Beam Power Levels Research Articles

Effect of different beam distances in laser soldering process: a numerical and experimental study

PurposeThis paper aims to investigate the effect of different beam distance by understanding laser beam influence on solder joint quality. The utilisation numerical-based simulations and experimental validation will help to minimise the formation of micro void in PTH that can lead to cracks and defects on passive devices.Design/methodology/approachThe research uses a combination approach of numerical-based simulation using Finite Volume Method (FVM) and experimental validation to explore the impact of different laser beam distances on solder joint quality in PTH assemblies. The study visualises solder flow and identifies the optimal beam distance for placing a soldering workpiece and a suitable tolerance distance for inserting the solder wire.FindingsThe simulation results show the formation of micro void that occurs in PTH region with low volume fraction and unbalance heat concentration profile observed. The experimental results indicate that the focus point of the laser beam at a 99.0 mm distance yields the smallest beam size. Simulation visualisation demonstrates that the laser beam’s converging area at +4.6 mm from the focus point which provides optimal tolerance distances for placing the solder wire. The high-power laser diode exhibits maximum tolerance distance at 103.6 mm from the focus point where suitable beam distance for positioning of the soldering workpiece with 50% laser power. The simulation results align with the IPC-A-610 standard, ensuring optimal filling height, fillet shape with a 90° contact angle and defect-free.Practical implicationsThis research provides implications for the industry by demonstrating the capability of the simulation approach to produce high-quality solder joints. The parameters, such as beam distance and power levels, offer practical guidelines for improving laser soldering processes in the manufacturing industry.Originality/valueThis study contributes to the field by combining high-power laser diode technology with numerical-based simulations to optimise the beam distance parameters for minimising micro void formation in the PTH region.

Numerical analysis and process optimization of electron beam melting for superalloys

This study aims to determine the optimal parameters for the electron beam melting process by employing a modified transient three-dimensional thermal model. The validity of the thermal model is confirmed through experimental results. Moreover, the proposed method establishes mathematical relationships between the resulting molten pool temperature and process parameters. A broader range of process parameters for a new Ni–Co-based superalloy was achieved by investigating the effects of scanning velocities (10–100 mm/s), scanning radius (20–60 mm), and melting mass (1500–3100 g) on temperature at various electron beam power levels (10–30 kW). Regression models were established between scanning velocities-temperature, and scanning radius-temperature under different electron beam power levels. These models laid the foundation for real-time automatic control of molten pool temperature. Significantly, orthogonal experimental design and response surface method are employed to conduct a multi-objective optimization based on sixteen experiments and three parameters. The results of multi-objective optimization indicate that with a smelting mass of 1.5 kg, an electron beam power of 11 kW, a scanning radius of 60 mm, and a scanning velocity of 75 mm/s, the energy consumption is 34.95 kW h, and the theoretical mass loss of Ni element is 0.002 kg. The desirability is 91.2 %.

Calculation position of the focal point in self-focusing media

Using a laser beam in a self-focusing environment with different power more and less than the critical one, more accurate coordinates of the point with the maximum radiation intensity were obtained. The results of the calculations corresponded to the experimental data obtained by spatial filtering of the angular spectra of forced Raman scattering. The agreement of the results was satisfactory for all beam power levels.

Three‐dimensional shaped and contour pattern synthesis with multiple beam approach

AbstractA multiple‐beam synthesis method is proposed to generate three‐dimensional (3D) shaped and contour patterns from a planar phased array antenna. Three‐dimensional radiation patterns are synthesized primarily with optimum beam positions and variable mainbeam power levels of multiple beams, followed by calculating the resultant element weights. Contour patterns are synthesized from multiple beam peaks by mapping the individual beam power levels to their corresponding 3 dB beamwidth coverage areas at each designated location on the contour. The far‐field contour shape affected by the influence of the element pattern, mutual coupling, and scan loss is compensated by the peak power of the scanned beam patterns. The proposed synthesis supports dynamically changeable contour shapes. Flat‐topped, stepped 3D patterns and arbitrary contour shapes with shaped null zones inside the contour are simulated and implemented on a 16 × 16 element 5G mmWave planar phased array. Measured radiation patterns are compared with simulations and presented.

