Nd:YAG laser synthesis of nanostructural V2O5 from vanadium oxide sols: Morphological and structural characterizations

Vanadium oxide thin films were prepared by sol-gel method, then subjected to Nd:YAG laser (CW, 1064 nm) radiation. The characteristics of the films were changed by varying the intensity of the laser radiation. The nanocrystalline films were characterized by X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), transmission electron microscopy (TEM) and scanning electron microscopy (SEM). XRD revealed that above 102 W/cm² the original xerogel structure disappears and above 129 W/cm² the films become totally polycrystalline with an orthorhombic structure. From TEM observations, we can see that due to laser radiation, the originally fibrillar-like particles disappear and irregular shaped, layer structured V₂O₅ particles are created. From XPS spectra we can conclude that due to laser radiation the O/V ratio increased with higher intensities.     

Processing of concretes with a high power CO2 laser

Laser material processing, being a non-contact process, minimizes many of the complexities involved in the decontamination and decommissioning of nuclear facilities. A high power laser beam incident on a concrete surface can produce spalling, glazing or vaporization, depending upon the laser power density and scan speed. This paper presents effect of various laser processing parameters on the efficiency of material removal by surface spalling and glazing. The size of laser beam at constant fluence or energy density had significantly different effect on the spalling process. In thick concrete block cutting the flow or removal of molten material limits the cutting depth. By employing repeated laser glazing followed by mechanical scrubbing process cutting of 150 mm thick concrete block was carried out. Gravitation force was utilized for molten materials to flow out while drilling holes on vertical concrete walls. The dependence of the incident laser beam angle on drilling time was experimentally studied.     

Investigation of CO2 laser beam modulation by rotating polygon

A beam-modulating system based on the rotating polygon has been proposed in a previous experimental work [14]. The aim was to improve the quality and efficiency of CO₂ laser surface texturing. Based on the generalized ABCD law, the focusing characteristics of a real beam through the modulating system are investigated in this paper. By introducing a precise defocusing, the velocity synchronization between the focal spot and the workpiece can be realized. Micro-dimples of nearly circular shape can be achieved on the surface. Surface texturing of mill roll has been performed. The experimental and theoretical results are in good agreement.     

CO2 laser cutting of MDF: 1. Determination of process parameter settings

This paper details an investigation into the laser processing of medium-density fibreboard (MDF). Part 1 reports on the determination of process parameter settings for the effective cutting of MDF by CO₂ laser, using an established experimental methodology developed to study the interrelationship between and effects of varying laser set-up parameters. Results are presented for both continuous wave (CW) and pulse mode (PM) cutting, and the associated cut quality effects have been commented on.     

Determination of gold fineness by laser induced breakdown spectroscopy with the simultaneous use of CW-CO2 and Q-SW Nd:YAG lasers

In this work, the gold fineness is precisely determined using the dual beam arrangement including simultaneous irradiation of CW-CO₂ and Q-SW Nd:YAG lasers. It was shown that the enhancement of the characteristic emission lines occurs at higher temperatures with minimal surface distortion of the target respect to that of single beam exposure. The accuracy of gold concentration was determined to be as low as 0.7% using calibration-free (CF) method.     

Model of a microwave beam coupling to CO2 laser plasma

We have designed a transmission line model of the microwave coupling mechanism for a microwave pumped CO₂ laser. The model is a total loss ridge waveguide transmission line having nonuniform impedance. The laser plasma is modeled as a frequency-dependent lossy dielectric and acts as a distributed resistance in the length of the microwave cavity. The coupling structure of the microwaves is designed not to be resonant at the microwave source frequency of 2.45 GHz at 1 kW and propagating the total microwave field energy to be absorbed without internal reflection. An exact solution to this general transmission line propagation constant for a shunt resistance along length of the guide is found. The measurements and predictions of the parameters of the plasma conductivity as a function of the attenuation constant agree closely.