Laser-matter Interaction Research Articles

Effect of powder and absorptivity assumptions in the high-fidelity modeling of Laser Powder Bed Fusion processes

Laser Powder Bed Fusion (LPBF) technology represents the most promising metal additive manufacturing process to be scaled up to an industrial level for producing full batches of parts within the automotive aerospace and health sectors, among others. Despite this higher technological readiness, imperfections such as warping, porosities or undesired non-equilibrium microstructures can arise unexpectedly due to the complex thermal histories inherent to LPBF. Being able to anticipate to such imperfections is thus of high importance. With this purpose, numerical modeling strategies can be employed to significantly reduce experimental work on the melt pool scale. This allows to quantify the odds and magnitude of these process unwanted effects. More precisely, Computational Fluid Dynamics (CFD) enables high-fidelity models on the laser-matter interaction during LPBF processing. In this work, a modeling approach is presented in which the driving forces for melt formation are included in a CFD workspace, where multiple reflections of the laser on the melt pool Liquid-Gas Interface (LGI) are considered by means of an absorptivity function of the LGI depth. This simplification and the use of adaptive mesh strategies allows the model to be computed within a reasonable time. Results and applicability of the model on the determination of the melting mode (conduction or keyhole) are displayed and compared with experimental measurements of the melt pool width and depth for 316L and Ti64 single tracks produced on a LPBF machine. Likewise, further aspects such as total absorbed power are assessed.

Focal volume optics for composite structuring in transparent solids

Abstract Achieving high-level integration of composite micro-nano structures with different structural characteristics through a minimalist and universal process has long been the goal pursued by advanced manufacturing research but is rarely explored due to the absence of instructive mechanisms. Here, we revealed a controllable ultrafast laser-induced focal volume light field and experimentally succeeded in highly efficient one-step composite structuring in multiple transparent solids. A pair of spatially coupled twin periodic structures reflecting light distribution in the focal volume are simultaneously created and independently tuned by engineering ultrafast laser-matter interaction. We demonstrated that the generated composite micro-nano structures are applicable to multi-dimensional information integration, nonlinear diffractive elements, and multi-functional optical modulation. This work presents the experimental verification of highly universal all-optical fabrication of composite micro-nano structures with independent controllability in multiple degrees of freedom, expands the current cognition of ultrafast laser-based material modification in transparent solids, and establishes a new scientific aspect of strong-field optics, namely, focal volume optics for composite structuring transparent solids.

Localized Laser Heat Treatment on AISI 1045 Steel Using a LPBF Laser

ABSTRACTLaser heat treatment (LHT) can provide local microstructure modification for metallic materials. This study investigates the viability of LHT on AISI 1045 steel using a laser designed for laser powder bed processing (LPBF) with a very small beam diameter compared to existing literature. Energy density models from the literature are analyzed and adapted to improve consistency across varying laser properties, mainly focusing on spot size and laser–material interaction time. Fifteen different laser parameter schematics are evaluated, comparing hardness versus depth relations as well as laser‐affected zone (LAZ) profiles. Through adapting the energy density model, new laser parameters are calculated and demonstrated to produce a valid localized heat treatment.

Probing rapid solidification pathways in refractory complex concentrated alloys via multimodal synchrotron X-ray imaging and melt pool-scale simulation