Economical evaluation of radiation processing with high-intensity X-rays

Abstract X-rays application for radiation processing was introduced to the industrial practice, and in some circumstances is found to be more economically competitive, and offer more flexibility than gamma sources. Recent progress in high-power accelerators development gives opportunity to construct and apply reliable high-power electron beam to X-rays converters for the industrial application. The efficiency of the conversion process depends mainly on electron energy and atomic number of the target material, as it was determined in theoretical predictions and confirmed experimentally. However, the lower price of low-energy direct accelerators and their higher electrical efficiency may also have certain influence on process economy. There are number of auxiliary parameters that can effectively change the economical results of the process. The most important ones are as follows: average beam power level, spare part cost, and optimal shape of electron beam and electron beam utilization efficiency. All these parameters and related expenses may affect the unit cost of radiation facility operation and have a significant influence on X-ray process economy. The optimization of X-rays converter construction is also important, but it does not depend on the type of accelerator. The article discusses the economy of radiation processing with high-intensity of X-rays stream emitted by conversion of electron beams accelerated in direct accelerator (electron energy 2.5 MeV) and resonant accelerators (electron energy 5 MeV and 7.5 MeV). The evaluation and comparison of the costs of alternative technical solutions were included to estimate the unit cost of X-rays facility operation for average beam power 100 kW.

Laser power and scanning speed influence on the microstructure, hardness, and slurry erosion performance of Colmonoy-5 claddings

A 4kW Yb: YAG solid-state disc laser, with a four-way co-axial cladding head with powder feeding technique was employed to fabricate single-layer clads of Ni-based hardfacing alloy (Colmonoy-5) on medium carbon steel (ASME SA105) substrate by varying the laser processing parameters namely, beam power level (designated as low: 1200 W, medium: 1400 W, and high: 1600 W) and scanning speed (designated as low: 300 mm/min, medium: 400 mm/min, and high: 500mm/min). The laser clads were evaluated for their microstructural characteristics, microhardness, and slurry erosive wear performance with an aim to understand the effect of process parametric variations on their properties. Microstructural analyses of the clads were carried out using an optical microscope and a field-emission scanning electron microscope with attached energy-dispersive X-ray spectrometer supplemented by their Vickers microhardness testing and X-ray diffraction examination. The variation in laser processing parameters exerted a strong influence on the microstructural features of the clads in terms of γ-Ni dendrite size as well as morphology and distribution of various complex precipitates such as Cr-carbides and borides with relatively uniform distribution observed for the clads corresponding to low laser power and high scanning speed. The variation in laser power had relatively a greater influence on microhardness than the scanning speed variation. Micro-cutting, plastic deformation, crater formation besides ploughing away of the softer matrix were the typical fracture features associated with slurry eroded clads when examined under field-emission scanning electron microscope. Results of the slurry erosive wear tests showed that the clads pertaining to low laser power and high scanning speed exhibited superior wear resistance as compared to their counterparts.

Electro-optical dust sensors calibration by aerosol image analysis

The paper describes the process of data obtaining for designing electro-optical sensors using a television aerosol particles image analyzer. Using simulation based on Mie theory, the process of calibration of simple electro-optical aerosol (dust) sensor is carried out. In the paper the main dependences for sensor calibration are shown. The proper calibration allows power saving by selection certain laser beam power level.

Apparatus for generating quasi-free-space microwave-driven plasmas.

An apparatus for generating quasi-free-space microwave-driven plasmas has been designed, constructed, and tested. The plasma is driven by a multi-kW, ∼5 GHz microwave beam focused at the center of a vacuum chamber using a Koch-type metal plate lens. Sustained plasma discharges have been generated in argon at pressures ranging from 150 to 200 mTorr, at beam power levels ranging from 5 to 10 kW, and at gas flow rates of approximately 200 SCCM.

