Laser Energy Density Research Articles

Laser powder bed fusion of Mg–Zn–Zr alloy: Formability, microstructure evolution and biodegradation behavior

Laser powder bed fusion (LPBF) was used to fabricate Mg–Zn–Zr (ZK60) parts, with a thorough investigation of processability by varying laser power and scanning rate. The combined effect of these parameters, which determines laser energy density, significantly impacted the forming quality of LPBF ZK60. Dense parts (over 99%) free of visible defects such as pores and cracks were achieved at a laser energy density of 74.1 J/mm2. The formation mechanisms of pores and cracks were extensively analyzed concerning the characteristics of the molten pool and subsequent cooling behavior. The LPBF ZK60 parts exhibited extremely fine grains, with an average grain size of 3.2 μm. Both equiaxed and columnar grains were observed, with a central equiaxed zone in the melt pool and a perpendicular lamellar zone along its boundary. Additionally, the Mg7Zn3 eutectic phase precipitated within the α-Mg matrix of ZK60. Immersion and electrochemical tests indicated that the XZ plane displayed superior corrosion resistance, attributed to fewer deformation regions and lower dislocation density. Furthermore, in vitro cell experiments confirmed that the ZK60 alloy possesses good biocompatibility.

Structural color of metallic glass through picosecond laser

Abstract The alteration in surface color of metallic glasses (MGs) holds great significance in the context of microstructure design and commercial utility. It is essential to accurately describe the structures that are formed during the laser and color separation processes in order to develop practical laser coloring applications. Due to the high oxidation sensitivity of La-based metallic glass, it can broaden the color range but make it more complex. Structure coloring by laser processing on the surface of La-based metallic glass can be conducted after thermoplastic forming. It is particularly important to clarify the role of structure and composition in the surface coloring process. The aim is to study the relationship between amorphous surface structural color, surface geometry, and oxide formation by laser processing in metallic glasses. The findings revealed that the periodic structure primarily determines the surface color at laser energy densities below 1.0 J/mm2. In contrast, the surface color predominantly depends on the proportion of oxides that are formed when energy densities exceed 1.0 J/mm2. Consequently, this study provides a novel concept for the fundamental investigation of laser coloring and establishes a new avenue for practical application.

Effect of Laser Energy Density on the Properties of CoCrFeMnNi High-Entropy Alloy Coatings on Steel by Laser Cladding

High-entropy alloys (HEAs) have emerged as a novel class of materials with exceptional mechanical and corrosion properties, offering promising applications in various engineering fields. However, optimizing their performance through advanced manufacturing techniques, like laser cladding, remains an area of active research. This study investigated the effects of laser energy density on the mechanical and electrochemical properties of CoCrFeMnNi HEA coatings applied to Q235 substrates. Utilizing X-ray diffraction (XRD), this study confirmed the formation of a single-phase face-centered cubic (FCC) structure in all coatings. The hardness of the coatings peaked at 210 HV with a laser energy density of 50 J/mm2. Friction and wear tests highlighted that a coating applied at 60 J/mm2 exhibited the lowest wear rate, primarily due to adhesive and oxidative wear mechanisms, while the 55 J/mm2 coating showed increased hardness but higher abrasive wear. Electrochemical testing revealed superior corrosion resistance for the 60 J/mm2 coating, with a slow corrosion rate and minimal passivation tendency in contrast to the 55 J/mm2 coating. The comprehensive evaluation indicates that the HEA coating with an energy density of 60 J/mm2 exhibits exceptional wear and corrosion resistance.

Mechanical properties and tensile failure mechanisms of SM400A steel treated by high-power continuous-wave laser

This study systematically investigates the effects of high-power continuous wave laser (CWL) treatment on the mechanical behavior and failure mechanisms of SM400A steel, comparing these outcomes with those of untreated specimens. The findings reveal that while CWL treatment enhances surface hardness, it has minimal impact on the strength of thick structural steel components. However, excessive laser energy density leads to surface defects and softening of the microstructure, adversely affecting the material's toughness. This results in a reduction in elongation at fracture, transitioning the failure mode from ductile to brittle. The study concludes that to ensure the safe use of laser-treated structures, the laser energy density should be carefully controlled not to exceed 3000 J/cm2.