AbstractRefractory complex concentrated alloys (RCCAs) show potential as the next-generation structural materials due to their superior strength in extreme environments. However, RCCAs processed by metal additive manufacturing (AM) typically suffer from process-related challenges surrounding laser material interaction defects and microstructure control. Multimodal in situ techniques (synchrotron X-ray imaging and diffraction and infrared imaging) and melt pool-level simulations were employed to understand rapid solidification pathways in two representative RCCAs: (i) multi-phase BCC + HCP Ti0.4Zr0.4Nb0.1Ta0.1 and (ii) single-phase BCC Ti0.486V0.375Cr0.111Ta0.028. As expected, laser material interaction defects followed similar systematic trends in process parameter space for both alloys. Additionally, both alloys formed a single-phase (BCC) microstructure after rapid solidification processing. However, significant differences in microstructure selection between these alloys were discovered, where Ti0.4Zr0.4Nb0.1Ta0.1 showed a mixture of equiaxed and columnar grains, while Ti0.486V0.375Cr0.111Ta0.028 was dominated by columnar growth. These behaviors were well described by the influence of undercooling effects on columnar-to-equiaxed transition (CET). Distinct microstructure formation in each alloy was verified through CET predictions via analytical melt pool simulations, which showed a ~ 5 × increase degrees in undercooling for Ti0.4Zr0.4Nb0.1Ta0.1 compared to Ti0.486V0.375Cr0.111Ta0.028. Overall, these results show that microstructure control based on modulating the freezing range must be balanced with process considerations which resist defect formation, such as solidification crack formation in RCCAs. Graphical abstract

Double-pulse laser peening as a surface enhancement technology

In this paper, we discuss double-pulse laser peening (DPLP) as surface enhancement technology. Although single-pulse laser peening (SPLP) has yielded excellent results across various applications, its processing performance and efficiency are limited. The DPLP technique involves two laser pulses with a controlled irradiation interval and intensity, enhancing laser absorption through the plasma plume and generating high-amplitude laser-induced shock waves. This study involved conducting DPLP experiments on stainless steel, comparing the outcomes with those of conventional SPLP to assess DPLP’s functionality. After the initial prepulse irradiation, the subsequent main pulse was timed and irradiated onto the stainless steel. We evaluated the surface hardness to ascertain the impact of laser peening. The findings indicated that the surface hardness achieved with DPLP was up to 64% greater than that with SPLP. Additionally, the surface hardness achieved through DPLP depended on the delay time between the pulses and the intensity of the initial prepulse. These findings suggest that DPLP can significantly enhance surface hardness, providing a potential pathway for improving material performance in various industrial applications. Furthermore, simulation experiments of DPLP were performed using a one-dimensional simulation code that calculates the laser-matter interaction during the peening process. The pressure profiles generated by the simulation closely matched the experimentally derived hardness profiles, confirming the simulation’s ability to predict the mechanical effects induced by DPLP on the target sample and assist in further optimization of the DPLP process.

Improving melt pool depth estimation in laser powder bed fusion with metallic alloys using the thermal dose concept

Laser-matter interactions in laser powder bed fusion for metals (LPBF-Ms) significantly impact the final properties of the fabricated components. Critical process parameters, such as the linear energy density (LED), the ratio of laser power to scan speed, modify the energy input and consequently modify the melt pool geometry. LED strongly influences the melt pool cross-sectional profile, which dictates the thermal effects, microstructure, and mechanical properties of the finished part. Recognizing the crucial role of the melt pool in additive manufacturing, researchers have developed predictive models to estimate its dimensions and morphology. These models aid in tailoring part properties, optimizing process parameters, and reducing the number of experimental trials. However, existing models are either computationally expensive or analytically overly simplified for general LPBF-M applications. This study proposes an improved model that incorporates the Rosenthal equation as described by Tang to increase the accuracy of melt pool depth prediction. By using the thermal gradient per unit time, termed the “thermal dose” in this paper, corresponding to the LED value that produces experimental near-semicircular melt pool shapes for each studied material, we can improve the melt pool depth estimation. The trend revealed a good fit across the LED range compared with experimental measurements, suggesting the model’s effectiveness.