Determination of pulse profile characteristics of multi spot retinal photocoagulation lasers

A system is described for determination of discrete pulse train characteristics of multi spot laser delivery systems for retinal photocoagulation. While photodiodes provide an ideal detection mechanism, measurement artifacts can potentially be introduced by the spatial pattern of the delivered beam relative to a discrete photodiode element. This problem was overcome by use of an integrating sphere to produce a uniform light field at the site of the photodiode detector. A basic current driven photodiode detection circuit incorporating an operational amplifier was used to generate a signal captured by a commercially available USB interface device at a rate of 10 kHz. Studies were undertaken of a Topcon Pascal Streamline laser system with output at a wavelength of 577 nm (yellow). This laser features the proprietary feature of ‘Endpoint Management’ ™ where pulses can be delivered as 100% of set energy levels with visible reaction on the retina and also at a reduced energy level to create potentially non visible but clinically effective lesions. Using the pulse train measurement device it was identified that the ‘Endpoint Management’ ™ delivery mode of pulses of lower energy was achieved by reducing the pulse duration of pulses for non-visible effect pulses while maintaining consistent beam power levels within the delivered pulse profile. The effect of eye geometry in determining safety and effectiveness of multi spot laser delivery for retinal photocoagulation is discussed.

Mechanical Properties of Fibre Laser Welded AZ31B Sheets and their Dependence on the Spot-Size

In the present work the mechanical behaviour of laser beam welded AZ31B alloy was studied, by changing systematically the spot size of the used fibre laser system between 200 µm and 1000 µm at different power levels between 2 kW and 8 kW. Maximum welding velocities with respect to imperfections were determined. The characterization of the obtained welds - in terms of Vickers hardness, UTS, Af and weld width, resp. weld area - was correlated with the micro-texture in dependence of the different Focus Spot Diameters and Laser Beam Power levels as well as the resulting cooling rates. Highest UTS of 94% of the base material was achieved with 200 µm Focus Spot Diameter and Laser Beam Power of 4 kW at welding velocity of 100 mm/s. By increasing the Focus Spot Diameter to 600 µm, the tensile strength was reduced to 86 % of the actual strength of the base material.

Embedded optics and electronics single digital micromirror device-based agile pixel broadband imager and spectrum analyzer for laser beam hotspot detection

To the best of the authors’ knowledge, proposed is the first embedded optics and electronics-based agile pixel broadband optical imager and spectrum analyzer using a single digital micromirror device (DMD) for laser beam hotspot detection. Specifically, the novel design engages both the wavelength-dependent grating structure of the DMD optical chip and its three-tilt-state micromirror programmability to form both an optical spectrum analyzer (OSA) and an agile pixel imager within one basic instrument. Also, to our knowledge, presented for the first time for a DMD chip is a complete mathematical analysis for incident laser beam operations via diffraction theory. Using off-the-shelf components and the Texas Instruments (TI) Lightcrafter DLP chip and drive electronics, embedded engineering of the proposed instrument is implemented for the visible laser wavelength band. Experimental OSA operation of the instrument is demonstrated using classic laser wavelengths of 633 and 532 nm with beam power levels of 20 and 180 mW, respectively. Experimental imaging operation of the instrument compared with a commercial scanning slit-based laser beam profiler is successfully conducted for a 633 nm test laser beam having a hotspot with ∼68% peak-to-null power drop near its center. Applications for the proposed imager-OSA instrument include laser beam testing during laser assembly and manufacturing operations.