Damage effects of KDP crystals induced by nanosecond laser

Abstract The surface morphology, compositions, microstructures, and chemical bond vibrations of potassium dihydrogen phosphate (KDP) crystals induced by nanosecond laser with different wavelengths, at different energy density are studied by scanning electron microscopy (SEM) and infrared spectroscopy (IR) techniques. SEM results showed that with the increase of laser energy density, the damage region on KDP surfaces presented three parts evidently. And the damage area increases nonlinearly with the laser energy density, accompanied by an increase in O element contents and a decrease in P and K element contents. Meanwhile, at the same energy density, the damage area induced by the 355 nm nanosecond laser is much larger than that by the 1064 nm nanosecond laser. Infrared spectrum results revealed that the laser irradiation leads to a break in hydrogen bonds and a dehydration of KDP crystals, in conjunction with a generation of P=O and P-H bonds. Moreover, with the increase of the laser energy density, the KDP crystal is damaged firstly, and then is annealed and repaired, finally is destroyed again. In addition, after irradiation at 10 J/cm2, all vibration modes of KDP crystals weaken or even disappear, and the sever damage occurs.

Research status on the effect of energy density on the forming microstructure and properties of nickel-based superalloys for laser additive manufacturing

Abstract Nickel-based superalloys have excellent high-temperature mechanical properties, corrosion resistance and oxidation resistance, and strong machinability. It is widely used in aerospace, submarine and shipbuilding, petrochemical, electronic industry and other industries. However, there are still challenges in the popularization and application of nickel-based superalloys for alloy components with complex structures and extremely harsh working conditions. In this paper, the research status of the influence of energy density on the microstructure and properties of laser additive fabrication of nickel-based superalloys at home and abroad is reviewed. The influence of energy density on the microstructure evolution behavior and mechanical properties improvement effect of laser additive manufacturing nickel-based superalloys is summarized. The mechanism of energy density was discussed from the perspectives of microstructure evolution and macroscopic performance change. Based on the individual effects and synergistic effects of each process parameter, the influence of laser energy density on dendrite growth, phase precipitation characteristics, element distribution and porosity defect control effect of nickel-based superalloy was expounded, as well as the influence mechanism on microhardness, wear resistance and residual stress. Finally, the energy density optimization and development prospect of laser additive fabrication of nickel-based superalloys are prospected.

Realization of Joints of Aluminosilicate Glass and 6061 Aluminum Alloy via Picosecond Laser Welding without Optical Contact.

To achieve laser direct welding of glass and metal without optical contact is hard, owing to the large difference in thermal expansion and thermal conductivity between glass and metal and an insignificant melting area. In this study, the high-power picosecond pulsed laser was selected to successfully weld the aluminosilicate glass/6061 aluminum alloy with a gap of 35 ± 5 μm between glass and metal. The results show that the molten glass and metal diffuse and mix at the interface. No defects such as microcracks or holes are observed in the diffusion mixing zone. Due to the relatively large gap, the glass collapsed after melting and caulking, resulting in an approximately arc-shaped microcrack between modified glass and unmodified glass or weakly modified glass. The shape of the glass modification zone and thermal accumulation are influenced by the single-pulse energy and linear energy density of the picosecond laser during welding, resulting in variations in the number and size of defects and the shape of the glass modification zone. By reasonably tuning the two factors, the shear strength of the joint reaches 15.98 MPa. The diffusion and mixing at the interface and the mechanical interlocking effect of the glass modification zone are the main reasons for achieving a high shear strength of the joint. This study will provide reference and new ideas for the laser transmission welding of glass and metal in the non-optical contact conditions.

Ni4Ti3 precipitates formed in NiTi alloy modulated by powder bed fusion and their effects on mechanical and electrical deformation

In this study, NiTi alloys featuring different distributions and morphologies of Ni4Ti3 precipitates were developed via powder bed fusion (PBF) technology. The effects of these Ni4Ti3 precipitates on the mechanical, resistive, and electrical deformational properties of the alloys were also studied. With increasing laser energy density, a coarsening behavior of the semi-coherent Ni4Ti3 precipitates was observed, with these precipitates transitioning from needle-like to disk-like structures. Consequently, their coherence with the B2 matrix diminished, thus weakening the surrounding strain field. The presence of dislocations and uniformly dispersed Ni4Ti3 precipitates, endowed the NiTi alloy with enhanced resistivity (7.294 μΩ·m) and stable tensile recovery strain (2–4 %) during stress-controlled loading and unloading. Employing PBF, a NiTi spring actuator was produced, capable of lifting loads over 145 times its weight, with a shape-memory recovery efficiency of 76.80 % at a current of 3.0 A. This study demonstrated the versatility of PBF technology in tailoring the microstructure of NiTi alloys by adjusting the laser energy density, providing a laboratory reference for advanced applications in electrically induced deformation.