Investigations on opportunities and challenges of brilliant high-power laser beam welding with 24 kW and adjustable power distribution for different materials

Solid-state laser beam sources offer the possibility of generating high-brilliance laser beams with low expansion and high usable intensity at the focal point. New approaches include beam shaping with the use of core and ring fiber and, therefore, variable power distribution in the laser beam focal point and material interaction area. Particularly, high-power laser beam welding benefits from beam shaping because of the stabilizing effect on the weld pool. Furthermore, the technical progress achieved with regard to beam quality also allows one to achieve high Rayleigh lengths and, therefore, a more uniform beam diameter over the whole material thickness. In this study, investigations on high-power laser beam welding with a 24 kW disk laser beam source are conducted for three different materials (mild steel, aluminum alloy, and copper), which are of high interest for welding in different sectors. The influence of power distribution between the core and the ring as well as welding speed on weld geometry (depth and width), weld pool stability, and the resulting weld seam quality is investigated. It is shown that the welding process cannot just be scaled up in comparison with welding with lower laser beam power but has its own challenges. It is possible that high welding depths (12 mm for copper, more than 12 mm is possible for aluminum, and 25 mm for mild steel) could be achieved in one pass. To achieve this, aluminum needs the lowest energy per unit length per mm of sheet thickness and copper the highest.

Morphological evolution mechanism of microstructures involved in shaping micro-pillar arrays into microlens arrays on fused silica surfaces by CO2 laser polishing

The periodic micro-pillars on the hard-brittle fused silica surface can be shaped into the smooth and defect-free microlens arrays (MLA) by CO2 laser polishing, which can be applied in imaging and beam-shaping. However, the morphology evolution mechanism of the micro-pillars is not clear during polishing, which seriously affects the rapid preparation of high-quality MLAs. Herein, a multi-physics coupling model is established to investigate the interaction between CO2 lasers and micro-pillars on the fused silica surface, and is verified from the perspectives of temporal and spatial temperature. The steady surface temperature evolution law with laser power and spot radius is explored, based on which, the parameter ‘Window’ for polishing is determined to make the material melt and flow without ablation removal. The morphology evolution of micro-pillars is investigated as well as laser-material interaction. It is found that under laser irradiation, the micro-pillar height first increases and then decreases, and its top curvature radius increases. The surface tension makes the dominant contributions to the melting and flow of the micro-pillar materials, while the Marangoni effect and the gravity have little effect. Furthermore, to fabricate the target MLAs with the specific dimensions, the influence of micro-pillar aspect ratio (φ) on microlens surface morphology is investigated. It is found that there are two critical φ for the target MLAs. For the required MLA with the target period of 200 μm and the target height of 40 μm, when the φ is larger than 5.1, the micro-pillar array fails to be shaped into the target MLA by CO2 laser polishing. As the φ decreases, the junction of micro-pillar and the substrate sags downwards significantly, and the deviation between the shaped- and the ideal spherical contours increases. To successfully prepared the target MLA and guarantee the geometry accuracy, the minimum φ is selected to be 0.71. This work has important theoretical significance for obtaining the smooth and defect-free target fused silica MLAs with the specific dimensions by CO2 laser non-evaporative polishing.

Advances in Design and Fabrication of Micro-Structured Solid Targets for High-Power Laser-Matter Interaction

Accelerated particles have multiple applications in materials research, medicine, and the space industry. In contrast to classical particle accelerators, laser-driven acceleration at intensities greater than 1018 W/cm2, currently achieved at TW and PW laser facilities, allow for much larger electric field gradients at the laser focus point, several orders of magnitude higher than those found in conventional kilometer-sized accelerators. It has been demonstrated that target design becomes an important factor to consider in ultra-intense laser experiments. The energetic and spatial distribution of the accelerated particles strongly depends on the target configuration. Therefore, target engineering is one of the key approaches to optimizing energy transfer from the laser to the accelerated particles. This paper provides an overview of recent progress in 2D and 3D micro-structured solid targets, with an emphasis on fabrication procedures based on laser material processing. Recently, 3D laser lithography, which involves Two-Photon Absorption (TPA) effects in photopolymers, has been proposed as a technique for the high-resolution fabrication of 3D micro-structured targets. Additionally, laser surface nano-patterning followed by the replication of the patterns through molding, has been proposed and could become a cost-effective and reliable solution for intense laser experiments at high repetition rates. Recent works on numerical simulations have also been presented. Using particle-in-cell (PIC) simulation software, the importance of structured micro-target design in the energy absorption process of intense laser pulses—producing localized extreme temperatures and pressures—was demonstrated. Besides PIC simulations, the Finite-Difference Time-Domain (FDTD) numerical method offers the possibility to generate the specific data necessary for defining solid target material properties and designing their optical geometries with high accuracy. The prospects for the design and technological fabrication of 3D targets for ultra-intense laser facilities are also highlighted.

