激光感生等离子体特性的三维数值模拟

在激光焊接过程中,作用于金属工件表面的高强度激光会引起材料的强烈蒸发,金属蒸汽与入射激光相互怍用,又会引起金属蒸汽部分电离,形成激光感生等离子体。本文采用三维模拟方法,考虑保护气和侧吹气的影响,对激光感生等离子体中的温度与速度分布进行了研究。     

Investigation of a novel hybrid process of laser drilling assisted with jet electrochemical machining

Recast layer and spatter are two inherent defects commonly associated with holes produced with laser drilling. This paper reports a novel hybrid process of laser drilling assisted with jet electrochemical machining (JECM-LD) that aims to minimize such defects and improve the quality of laser-drilled holes. The process based on the application of a jet electrolyte, being aligned coaxially with the focused laser beam, on the workpiece surface during laser drilling. The effect of the jet electrolyte mainly is an electrochemical reaction with materials. The jet electrolyte also cools the workpiece and transports debris during the process. On the basis of a measurement of laser attenuation in electrolyte, an experimental apparatus system is made and JECM-LD experiments have been performed on 0.5-mm-thick 321S20 stainless steel with two lasers at wavelength of 1064 and 532 nm. It is shown that recast layer and spatter have been effectively reduced during the JECM-LD compared with laser drilling in ambient atmosphere conditions.     

Some aspects of laser-metal vapour interaction

The vapour beam interaction plays an important role in laser machining process, since the vapour generated on the workpiece surface absorbs some fraction of the incident beam and heats the workpiece surface. Consequently, a study of this interaction mechanism is essential. For this purpose, a computer program was developed to investigate the interaction interaction, it provides a foundation to do further studies. It was found that the vapour locally high pressure gradients. Although the analysis presents a simplified picture of the interaction, it provides a foundation to do further studies. It was found that the vapour temperature reaches 5000 K after 10⁻⁶ s for a laser pulse of 10¹¹ W/m² power intensity. The leading edge of the vapour velocity had a velocity of the order of 4000–7000 m/s.     

Experimental investigation of plume expansion dynamics of nanosecond laser ablated Al with small incident angle

Experimental study of expansion dynamics of pulsed-laser ablation plasmas from Al is presented. A systematic investigation of plasma plume expansion is done. The laser beam is focused on the target with an incident angle between 0° and 20°. The results show that the plume growth is almost normal to the target surface, irrespective of the incident angle of the laser. Besides, the time evolution of the plasma plume geometry ratio at different incident angles shows that the incident angle of laser beam influences very slightly its shape at later delay time. The results imply that when the incident angle is small (ranging from 0° to 20°), the influence of the incident angle on the plume expansion is rather trivial.     

The absorption of incident beams during laser drilling of metals

Laser produced plasma plays an important role in the laser drilling of sheet metals as it can partially block and absorb the incident laser beam. A previous study of the transient properties of charged particles in the plasma plume has shown that, at low electron densities with high electron temperatures, laser drilling improves. This suggests that measurement of the absorption of the plasma plume is essential.The present study covers measurement of the absorption of a HeNe beam passing transversely through the plasma plume. The measurement was carried out using two fast response photodiodes and was repeated for sub-atmospheric pressures of air.The results obtained show that drilling is best at a pressure of 200 torr (2.7 x 10⁴ Pa) and rapid expansion of the flares is favourable at 2 mm above the surface. Coupling of absorption and heating is also best at this pressure.     

盘型激光焊金属蒸汽特征色调-色饱和度-亮度分析法研究

对于大功率盘型激光焊,金属焊件表面在激光束辐射下强烈汽化并形成等离子体状的金属蒸汽羽状物. 该金属蒸汽羽状物可逆向激光束传输,对激光有明显的屏蔽作用, 降低激光辐射至焊件的能量密度,影响焊接效率和质量. 因此研究金属蒸汽特征变化规律及其与焊接质量之间的关联 ,可实现由金属蒸汽特征实时监测激光焊接状态. 以10 kW大功率盘型连续激光焊接304不锈钢钢板为试验对象, 应用高速摄像机摄取金属蒸汽动态图像,将其转换至色调-色饱和度-亮度空间, 提取金属蒸汽面积、激光束受影响路径长度等相关特征量, 以焊缝熔宽的变化作为衡量焊接状态稳定性的参数. 通过金属蒸汽特征值的均值统计和方差分析,试验证明根据金属蒸汽面积和激光束受影响路径长度等金属蒸汽特征可有效地反映熔宽质量, 从而对焊接状况做出动态评估.     

