In-Situ Femtosecond Micromachining in Laser Powder Bed Fusion Processes
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Reyes, Gonzalo↗
SEARCH · Engineering Papers
Results for “laser processing”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Laser Induced Breakdown Spectroscopy for Material Identification in Laser Powder Bed Fusion Processing
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Krantz, Justin↗
Process Development of Laser-Wire DED of Haynes 282 Ni-based Superalloy
TMS 2022 On Demand, Virtual, March 14, 2022
Tippey, Kristin↗
A Machine Learning Approach to Accelerated Prediction of Statistics of Microstructures Produced by the Laser Powder Bed Fusion Process
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Jones, Mason Avery [University of California Davis↗
Suppressing Ordering in Equiatomic Fe-Co via Laser Powder Bed Fusion
Neutron and electron diffraction was employed to evaluate the effectiveness of thermal management strategies in suppressing the formation of the equilibrium-ordered B2 (CsCl) phase in equiatomic binary Fe-Co specimens fabricated by laser powder bed fusion additive manufacturing. Specimens with a tensile dogbone geometry were fabricated using various combinations of process parameters (laser power and raster speed) and thermal management strategies (no support struts, struts only in the top gauge section, and struts throughout the gauge section). Diffraction results demonstrate that the rapid solidification during PBF-L effectively minimized B2 formation, with laser power and effective scan velocity having no significant impact on the degree of ordering. Furthermore, the inclusion of support struts in the top grip region had no perceivable impact on ordering, whereas specimens with support struts in the gauge region exhibited no detectable ordering. Results are discussed in the context of thermal finite element analysis predictions.
Laser Material Processing↗
Mechanical and thermal behavior of additively manufactured Invar 36 using a laser hot wire hybrid DED process
Invar 36 alloy is a material of high interest in the composite tooling sector due to its low coefficient of thermal expansion. Current production of Invar 36 tooling using traditional manufacturing such as casting and forging is associated with long lead times due to a multitude of factors such as labor and component shortages, high material costs, foreign competition, and supply chain issues. An attractive alternate process is the use of an integrated 5-axis CNC hybrid Laser Hot Wire Deposition System (LHWD) for manufacturing invar molds. Here, the hybrid process provides a combination of the additive and subtractive technologies resulting in a synergistic platform for producing and repairing structures and molds. The main novelty and goal of this work is to study the properties of Invar deposited by a LHWD and to provide guidelines for the manufacture of parts using this process. In this study, the thermal expansion behavior of the manufactured specimens has been analyzed and related to its printing parameters and direction. Multiple specimens were extracted for mechanical, dilatometry and metallographic testing. A thermal IR recording of the printing process was also carried out to observe the thermal history of the produced parts to establish thermal influence on performance-property-processing relationship. The results of these tests show the advantage of LHWD technology for the manufacture of Invar alloy parts, as it presents similar thermal expansion behavior as those commercially available with minimal presence of precipitates and no macrostructural failures such as pores, cracks and lacks of fusion.
36 MATERIALS SCIENCE↗
Photoluminescence and Raman spectroscopy of wide bandgap semiconductors damaged by deep-UV laser irradiation
The effects of a pulsed, focused, deep-UV (4.66 eV) laser on wide and ultra-wide bandgap semiconductors were investigated with photoluminescence (PL) and Raman spectroscopy. Three semiconductor single crystals were studied: silicon carbide (6H-SiC), gallium nitride (GaN), and gallium oxide (β-Ga 2 O 3 ). Atomic emission lines from neutral Ga or Si were observed during the laser-damage process. For all three semiconductors, PL mapping (3.49 eV laser excitation) of the damaged material revealed visible emission bands in the 2.6–2.8 eV range, attributed to point defects. Raman spectra (2.33 eV excitation) showed a reduction in the Raman peak intensities in the damaged region, along with weak PL bands around 1.9–2.1 eV.
36 MATERIALS SCIENCE↗
A Microchannel Heat Exchanger Produced From a Metal Matrix Composite by Hybrid Laser Powder Bed Fusion and Inkjet Printing
Abstract This paper explores the production of an oxide dispersion strengthened (ODS) 304L stainless steel microchannel heat exchanger (HX) using a hybrid additive manufacturing process of laser powder bed fusion and inkjet printing. The study investigates the capabilities and economics of the hybrid inkjet-laser powder bed fusion (LPBF) process and evaluates the dimensional accuracy, functionality, and mechanical properties of the resulting ODS alloy. The effectiveness and pressure drop of the ODS heat exchangers produced by the hybrid LPBF tool are also determined. Results show that the inkjet-doped samples have a lower mean channel height with higher standard deviation than samples produced by LPBF alone. This is attributed to greater absorption of laser energy for the powder coated with the oxide precursor. The economic analysis shows that the hybrid process has a potential for reducing the unit cost of the heat exchanger based on cost modeling assumptions.