Effect of Direct Aging Heat Treatment on Microstructure and Mechanical Properties of Laser Powder Bed Fused Maraging Steel 300-Grade Alloy

Abstract This paper investigates the effects of a 6-hour direct aging heat treatment at 490 °C on the mechanical, tribological, and microstructure characteristics of laser powder bed fused maraging 300 steels, which is produced at various laser energy densities. After direct aging heat treatment, the grain boundaries become irregular and vague due to the residual stress releasing, squeezing of precipitates into the grain boundaries, and phase transformations. The XRD analysis reveals the reverted austenite (γ′) phase forms during aging treatment due to the inevitable reversion of metastable martensite to the stable reverted γ′ phase. The heat-treated samples' microhardness rises with rising the laser energy density (LED) from 61.41 to 92.10 J/mm3 due to a decrease in the reversed austenite phase and a further rise in LED decreases the microhardness of heat-treated samples due to a rise in the reversed austenite phase after heat treatment. The heat-treated sample produced at LED of 92.10 J/mm3 shows maximum yield, ultimate tensile strengths, and minimum elongation percentage due to its high microhardness, and the fractography results show the failure mode as a mixed brittle and ductile fracture. The wear-rate of the heat-treated additively manufactured maraging 300 steel decreases as the LED increases from 61.41 to 92.1 J/mm3 and a further rise in LED from 92.10 J/mm3 to 166.66 J/mm3, the wear-rate increases. The wear-rate rises with a rise in sliding velocity from 1.5–3.5 m/s. The dominant wear mechanism was observed as abrasion with small grooves and saplings.

Orthogonal experimental method to investigate the effect of process parameters on the mechanical properties of thin-walled parts by PBF-LB/M

Lightweight thin-walled parts are widely used in the aviation and aerospace industries, and with the further increase in the complexity of their features, the traditional manufacturing process can no longer fully meet the high requirements of industrial component manufacturing. In this work, thin-walled parts are processed by Laser based powder bed fusion of metals (PBF-LB/M), and the effects of process parameters on residual stress, hardness, mechanical properties and microstructure of thin-walled parts are systematically investigated. The simulation results show that the maximum equivalent residual stresses are distributed in the combination of the solid and the substrate, and the minimum equivalent residual stresses are mainly distributed in the top two ends and the middle part of the solid, and the stress distribution is symmetrical. In addition, the maximum equivalent residual stress increases with the increase of laser power, and decreases with the increase of scanning spacing or scanning speed. The experimental results show that with the increase of laser energy density, the tensile strength and yield strength of thin-walled parts show a tendency of increasing first and then decreasing. Finally, high-quality thin-walled parts were successfully fabricated by the optimized process parameters, and their tensile and yield strengths were increased by 6.1% and 15.9%, respectively.

22.56% total area efficiency of n-TOPCon solar cell with screen-printed Al paste

Screen-printing Ag paste on the rear side of the Tunnel Oxide Passivated Contact solar cells (TOPCon) is still the mainstream method to form electrodes. However, the high price of precious metals increases the cost of TOPCon cells. Al is a cheap and high-performance conductor, and its work function is compatible with the rear side of TOPCon cells. In this study, we used a UV pulse laser (355 nm, 10 ps) to ablate the rear side SiNx passivation layer of TOPCon cells and then printed Al paste with different weight percentages of silicon (Si-wt.%) on the phosphorus-doped polycrystalline silicon (n+-poly-Si) layer to reduce the cost. We investigated the damage mechanism of laser on SiOx/n+-poly-Si/SiNx passivation structure and the contact mechanism between Al paste and n+-poly-Si layer. The results show that the Voc of SiOx/n+-poly-Si/SiNx passivation structure reduced about 6–7 mV when the laser energy density was 0.431 J/cm2. We got the best electrical performance of TOPCon cells printed with Al paste (25 wt%-29 wt% silicon). The open-circuit voltage (Voc) and the conversion efficiency (Eff), have reached 663.60 mV and 22.56 % respectively. Although the efficiency was 9.40 % relative lower than that of TOPCon cells printed with Ag paste, but the cost of Al paste only accounted for 10 % of Ag paste. In the future, the highest Eff of TOPCon solar cells printed with Al paste on the rear side are expected to reach the commercial TOPCon based on Ag paste, which applies laser doping selective emitter technology (SE) and bifacial poly-Si passivation structure.