In Situ Thermal Characterization of the Accelerator Grid of an Ion Thruster

hole diameter, distance between holes, or grid shape. These parameters are also measured in situ with a telemicroscope for high-resolution optical imaging and a triangular laser head for surface profile scanning. The distance between grid surface and pyrometer optics are precisely monitored with the support of the triangular laser head, for which the position is fixed with respect to the pyrometer. The distance measurement allows for correcting the measurement spot size of the pyrometer. The temperature profiles at three different beam power levels (1250, 2250,and4000W),andwarm-upandcool-downphases demonstrate thecapabilities ofthe complexequipment.Itis found that thermal steady state is reached after 4 h of thruster firing. Furthermore, it is shown that the accelerator grid surface temperature increases almost linearly with increasing beam current.

The development of enabling technologies for producing active interrogation beams

A U.S./Russian collaboration of accelerator scientists was directed to the development of high averaged-current (∼1 mA) and high-quality (emittance ∼15 πmm mrad; energy spread ∼0.1%) 1.75 MeV proton beams to produce active interrogation beams that could be applied to counterterrorism. Several accelerator technologies were investigated. These included an electrostatic tandem accelerator of novel design, a compact cyclotron, and a storage ring with energy compensation and electron cooling. Production targets capable of withstanding the beam power levels were designed, fabricated, and tested. The cyclotron/storage-ring system was theoretically studied and computationally designed, and the electrostatic vacuum tandem accelerator at BINP was demonstrated for its potential in active interrogation of explosives and special nuclear materials.

Scoping-level Probabilistic Safety Assessment of a complex experimental facility: Challenges and first results from the application to a neutron source facility (MEGAPIE)

This paper presents a scoping-level application of Probabilistic Safety Assessment (PSA) to selected systems of a complex experimental facility. In performing a PSA for this type of facility, a number of challenges arise, mainly due to the extensive use of electronic and programmable components and of one-of-a-kind components. The experimental facility is the Megawatt Pilot Target Experiment (MEGAPIE), which was hosted at the Paul Scherrer Institut (PSI). MEGAPIE demonstrated the feasibility of a liquid lead-bismuth target for spallation facilities at a proton beam power level of 1 MW. Given the challenges to estimate initiating event frequencies and failure event probabilities, emphasis is placed on the qualitative results obtainable from the PSA. Even though this does not allow a complete and appropriate characterization of the risk profile, some level of importance/significance evaluation was feasible, and practical and detailed recommendations on potential system improvements were derived. The second part of the work reports on a preliminary quantification of the facility risk. This provides more information on risk significance, which allows prioritizing the insights and recommendations obtained from the PSA. At the present stage, the limited knowledge on initiating and failure events is reflected in the uncertainties in their probabilities as well as in inputs quantified with bounding values. Detailed analyses to improve the quantification of these inputs, many of which turn out to be important contributors, were out of the scope of this study. Consequently, the reported results should be primarily considered as a demonstration of how quantification of the facility risk by a PSA can support risk-informed decisions, rather than precise figures of the facility risk.

Verification of the TRACE code against the MEGAPIE transient data

Megawatt pilot target experiment (MEGAPIE) is an international project aimed at demonstrating the feasibility of a liquid lead–bismuth target for spallation facilities at a maximum beam power level of 1 MW. The thermal-hydraulics data measured during the MEGAPIE experiment was used for the TRACE code qualification for transient analysis of liquid metal cooled systems.

Experimental Investigation of a Novel Circuit for Millimeter-Wave TWTs

A novel folded waveguide circuit that features thick iron pole pieces with hollow centers was built as part of a periodic-permanent-magnet-focused W-band single-stage test-vehicle traveling-wave tube (TWT). These hollow centers, which comprise part of the slow wave circuit, increase the rms axial field and significantly reduce the unwanted transverse field imbalance. For this TWT, a tetrode gun that creates an ultralaminar 20-kV 0.25-A nominal electron beam was used. It was demonstrated that this gun and magnetic structure can provide greater than 97% beam transmission for peak beam power levels as high as 9.25 kW (25 kV, 0.37 A). The unplated circuit, operating around 91 GHz on the edge of a passband, exhibits between 10 dB and 12 dB gain that compares favorably with results of device modeling utilizing the 3D particle-in-cell code Magic3D. Using a feedback approach to characterize large-signal operation, the tube generated 40 W of regenerative oscillator power. Design-optimized versions of this circuit show promise of enabling W-band TWT amplifiers that provide up to 300 W of peak RF output power