Engineering↗
Types of spatter and their features and formation mechanisms in laser powder bed fusion additive manufacturing process
Spatter causes defect formation, powder redistribution and contamination in laser powder bed fusion (LPBF) additive manufacturing process. It is critical to distinguish different types of spatter and understand their features and formation mechanisms. This work reveals the features and formation mechanisms of five unique types of spatter during the LPBF process by in-situ high-speed, high-energy x-ray imaging. Spatters observed during LPBF testing are quantified by their speed, size, and direction. Distinct quantifiable characteristics for each type of spatter are identified. Finally, effects of the laser power, scan speed, and ambient pressure on spatter formation and features are unraveled. A spatter formation map for AlSi10Mg alloy is constructed.
36 MATERIALS SCIENCE↗
Creation of Multi-Principal Element Alloy NiCoCr Nanostructures via Nanosecond Laser-Induced Dewetting
The multi-principal element alloy nanoparticles (MPEA NPs), a new class of nanomaterials, present a highly rewarding opportunity to explore new or vastly different functional properties than the traditional mono/bi/multimetallic nanostructures due to their unique characteristics of atomic-level homogeneous mixing of constituent elements in the nanoconfinements. Here, in this paper, the successful creation of NiCoCr nanoparticles, a well-known MPEA system is reported, using ultrafast nanosecond laser-induced dewetting of alloy thin films. Nanoparticle formation occurs by spontaneously breaking the energetically unstable thin films in a melt state under laser-induced hydrodynamic instability and subsequently accumulating in a droplet shape via surface energy minimization. While NiCoCr alloy shows a stark contrast in physical properties compared to individual metallic constituents, i.e., Ni, Co, and Cr, yet the transient nature of the laser-driven process facilitates a homogeneous distribution of the constituents (Ni, Co, and Cr) in the nanoparticles. Using high-resolution chemical analysis and scanning nanodiffraction, the environmental stability and grain arrangement in the nanoparticles are further investigated. Thermal transport simulations reveal that the ultrashort (≈100 ns) melt-state lifetime of NiCoCr during the dewetting event helps retain the constituent elements in a single-phase solid solution with homogenous distribution and opens the pathway to create the unique MPEA nanoparticles with laser-induced dewetting process.
36 MATERIALS SCIENCE↗
Experimental and numerical evaluation of laser shinethrough in polystyrene at 3 ω and 4 ω laser frequencies
In laser-direct-drive inertial confinement fusion (ICF), laser shinethrough is the process associated with laser propagation through the target plastic ablator, polystyrene is often used in ICF experiments, and leads to energy deposition in the target until the critical density is established at the ablator front surface. This process causes material modifications that may change the shock propagation and lead to density and pressure perturbations at the interface between the polystyrene and cryogenic deuterium-tritium (DT) layer. This work reports on experimental observations and numerical investigations of laser shinethrough at the third and the fourth harmonic of ICF class laser systems (1 ω corresponds to a wavelength of ∼1.06 μm ). The experiments evidence that, at 4 ω , the laser is absorbed over a distance of about a few microns and laser shinethrough is completely eliminated in contrast with the behavior at 3 ω . These experimental observations are reproduced by numerical simulations. The laser fluence required to reach the critical density at the ablator front surface is also found to be more than one order of magnitude higher at the third harmonic. Finally, modeling suggests that the back surface of the ablator exhibits ion temperatures greater than the melting temperature of cryogenic DT and electron pressure larger than the bulk and shear moduli of cryogenic DT for the case of using a 3 ω laser.
Pineau, A. [Univ. of Rochester, NY (United States)↗
Ultrahigh strength and plasticity in laser rapid solidified Al–Si nanoscale eutectics
As-cast Al–20wt.% Si alloys were processed via laser rapid solidification (LRS) techniques to create eutectic microstructures with nanoscale interconnected, nanotwinned Si fibers. LRS morphologies exhibit higher flow stress, exceeding 800 MPa and uniform plastic deformation above 20% compared to as-cast alloy that fractures at strains below 8% at flow strength of approximately 200 MPa. The strengthening mechanisms of LRS morphologies are interpreted in terms of the interfacial constraints: increase in yield strength as well as strain hardening rate due to nanoscale confined slip in fibrous Al–Si eutectic, and load transfer and eventual plasticity in the nanoscale Si fibers.