Tailored microstructure control in Additive Manufacturing: Constant and varying energy density approach for nickel 625 superalloy

The main challenge in the L-PBF process is finding the right combination of laser power (LP), scan speed (SS), and energy density (ED). This combination is crucial in controlling the microstructure and texture. This study introduces a new process parameter matrix (PPM) and its variation within the ED to adjust the microstructure by changing the LP/SS while keeping the ED constant or varying in the L-PBF process. Twenty-five Inconel 625 cubes were produced at different LP and SS, ranging from 230 to 350 W and 790 to 1190 mm/s. The resulting microstructure indicated that textured grains increased with ED. It also indicates that increasing the ED reduced relative density (RD) and porosity formation, while constant ED did not significantly affect them. Consequently, the hardness of the cube at the highest ED was about 21 % higher than that of the cube at the lowest ED. This study demonstrates the effectiveness of adjusting PPM to tailor the microstructure and texture using the L-PBF technique, which could be applied to complex shapes.

Ablation threshold, structural modification, and sensing of graphene oxide thin film induced by UV nanosecond laser

Reduction of graphene oxide by laser irradiation is crucial for developing conductive thin films. This study investigates the ablation threshold, reduction of graphene oxide, and high-precision patterning by UV nanosecond laser irradiation of graphene oxide films on flexible substrates. The ablation threshold of graphene oxide thin film was evaluated by examining the relationship between micropore diameters and laser pulse energy density. The single pulse ablation threshold was 2.29 J/cm², indicating that the UV nanosecond laser energy density is sufficient for the ablation of graphene oxide. Based on ablation threshold evaluation, graphene oxide was reduced by UV nanosecond laser irradiation, and laser-irradiated graphene oxide-based flexible thin film with four different line widths was fabricated. UV nanosecond laser irradiation graphene oxide-based grid structure patterns on the flexible substrates were fabricated by analyzing these different line widths. In addition, laser-irradiated graphene oxide-based grid structure flexible electrode were used to monitor human hand motion and finger press sensing. This study underscores the significance of laser irradiation of graphene oxide, a controllable strategy, and highlights the novelty and practical applications for fabricating flexible graphene oxide-based electronics.

Optimization design and interface characteristics research of high damping NiTi - Nickel-Aluminum Bronze functional gradient composite coating additively manufactured by high-speed laser-directed energy deposition

The near-equatomic NiTi shape memory alloy demonstrates exceptional damping performance due to its distinctive low-temperature self-cooperative martensitic internal friction. This study successfully fabricated NiTi-NAB (Nickel-Aluminium bronze shape memory alloy) functionally graded composite coatings with excellent metallurgical bonding between layers on Q235 steel substrates by designing an appropriate interlayer structure and employing the high-speed laser-directed energy deposition (LDED). Through comprehensive evaluation of the composite coating's performance and the numerical simulations of heat transfer within the molten pool, we elucidated the impact of process parameter levels on the microstructure and phase transformation characteristics of the NiTi alloy coating (NTC). The phase composition and phase interface characteristics of the NTC surface and bonding interface were analyzed using an electron probe microanalyzer and transmission electron microscopy, while dynamic thermomechanical analysis was employed to evaluate the damping performance of the NTC. The results indicate that an optimal parameter combination area still exists within the NTC-LDED process parameter window, even with equal laser energy density. Insufficient parameter levels can lead to an increase of micro-defects within the NTC, consequently causing a deterioration in both the cohesion and deformation resistance of the coating. Excessively high parameter levels can lead to significant element loss and residual stress, which in turn contributes to an increase in microcracks within the coating. A considerable quantity of reaction product mixture phases was formed at the interface between NTC and NAB, tending to align coherently with the NAB phase interface. The NTC, prepared with optimal process parameters, exhibits exceptional damping performance with a damping ratio of 0.498 at internal friction equilibrium, rendering it highly promising for applications in surface erosion protection for fluid machinery.

