Generation Of Surface Structures Research Articles

Post-processing of additively manufactured metal parts by ultrashort laser pulses for high-quality net shape geometries and advanced functionality

Additive manufacturing by means of laser-based powder bed fusion (LPBF) offers high flexibility with respect to the generation of individualized and light-weight metal parts. However, the produced parts are typically attached to support structures and deviate a few tens of micrometers from the targeted final component in geometrical net shape and surface roughness due to the melt-based fusion process. Therefore, different post-processing techniques were examined in the past to resolve the mentioned quality drawbacks. In our work, we investigated the potential of post-processing of LPBF-generated Ti6Al4V parts with ultrashort pulse laser ablation. As a result, the support structures were effectively removed, the surface roughness was reduced by 81% and complex geometries with high shape accuracy were fabricated. Furthermore, the LBPF-generated parts were laser surface structured to investigate the potential of post-processing with ultrashort laser pulses for advanced functionality, such as water-repellent surfaces. The generation of surface structures on the LPBF-generated Ti6Al4V part changed the wetting behaviour from hydrophilic to hydrophobic with an increased contact angle from 73° up to 130°.

Femtosecond laser generation of microbumps and nanojets on single and bilayer Cu/Ag thin films.

The formation mechanisms of microbumps and nanojets on films composed of single and double Cu/Ag layers deposited on a glass substrate and irradiated by a single 60 fs laser pulse are investigated experimentally and in atomistic simulations. The composition of the laser-modified bilayers is probed with the energy dispersive X-ray spectroscopy and used as a marker for processes responsible for the modification of the film morphology. For the bilayer with the top Ag layer facing the laser, the increase in fluence is found to result in a sequential appearance of a Ag microbump, the exposure of the Cu underlayer by removal of the Ag layer, a Cu microbump, and a frozen nanojet. The Cu on Ag bilayer exhibits a partial spallation of the top Cu film, followed by the generation of surface structures that mainly consist of Ag at higher fluences. The experimental observations are explained with atomistic simulations, which reveal that the stronger electron-phonon coupling of Cu results in the confinement of the deposited laser energy in the top Cu layer in the Cu on Ag case and channelling of the energy from the top Ag layer to the underlying Cu layer in the Ag on Cu case. This difference in the energy (re)distribution directly translates into differences in the morphology of the laser-modified bilayers. In all systems, the generation of microbumps and nanojets occurs in the molten state. It is driven by the dynamic relaxation of the laser-induced stresses and, at higher fluences, the release of vapor at the interface with the substrate. The resistance of the colder periphery of the laser spot to the ejection of spalled layers as well as the rapid solidification of the transient molten structures are largely defining the final shapes of the surface structures.

Using Chatter Vibrations in Milling to Create Tribo-Functional Surfaces for Sheet-Bulk Metal Forming Tools

The studies presented in this paper show a concept for setting up a milling process with intentionally invoked chatter vibrations. The process is used for the generation of surface structures on forming tools. Wear of the milling tool is investigated as well as the tribological characteristics of the surfaces. The results lead to the conclusion that this method is suitable for machining challenging materials like high speed steel.

Refining femtosecond laser induced periodical surface structures with liquid assist

Laser induced periodic surface structures were generated on silicon wafer using femtosecond laser. The medium used in this study is both air and ethanol. The laser process parameters such as wavelength, number of pulse, laser fluence were kept constant for both the mediums. The focus of the study is to analyze spatial wavelength. When generating surface structures with air as a medium and same process parameter of the laser, spatial wavelength results showed a 30% increase compared to ethanol. The cleanliness of the surface generated using ethanol showed considerably less debris than in air. The results observed from the above investigation showed that the medium plays a predominant role in the generation of surface structures.

Multipulse irradiation of silicon by femtosecond laser pulses: Variation of surface morphology

The multipulse interaction of ultraviolet femtosecond laser pulses with silicon and generation of surface structures in a large area spot (≳1mm2) has been studied. The evolution of multiscale structures at the constant fluence strongly depends on the number of pulses, N. For N<200, the “carpet-like” pattern of nano-, and micro-spikes is generated by the bubble explosion in a thin surface foam layer. The accumulation of bubbles and their explosion due to repetition of laser pulses cause damped membrane-like oscillations of the silicon surface. For 200≤N, bifurcation of surface morphology takes place: (i) the surface tension waves of the wavelength ∼200μm appear in the peripheral region of the spot. Generated by the surface thermal gradient in the liquid foam layer, they spread from the hot centerline towards the periphery of the spot. The change of their wavelength with propagation distance indicates onset of the Eckhaus instability caused by the phase modulation in multipulse interaction. (ii) Deep caverns appear in a highly superheated silicon layer in the central region of the spot due to the fast gas–liquid phase separation and the fragmentation process.