Investigation into absorption of the incident laser beam during Nd:YAG laser processing of metals

Laser materials processing is highly affected by the existence of surface plasma. The absorption of surface plasma during drilling alters the power intensity distribution of the incident laser beam across the irradiated spot. The present study is carried out to measure the electron number density and temperature using a Langmuir probe while a mathematical formulation is conducted for the absorption coefficients due to electron-ion, electron-neutral atom collisions, inverse Bremsstrahlung, and photoionization processes. Consequently, a computer program is developed to compute the relevant absorption coefficients as well as the overall absorption coefficient. The laser power intensity distribution before and after the plasma absorption is computed at a plane 2.6 mm above the workpiece surface. It is found that 13% of the reduction occurs in the incident laser output power intensity at this plane in the plasma.     

Theoretical determination of the ablation rate of metals in multiple-nanosecond laser pulses irradiation regime

A detailed understanding of the physical determinants of the ablation rate in multiple nanosecond laser pulses regime is of key importance for technological applications such as patterning and pulsed-laser deposition. Here, theoretical modeling is employed to investigate the ablation of thick metallic plates by intense, multiple nanosecond laser pulses. A new photo-thermal model is proposed, in which the complex phenomena associated to the ablation process are accounted for as supplementary terms of the classical heat equation. The pulsed laser ablation in the nanosecond regime is considered as a competition between thermal vapourization and melt ejection under the action of the plasma recoil pressure. Computer simulations using the photo-thermal model presented here and the comparison of the theoretical results with experiment indicate two different mechanisms that contribute to the decrease of the ablation efficiency. First, during the ablation process the vapour/plasma plume expanding above the irradiated target attenuates the laser beam that reaches the sample, leading to a marked decrease of the ablation efficiency. Additional attenuation of the laser beam incident on the sample is produced due to the heating of the plasma by the absorption of the laser beam into the plasma plume. The second mechanism by which the ablation efficiency decreases consists of the reduction of the incident laser intensity with the lateral area, and of the melt ejection velocity with the depth of the hole.     

Optical transmission and reflection of aluminum film irradiated by nanosecond laser beam and experimental studying of phase-explosion

In this paper we present evidence for a phase explosion during the laser-induced ablation process by studying the optical reflectivity of the ablated plume. The ablation was produced by irradiating thin film aluminum coated on a quartz substrate with a single pulse laser beam in ambient air. The laser pulse was provided by the second harmonic of a Q-switched Nd:YAG laser with ∼10 ns pulse duration. The transmission of a low power He–Ne laser beam through the hot ablated material plume and its reflection (from the front surface, and rear surface of aluminum film) were also monitored during the duration of the ablation event. The results show that the front surface reflectivity is enhanced at an early time of ablation which is described as strong evidence for the creation of a phase explosion in this process.     

Double-peak droplet mass distribution observed during sub-ps laser ablation of Si targets

The angular distribution of the ablated material was studied during sub-ps Si laser ablation deposition using a special hemicylindrical substrate holder and different laser fluences ranging between 0.4 and 1.7 J/cm². Scanning electron microscopy analysis of the deposited films showed that, independent of the fluence, the distribution of the deposited droplets presents two maxima. The first maximum corresponds to the average plume deflection angle value due to the local surface orientation produced by the preferential etching process. The second maximum is observed approximately at 45° with respect to the normal of the target surface, and is related to the phase explosion products that expand along the incident laser beam direction. The investigation of the twofold distribution of the sub-μm size deposited droplets is important to improve the quality of the deposited coatings. PACS 81.15.Fg; 68.55.Jk; 79.20.Ds     

Nanosecond laser ablation for pulsed laser deposition of yttria

A thermal model to describe high-power nanosecond pulsed laser ablation of yttria (Y₂O₃) has been developed. This model simulates ablation of material occurring primarily through vaporization and also accounts for attenuation of the incident laser beam in the evolving vapor plume. Theoretical estimates of process features such as time evolution of target temperature distribution, melt depth and ablation rate and their dependence on laser parameters particularly for laser fluences in the range of 6 to 30 J/cm² are investigated. Calculated maximum surface temperatures when compared with the estimated critical temperature for yttria indicate absence of explosive boiling at typical laser fluxes of 10 to 30 J/cm². Material ejection in large fragments associated with explosive boiling of the target needs to be avoided when depositing thin films via the pulsed laser deposition (PLD) technique as it leads to coatings with high residual porosity and poor compaction restricting the protective quality of such corrosion-resistant yttria coatings. Our model calculations facilitate proper selection of laser parameters to be employed for deposition of PLD yttria corrosion-resistive coatings. Such coatings have been found to be highly effective in handling and containment of liquid uranium.     