Layer-level fabrication of continuous functionally graded materials (cFGMs) via Powder Bed Fusion – Laser Beam technology

Multi-material fabrication of metals through Additive Manufacturing (AM) processes is attracting more and more attention in recent years. This work presents a novel methodology that enables the fabrication of continuous functionally graded materials (cFGMs) at the layer level using Powder Bed Fusion – Laser Beam (PBF-LB) technology. This has been achieved by designing and building a customized powder separation system that can be easily installed on a currently operating PBF-LB system with a blade/roller-based powder spreading technique (extremely limited for layer-level multi-material fabrication). This technique overcomes one of the main drawbacks of AM multi-material fabrication by properly joining materials with very different mechanical properties and low compatibility, thus extending the productive capacity of this technology. Two steels, AISI 316 L and 18 Ni Maraging 300, with different physical, chemical and mechanical properties, were used to study the applicability and verify the proposed methodology. A high-resolution optical system was used to monitor, layer by layer, the different laser-matter interactions given by the different materials and thus the presence of a graded transition zone between them. Results in terms of statical mechanical properties, microstructure, chemical analysis and optical monitoring showed that the proposed solution is reliable and cost-effective, paving the way for future applications.

Review of high-precision femtosecond laser materials processing for fabricating microstructures: Effects of laser parameters on processing quality, ablation efficiency, and microhole shape

Femtosecond lasers are promising tools for achieving high-precision processing of thin materials without causing any thermal surface damage and bulk distortion. However, thermal damage can occur even with ultrashort laser pulses. This is because of high electron penetration depth and heat accumulation at high fluence and high repetition rate. Nanoparticle redeposition can be dramatically altered with variation in repetition rate. The symmetry of microholes and ablation efficiency vary with laser polarization. The laser wavelength affects the ablation efficiency and surface roughness. Therefore, understanding these laser–matter interactions that depend on the laser parameters is essential for high-precision laser processing. This article reviews laser–matter interactions in the 64FeNi alloy, as well as analytical models for designing the desired hole size and taper angles. This can help establish strategies for creating various high-precision microstructures using femtosecond lasers.

Theoretical insights into laser-assisted field evaporation of ionic compounds

This study addresses the kinetic process of field evaporation of MgO assisted by ultrafast laser pulses combining density functional theory and molecular dynamics. A quantitative model is presented to describe the competitive evaporation of Mg and O ions under various conditions by comparing the activation barriers. The coordination number has a significant impact on the evaporation kinetics. The evaporation ratio of Mg to O rises with increasing DC field strength and laser intensity. Moreover, the energetics of evaporation is in correlation with photo-induced field ionization, revealing distinct mechanisms of evaporation for Mg and O. While Mg undergoes further ionization and field evaporation simultaneously, the evaporation of O is coupled with the relaxation of excited carriers. The final charge state of evaporated O is determined by the DC field strength rather than the laser intensity. Our findings provide insights into laser–matter interactions in ionic compounds and contribute to the development of atom probe techniques.