Summary of cavitation erosion investigations for the SNS mercury target

Intense proton beam-induced heating of the spallation neutron source mercury target will cause pressure spikes that lead to the formation of cavitation bubbles in the mercury. Erosion of the mercury container walls caused by violent collapse of bubbles could potentially limit its service lifetime. In-beam tests for a limited number of pulses (<1000 pulses for each test target) have demonstrated that pitting damage appears to be especially sensitive to beam intensity, surface treatment, and gas injection. Using results of off-line pressure pulse tests conducted for a million cycles or more to scale the results from limited in-beam tests, it is concluded that the mercury target will last at least two weeks at a time-averaged proton beam power level of 1 MW. However, because of remaining uncertainties, it is concluded that further research and development and target design efforts are needed to verify these conclusions and extend the target to higher operating powers and longer lifetimes.

Optoelectronics of liquid crystals with nanoparticulate internal structure

We present the results of a detailed characterization of electro-optical and nonlinear optical properties of liquid crystals with nanoparticulate internal structures. The experiments revealed three different states of transmission of the material: diffusive, translucent, and semitranslucent. Transformations between them are induced by electric fields and laser beams. A threshold power exists for a laser beam to change the transmission state of the material. An increase in the strength of laser/material interaction with an increase of scan speed of the beam across the material was observed. One- and two-dimensional diffraction gratings were recorded using two techniques: overlap of two 1-D gratings, and modulation of the speed of laser beam scan. We show that information pixels that are recorded in such materials may possess microstructures for certain laser power and exposure times. We also report the observation of netquake, a phenomenon of long-range propagation of thermal shocks at high laser beam power levels.

MEGAPIE, a 1 MW pilot experiment for a liquid metal spallation target

Megawatt pilot target experiment (MEGAPIE) is an initiative launched by Commisariat à l'Energie Atomique, Cadarache (France) and Forschungszentrum Karlsruhe (Germany) together with Paul Scherrer Institut (Switzerland), to demonstrate, in an international collaboration, the feasibility of a liquid lead bismuth target for spallation facilities at a beam power level of 1 MW. Such a target is under consideration for various concepts of accelerator driven systems (ADS) to be used in transmutation of nuclear waste and other applications world wide. It also has the potential of increasing significantly the thermal neutron flux available at the spallation neutron source SINQ for neutron scattering. SINQ's beam power being close to 1 MW already, this facility offers a unique opportunity to realize such an experiment with a reasonably small number of new ancillary systems. The paper describes the basic features of the experiment and its boundary conditions, the technical concept of the target and underlying research carried out at participating laboratories.

Optical manipulation of bubbles in water using solid-state laser technology

For some experiments on the acoustics of bubbles in water, it may be desirable to counter buoyancy using optical radiation pressure. A previous demonstration of the optical trapping of small bubbles that would have otherwise been freely rising used a green continuous downward-directed beam from an Ar-ion gas laser having an irradiance minimum on the beam axis [B. T. Unger and P. L. Marston, J. Acoust. Soc. Am. 83, 970–975 (1988)]. Some of the difficulties in using solid-state laser technology for this purpose are that the beam should be green (to minimize absorption) and have an axial irradiance minimum (for lateral stability). We have generated the required beam using a diode-pumped Nd:YVO4 laser crystal with intracavity-second-harmonic-generation in a lithium-tri-borate crystal. The 5.5-W external green beam power levels achievable were more than sufficient for suspension of gas bubbles having 20- and 40-μm radii generated by electrolysis. The bubble size is measured using forward scattering. Occasionally, two vertically offset bubbles can be trapped along the axis of the downward directed beam. [Work supported by NASA.]