激光辐照下金属靶表面汽化现象研究

用高速纹影诊断技术研究激光辐照下金属表面发生汽化的特征及蒸气发展运动过程,结合汽化模型给出了凝聚相表面温度与激光入射功率密度的关系。由实验得到了不同入射激光功率密度下汽化表面(凝聚相)温度,蒸气羽阵面速度,前驱空气冲击波速度。     

实际加工表面红外激光散射特性的实验研究

为了研究激光在实际加工表面的散射特性,利用分辨率为10 nW的激光功率计PM100D,波长为1550 nm的激光器和精密转台,自行设计并搭建了半球空间中目标表面散射特性的测量系统. 以典型的刨床加工的若干标准粗糙度比较样块为被测目标,在1550 nm红外激光以不同方位照射下,测量了微观具有V形槽结构的不同粗糙度的样块表面的散射功率分布. 实验结果转换成双向反射分布函数后,对比分析了入射光方位、入射角和表面粗糙度对此类典型表面散射特性的影响,并分析了特殊散射场形成的原因. 结果表明,表面纹理、入射角以及粗糙度均对目标表面的散射特性有规律性影响,这一结果对于具有规律性加工纹理表面的散射特性的研究和建模有一定的参考价值,对激光技术在实际加工表面的应用研究提供了一定的基础. 关键词： 散射特性 双向反射分布函数 红外激光 实际加工表面     

Research of laser evaporation of fast-moving target

Evaporation of a stainless steel target moving with high speed (～50 m/s) under action of laser radiation was investigated theoretically and experimentally. In our experiments we used an electroionization CO₂—laser, which generated pulses with duration up to 1 ms and energy up to 100 J. We carried out the microscopic research of laser beam trace on the target surface and investigated the dynamics of the laser plume luminescence. For theoretical research we used 3D numerical model, which took into account: heating, melting and evaporation of target by laser beam, and, thermal effect of oxidation reaction. The results of calculations can explain the experimental data quite good. In particular, it is possible to explain occurrence of interrupted trace on the target at 12–24 kW laser power, that corresponds to intensity in the focal spot of ～10⁷ W/cm². This power is a threshold of unstable mode of laser evaporation. The unstable mode is caused by lack of oxygen, which was pushed away with metal vapor. The lack of oxygen leads to shutting down the oxidation reaction on target surface. The reaction resumes when the vapors fly away and oxygen riches the surface. As the result pulsed mode of evaporation takes place. This phenomenon was observed as pulse mode of laser plume luminescence and was obtained by calculations.     

Numerical study on the splitting of a vapor bubble in the ultrasonic assisted EDM process with the curved tool and workpiece

Electrical discharge machining (EDM) is a powerful and modern method of machining. In the EDM process, a vapor bubble is generated between the tool and the workpiece in the dielectric liquid due to an electrical discharge. In this process dynamic behavior of the vapor bubble affects machining process. Vibration of the tool surface affects bubble behavior and consequently affects material removal rate (MRR). In this paper, dynamic behavior of the vapor bubble in an ultrasonic assisted EDM process after the appearance of the necking phenomenon is investigated. It is noteworthy that necking phenomenon occurs when the bubble takes the shape of an hour-glass. After the appearance of the necking phenomenon, the vapor bubble splits into two parts and two liquid jets are developed on the boundaries of the upper and lower parts of the vapor bubble. The liquid jet developed on the upper part of the bubble impinges to the tool and the liquid jet developed on the lower part of the bubble impinges to the workpiece. These liquid jets cause evacuation of debris from the gap between the tool and the workpiece and also cause erosion of the workpiece and the tool. Curved tool and workpiece affect the shape and the velocity of the liquid jets during splitting of the vapor bubble. In this paper dynamics of the vapor bubble after its splitting near the curved tool and workpiece is investigated in three cases. In the first case surfaces of the tool and the workpiece are flat, in the second case surfaces of the tool and the workpiece are convex and in the third case surfaces of the tool and workpiece are concave. Numerical results show that in the third case, the velocity of liquid jets which are developed on the boundaries of the upper and lower parts of the vapor bubble after its splitting have the highest magnitude and their shape are broader than the other cases.     