Investigations of the Laser Ablation Mechanism of PMMA Microchannels Using Single-Pass and Multi-Pass Laser Scans.

CO2 laser machining is a cost effective and time saving solution for fabricating microchannels on polymethylmethacrylate (PMMA). Due to the lack of research on the incubation effect and ablation behavior of PMMA under high-power laser irradiation, predictions of the microchannel profile are limited. In this study, the ablation process and mechanism of a continuous CO2 laser machining process on microchannel production in PMMA in single-pass and multi-pass laser scan modes are investigated. It is found that a higher laser energy density of a single pass causes a lower ablation threshold. The ablated surface can be divided into three regions: the ablation zone, the incubation zone, and the virgin zone. The PMMA ablation process is mainly attributed to the thermal decomposition reactions and the splashing of molten polymer. The depth, width, aspect ratio, volume ablation rate, and mass ablation rate of the channel increase as the laser scanning speed decreases and the number of laser scans increases. The differences in ablation results obtained under the same total laser energy density using different scan modes are attributed to the incubation effect, which is caused by the thermal deposition of laser energy in the polymer. Finally, an optimized simulation model that is used to solve the problem of a channel width greater than spot diameter is proposed. The error percentage between the experimental and simulation results varies from 0.44% to 5.9%.

Achieving excellent strength and ductility of 24CrNiMoY alloy steel fabricated by high power selective laser melting technology

In order to increase the productivity, new generation of selective laser melting (SLM) machines are evolving towards higher power lasers. In this paper, the microstructure evolution and mechanical properties of 24CrNiMoY alloy steel fabricated by high power selective laser melting (HP-SLM) have been reported. The results show that with the optimized laser power over 400 W, the powder layer thickness can be increased to 60 μm, and the theoretical productivity reaches 7.2 mm3/s, which is more than two times of the normal SLM technology. As the laser energy density increases, the structure of melt pool changes from a thermal conduction mode to a keyhole mode, and the microstructure mainly consists of martensite, bainite and pre-eutectic ferrite, and the phase composition of the specimen is α-Fe phase and a small amount of Fe3C,with fine grain size and irregular orientation. When the laser energy density is 68 J/mm3, the microhardness of the specimen is 410HV0.2, the tensile strength reaches 1121 MPa and the percentage elongation after fracture is 11.5%, which realizes a good match between strength and ductility. The fine tempered martensite and lower bainite in the microstructure is the key to excellent strength and ductility. This research is of guiding significance and serves as a technical reference for understanding the microstructure evolution and mechanical properties of HP-SLM 24CrNiMoY alloy steel.

Effect of laser energy density on the phase transformation behavior and functional properties of NiTi shape memory alloy by selective laser melting

NiTi shape memory alloy (SMA) was prepared via selective laser melting (SLM). Orthogonal tests were conducted with varying laser power and scanning speeds to explore the influence of laser energy density on microstructure, phase transformation behavior, mechanical properties and functional properties (superelasticity and shape memory effect). As energy density increases from 24.3 to 106.3 J/mm³, microstructure transforms from fine to columnar grains. Ni consumption intensifies, boosting transformation temperature and B2 content at room temperature. Post cyclic stretching, B2 content in alloy escalates further at room temperature. Tensile strength peaked at 53.6 J/mm³, while the elongation rate significantly increases with increasing energy density. During cyclic stretching, low or high energy densities in SLM NiTi induce high-density dislocations and stable residual martensite, respectively, significantly inhibiting martensitic transformation and resulting in extremely poor functional properties. The alloy produced at 53.6 J/mm³ boasts exceptional superelasticity due to stress-induced martensitic transformation and phase inversion post-unloading. Following heating past the critical transition, it nearly fully recovers (97.78 % recovery rate). Despite multiple shape memory fatigue tests, it maintains a recovery rate above 90 %. This study provides crucial theoretical insights for optimizing NiTi SMA phase transformation behavior and enhancing the performance.