Femtosecond laser-induced damage threshold incubation in SrTiO3 thin films

This study delved into the microfabrication process on SrTiO3 thin films using femtosecond laser pulses, focusing on characterizing ablation behavior and elucidating on incubation parameters. A combination of microscopy techniques and systematic analysis of laser-material interactions provided insights into the features and fundamental processes governing the laser-induced modification of SrTiO3 thin films. The cutting profile morphology indicated high-resolution material removal, with line widths ranging from 0.6 to 1.6 µm, depending on number of pulses and energy. The study revealed a low incubation parameter for SrTiO3 thin films, quantified as (0.03 ± 0.01), indicating that a considerable number of pulses is required to cause damage to the material. Additionally, threshold energies for damage were determined to be 17.9 nJ for 20,000 pulses and 35.2 nJ for a single pulse. AFM analysis showed that the depth of the micromachined lines increased from approximately 80 nm to 315 nm with higher pulse energies, confirming substantial material removal. The Keldysh parameter provides insights into ionization mechanisms under femtosecond-laser irradiation, highlighting the dominance of tunneling ionization. Using higher pulse energies, the center of the microstructures exhibited significantly reduced Raman signals, correlating with substantial material removal, which was confirmed by atomic force microscopy. EDS analyses indicated that the elemental composition of the irradiated regions closely resembled the stoichiometric composition of SrTiO3, while the center of the microstructures showed significant oxygen levels but lacked titanium and strontium, consistent with the findings from AFM and Raman microscopy.

Overview and Recent Developments of the Frascati Laser for Acceleration and Multidisciplinary Experiments Laser Facility at SPARC_LAB

An overview of the 200 TW Frascati Laser for Acceleration and Multidisciplinary Experiments (FLAME) at the SPARC_LAB Test Facility at the National Laboratories of Frascati (LNF-INFN) is presented. The FLAME laser is employed to investigate different laser–matter interaction schemes, i.e., electron acceleration and secondary radiation sources through Laser Wakefield Acceleration (LWFA) or ion and proton generation through Target Normal Sheath Acceleration (TNSA), for a wide range of scientific areas including the biomedical applications. Finally, recently performed experimental campaigns within the EuAPS and EuPRAXIA frameworks are reported.

Numerical simulation of a laser beam welding process: From a thermomechanical model to the experimental inspection and validation

In laser beam welding (LBW) complex physical phenomena occur during laser-material interaction, which prolong the parameterisation of the process due to the extended trial and error tests. Therefore, predicting the process behaviour leads to a more productive and cost-reduced process experimental tuning. Besides, as LBW is a thermal process, part distortion plays a relevant role in the final result, and hence, thermal and mechanical analysis are both required. In view of this, in the present research, a novel multiscale numerical model, capable of predicting the thermomechanical behaviour of the LBW process has been developed. The significance of the model is its capability of forecasting the part distortion and thermal field employing two fully coupled modules, where the laser heat source automatically adapts to the welding regime without the need to consider the melt pool dynamics and at a low computational cost. The local model determines the melt pool dimensions and thermal field. Besides, the second module, the global model, figures out the part distortion based on the thermal results. Finally, the presented numerical simulations are experimentally validated with the corresponding temperature monitoring during the welding process, the posterior metallography inspection, and the part deformation measurement. The results present a high accuracy, with a maximum error below 10 % at the temperature measurements, an average dimensional deviation of 0.14 mm and 0.18 mm respectively for the weld bead depth and width, and a vertical deformation average error of 0.15 mm.

Impulse coupling enhancement of aluminum targets under laser irradiation in a soft polymer confined geometry

Laser pulses were applied to a target mounted on a ballistic pendulum to study the momentum imparted by a laser shock impact. Photonic Doppler Velocimetry was used to assess the momentum imparted by each laser pulse. To increase the momentum produced, a layer of polymer transparent to the laser wavelength was applied to the surface of the targets to confine the plasma generated as a result of the laser–matter interaction. This yielded momentum coupling coefficients one hundred times higher than those obtained for equivalent laser parameters in the classical direct regime configuration. The study was completed by simulating the experiments with the one-dimensional Lagrangian hydrodynamics code ESTHER, which showed good agreement with the experimental results.