36 MATERIALS SCIENCE↗
Innovative laser-based methods for monitoring fuel retention in ITER
This paper addresses the challenge of tritium inventory management in ITER and future fusion reactors, highlighting the importance of accurate tritium measurement and its spatial distribution within the vacuum vessel. Given ITER’s operational constraints, especially the limit on tritium retention, precise measurement is essential for both safety and regulatory compliance. To tackle these questions, the paper presents the T-monitor diagnostic system developed by Forschungszentrum Jülich, which uses Laser-Induced Desorption (LID) in combination with Diagnostic Residual Gas Analysis (DRGA) to measure hydrogen isotope concentrations on the surface of divertor tiles. The system integrates a high-power laser, advanced optical components, and a Fast Scanning Mirror Unit (FSMU) for accurate laser spot positioning with rapid response. Designed to measure in situ tritium retention, the diagnostic provides high-resolution spatial mapping, vital for evaluating detritiation strategies. The laser heating process increases the divertor surface temperature to 1600 K within the laser spot, promoting hydrogen isotope desorption. Accurate measurements require the precise control of laser parameters, including pulse duration and spot size, with a target relative accuracy of 20%. The optical design includes both in-vessel and ex-vessel components, such as durable high-reflectivity mirrors made of gold and copper, selected not only for their infrared performance but also for their transmission of visible wavelengths for observation purposes. To protect optical components from contamination, a pneumatic shutter is used.
Hydrogen isotopes↗
Dynamics of nanoscale phase decomposition in laser ablation
Abstract Laser ablation is a process that bears both fundamental physics interest and has wide industrial applications. For decades, the lack of probes on the relevant time and length scales has prevented access to the highly nonequilibrium phase decomposition processes triggered by laser excitation. In this study, a close integration of time-resolved probing by intense femtosecond X-ray pulses with large-scale atomistic modeling has yielded unique insights into the ablation dynamics of thin gold films irradiated by femtosecond laser pulses. The emergence and growth of nanoscale density heterogeneities in the expanding ablation plume, predicted in the simulations, are mapped to the rapid evolution of distinct small angle diffraction features. This mapping enables identification of the characteristic signatures of different phase decomposition processes occurring simultaneously in the plume, which are driven by photomechanical and thermodynamic driving forces. Beyond the specific insights into the ablation phenomenon, this study demonstrates the power of joint X-ray probing and atomistic modeling of material dynamics under extreme conditions of thermal and mechanical nonequilibrium.
Sun, Yanwen (ORCID:0000000159266565)↗
Evolution of the self-injection process in long wavelength infrared laser driven LWFA
In this work, long wavelength infrared laser-driven plasma wakefield accelerators are investigated in the self-modulated laser wakefield acceleration (SM-LWFA) and blowout regimes using 3D particle-in-cell simulations. The simulation results show that in the SM-LWFA regime, self-injection arises with wave breaking, whereas in the blowout regime, self-injection is not observed under the simulation conditions. The wave breaking process in the SM-LWFA regime occurs at a field strength that is significantly below the 1D wave-breaking threshold. This process intensifies at higher laser power and plasma density and is suppressed at low plasma densities (≤1×10 17 cm –3 here). The produced electrons show spatial modulations with a period matching that of the laser wavelength, which is a clear signature of direct laser acceleration.
97 MATHEMATICS AND COMPUTING↗
GRCop-42: Comparison between laser powder bed fusion and laser powder direct energy deposition
This study involves a comparative analysis of additively manufactured GRCop-42 specimens produced using two processes: laser-powder bed fusion (L-PBF) and laser powder direct energy deposition (LP-DED). The investigation characterizes a range of material attributes, including surface topography, internal defects, microstructural features, quasi-static mechanical properties, and fractographic characteristics. The findings demonstrate that, despite the specimens being fabricated with the same base material, the resulting material properties vary significantly between the two additive manufacturing processes. As such, material properties cannot be presumed to be uniform across different manufacturing methods. Consequently, material characterization must be conducted for individual manufacturing processes based on specific parameters.
36 MATERIALS SCIENCE↗
The Electrochemical Behavior of As-Prepared Aluminum Alloy A360 Produced by Selective Laser Melting Fabrication with and without a Trivalent Chromium Process Conversion Coating
In this paper, we report on the electrochemical behavior and corrosion resistance of as-prepared aluminum alloy, A360 (AlSi10Mg), fabricated by additive manufacturing, with and without a trivalent chromium process conversion coating. Selective laser melting was the 3D printing process used for the alloy build. The corrosion suppression provided by the coating system was assessed through electrochemical measurements and accelerated degradation testing during a 14-day continuous neutral salt-spray exposure. The results indicate that the conversion coating can be formed by solution pretreating (degreasing and deoxidation) the alloy (X-Z plane perpendicular to the build plane) with its native surface roughness (as-prepared) followed by immersion for 10, 15 or 20 min in the coating bath. All three immersion times provide an equivalent level of corrosion protection to the alloy. The conversion coating suppresses both anodic and cathodic currents, increases the polarization resistance, and provides both anodic and cathodic corrosion protection to the as-prepared alloy. The conversion-coated specimens exhibit good stand-alone corrosion resistance during a 14-day neutral salt-spray exposure with corrosion intensity values (g/m 2 -year) ~10x lower than values for the uncoated, as-prepared alloy specimens.
36 MATERIALS SCIENCE↗