Experimental investigation of nanosecond pulsed laser ablation of polycrystalline diamond composite

A fundamental understanding of the laser ablation of polycrystalline diamond composite (PCD) at different laser energy intensities is indispensable for extending these findings to practical applications where, through appropriate parameter combinations, a substantial amount of material with minimal thermal damage should be removed. The objective of this study is to investigate experimentally the nanosecond ablation of polycrystalline diamond composite at different laser pulse energies and input energy densities. The research comprised two distinct categories of experiments: (1) single-point and (2) line experiments. In single-point tests, the number of the incidence pulses (N.P) was varied from 1 to 100 pulses with different pulse energies (Ep) ranging from 40 to 200 µJ. As the N.Ps increased, the ablation depth increased as well. No considerable enhancement in ablation depth was observed with the increase in pulse energies. For the line experiments, the results emphasized the differences in ablation depths by nearly a factor of 2, resulting in a corresponding change in laser input densities from 6.5 J/mm2 to 1.3 J/mm2. The ablation difference was pronounced as the number of repeats of the scanning path increased. The results emphasize that the ablation depth varies at the same pulse energy when the pulse overlap decreased from 100 % to lower percentages. Based on these results, a constant laser energy density with three different combinations of laser inputs—namely, scanning speed and average power—was selected to evaluate the ablation depth and quality. The results show that in moderate numbers of scan repeats (here 20, 30 & 40 times), it is advisable to adopt a minimum pulse energy when the same ablation depth is achieved compared to higher pulse energies. The ablation pile-up was also evaluated in these repeat ranges, indicating that higher pulse energies and repeats do not result in ablation improvement and cause excessive melt deposition.

Simulation and Experimental Investigation on Additive Manufacturing of Highly Dense Pure Tungsten by Laser Powder Bed Fusion.

Tungsten and its alloys have a high atomic number, high melting temperature, and high thermal conductivity, which make them fairly appropriate for use in nuclear applications in an extremely harsh radioactive environment. In recent years, there has been growing research interest in using additive manufacturing techniques to produce tungsten components with complex structures. However, the critical bottleneck for tungsten engineering manufacturing is the high melting temperature and high ductile-to-brittle transition temperature. In this study, laser powder bed fusion has been studied to produce bulk pure tungsten. And finite element analysis was used to simulate the temperature and stress field during laser irradiation. The as-printed surface as well as transverse sections were observed by optical microscopy and scanning electron microscopy to quantitatively study processing defects. The simulated temperature field suggests small-sized powder is beneficial for homogenous melting and provides guidelines for the selection of laser energy density. The experimental results show that ultra-dense tungsten bulk has been successfully obtained within a volumetric energy density of 200-391 J/mm3. The obtained relative density can be as high as 99.98%. By quantitative analysis of the pores and surface cracks, the relationships of cracks and pores with laser volumetric energy density have been phenomenologically established. The results are beneficial for controlling defects and surface quality in future engineering applications of tungsten components by additive manufacturing.

Investigation on the characteristics of porosity, melt pool in 316L stainless steel manufactured by laser powder bed fusion

Pores are among the primary defects in 316L stainless steel when fabricated through laser powder bed fusion (L-PBF). To better understand and precisely control the formation behavior of pores in the L-PBF-manufactured 316L stainless steel, effects of L-PBF process parameters on the melt pool and pore characteristics have been investigated. A method utilized for extreme values statistics analysis was also applied to investigate and predict the sizes of pores. Relationships among the count of measurements, the laser energy density, the reduced variate, and the maximum pore size were revealed. The findings showed an overall increase in melt pool depth as the laser energy densities was raised, yet the magnitude of this growth weakened as the laser energy density continued to increase. Conversely, it was discovered that the connection between the width of the melt pool and the density of laser energy exhibited a markedly less distinct correlation. As laser energy density escalated, there was a shift in the melt pool mode from conduction-based to a transitional phase, and upon further elevation of the laser energy density, it transitioned to keyhole mode. To obtain a reliable statistical analysis of pores, at least 40 measurements should be acquired for the estimation of the pore sizes by taking comprehensive consideration of time cost. Beside, in all three melt pool modes, at a fixed observation area, the maximum size of pores generally decreased with the escalation in laser energy densities.