Elucidating the origin of laser induced nonlinearities in propagation inside transparent medias: A comparative numerical study of silicon and fused silica

Abstract The creation of localized bulk modification using femtosecond pulses inside semiconductors like silicon (Si) is quite challenging whereas it is not difficult to achieve it for dielectric material like fused silica (FS). So, this report addresses the fundamental origin of this issue. By taking simple numerical approach, it has been found that in FS we can deliver stronger fluence due to self-focusing on higher power level as compared to Si. The origin for the above lies on the spatial-temporal pulse-splitting behavior which is dominant in case of FS at the focus, whereas for Si it is only effective after focus. We have also considered the influence of plasma and Kerr terms to elucidate the reason behind such nonlinearities. For FS case, omission of Kerr term dominates whereas for Si the influence of each term does not significantly create self-focusing like FS under a similar focusing condition. This study could make an important guideline for researchers to understand the complexity of laser-matter interaction in transparent materials specifically being studied by many laser processing industries.

Study of burst mode for enhancing the ps-laser cutting performance of lithium-ion battery electrodes

The demand for lithium-ion batteries (LIBs) has increased significantly, leading to an increased focus on high quality production methods. In response to this growing demand, laser technology has been increasingly used for electrode notching and cutting. In addition, the advent of high-power ultrashort lasers equipped with burst mode capabilities represents a promising option for electrode cutting of LIBs. On the other hand, these types of lasers for this purpose are relatively unexplored in the literature. This study investigates the effect of various parameters, including the number of pulses per burst (ranging from 1 to 8), the pulse repetition rate (200.0, 550.3, and 901.0 kHz), and the burst shape (equal pulse peak and increasing pulse peak), on the laser cutting process of aluminum foil, cathode, copper foil, and anode. The results indicate that increasing the number of pulses per burst and the pulse repetition rate improves productivity and quality for all materials, with a more significant effect observed for metal foil than for cathode and anode materials due to the different laser-material interactions for metal foil and active material. The burst shape with equal pulse peaks was found to be a more suitable temporal distribution for cutting all materials compared to an increasing pulse peak distribution. The ablation efficiency was evaluated as a function of the peak fluence of a single pulse within the burst. The results emphasize that higher productivity at higher average power can be achieved by increasing the pulse repetition rate toward the MHz range with moderate pulse energies.

All-fiber GHz few-cycle pulse generation at 2 µm.

We demonstrate an all-fiber GHz mode-locked laser system with few-cycle duration operating at 2 µm. Based on a dispersion-managed mode-locked oscillator, a multi-stage fiber amplifier, and a nonlinear pulse compressor, the laser system can deliver watt-level few-cycle pulses at a fundamental repetition rate of 1.041 GHz. This 2-µm pulsed laser offers outstanding performance metrics, including a pulse duration of 33 fs (corresponding to ∼5 optical cycles) and an average power of 4.17 W. Moreover, the all-fiber laser system exhibits excellent power stability, and the integrated relative intensity noise (RIN) is only 0.052% (10 Hz-1 MHz). It is anticipated that this new, to the best of our knowledge, laser source is promising for frontier applications, including coherent supercontinuum generation, nonlinear frequency conversion, and laser-material interaction.

Inverse muon decay in a circularly polarized laser field

In this paper, we investigate the effect of a circularly polarized laser field on the inverse muon decay process [Formula: see text] in electroweak theory with the exchange of a boson vector [Formula: see text]. Our method accounts for the dressing of incident electron and scattered muon by introducing the first-order laser-matter interaction of perturbation theory and using the relativistic Dirac–Volkov formalism. We have analyzed the behavior of the total cross-section (TCS) with charged-current as a function of the center-of-mass energy and the laser field parameters, such as the number of photons exchanged, the laser field strength and frequency. We have found that the circularly polarized laser field significantly affects the inverse muon decay process by reducing the TCS. We have also shown that the photonic energy transfer envelopes are perfectly symmetric with respect to the number of photons exchanged and rapidly drop when the indices of the Bessel functions are close to their arguments.