Spectral diagnostics of a vapor-plasma plume produced during welding with a high-power ytterbium fiber laser

We have conducted spectroscopic studies of the welding plasma formed in the process of welding with an ytterbium fiber laser delivering output power of up to 20 kW. The influence of shielding gases (Ar, He) on different parts of the welding plume is investigated. The absorption coefficient of the laser radiation by the welding-plume plasma is estimated. Scattering of 532-nm probe radiation from particles of the condensed metal vapor within the caustic of a high-power fiber laser beam is measured. Based on the obtained results, conclusions are made on the influence of the plasma formation and metal vapor condensation on the radiation of the high-power fiber laser and the stability of the welding process.     

激光辐照铝靶汽化过程的高速纹影诊断技术

应用高速纹影系统记录激光束辐照在Ly12铝靶时所产生的汽化羽扩张、空气爆炸波、熔融物质喷溅以及穿靶等现象.并由扫描摄影记录的轨迹图测出汽化羽的扩张速度为150～190m/s,空气冲击波速度为450～500m/s,靶表面高压蒸汽速度为5～7.8km/s。     

3D transient multiphase model for keyhole,vapor plume,and weld pool dynamics in laser welding including the ambient pressure effect

The physical process of deep penetration laser welding involves complex, self-consistent multiphase keyhole, metallic vapor plume, and weld pool dynamics. Currently, efforts are still needed to understand these multiphase dynamics. In this paper, a novel 3D transient multiphase model capable of describing a self-consistent keyhole, metallic vapor plume in the keyhole, and weld pool dynamics in deep penetration fiber laser welding is proposed. Major physical factors of the welding process, such as recoil pressure, surface tension, Marangoni shear stress, Fresnel absorptions mechanisms, heat transfer, and fluid flow in weld pool, keyhole free surface evolutions and solid–liquid–vapor three phase transformations are coupling considered. The effect of ambient pressure in laser welding is rigorously treated using an improved recoil pressure model. The predicated weld bead dimensions, transient keyhole instability, weld pool dynamics, and vapor plume dynamics are compared with experimental and literature results, and good agreements are obtained. The predicted results are investigated by not considering the effects of the ambient pressure. It is found that by not considering the effects of ambient pressure, the average keyhole wall temperature is underestimated about 500 K; besides, the average speed of metallic vapor will be significantly overestimated. The ambient pressure is an essential physical factor for a comprehensive understanding the dynamics of deep penetration laser welding.     

脉冲激光与电化学复合的应力刻蚀加工质量研究

脉冲激光电化学复合加工可以有效去除激光辐照区域内的电解产物, 提高加工效率, 改善加工质量. 针对高性能金属材料的微细加工要求, 采用脉冲激光电化学复合的应力刻蚀加工方法对铝合金的刻蚀特性进行理论和试验研究. 通过比较激光直接刻蚀加工和激光电化学复合加工的特点, 应用扫描电子显微镜、光学轮廓仪等检测技术分析了刻蚀区域的形貌特征. 根据力学电化学原理, 探讨了金属材料微结构加工的应力去除机理. 通过加工试验, 研究了工艺参数和加工方式对加工质量的影响, 采用优化的工艺参数, 加工出了质量较好的微结构. 试验结果表明, 激光电化学复合的连续扫描加工稳定性好, 可以有效地降低表面粗糙度, 提高加工质量. 关键词： 激光电化学 应力刻蚀 加工质量 工艺参数     

Effect of Surface Plasma on Nanosecond Laser Ablation

For the first time, the effect of target surface plasma on nanosecond laser ablation is studied. Surface plasma was generated by a high-power cw fiber laser beam incident on an iron target. A comparison of laser ablation by nanosecond Nd:YAG laser pulses (1064 nm, 5 ns) was performed upon exposure to the cw laser and during its short-term (5 ms) turn off. It was found that the emission intensity twofold increases in the presence of surface plasma. The temperature and electron density of the laser plume induced by the nanosecond laser also increased.