Laser Power Research Articles

Process Parameter Optimization of Directed Energy Deposited QT17‐4+ Steel

AbstractThe feasibility of using argon‐atomized QT 17‐4+ stainless steel powder for directed energy deposition (DED) additive manufacturing is studied. The QT 17‐4+ steel is a novel martensitic steel designed based on the compositional modification of the standard 17‐4 precipitation‐hardened (PH) stainless steel. This modification aims to achieve better mechanical properties of as‐deposited components compared to the heat‐treated wrought 17‐4PH steel. In this study, QT 17‐4+ steel powder is used for DED, for the first time. The influence of laser power, laser scan speed, powder feed rate, and hatch overlap on the density is studied. The central composite design is used to determine the experimental matrix of these factors. The response surface methodology is used to obtain the empirical statistical prediction model. Both columnar and equiaxed parent austenite grain structures are observed. X‐ray diffraction analyses reveal a decrease in the percentage of retained austenite from 19% in the powder to 5% after DED. The microhardness of the DED processed sample in the as‐deposited state is slightly higher than that of wrought 17‐4PH steel either solution‐annealed or H900‐aged. A higher 0.2% yield strength, a lower ultimate tensile strength, and lower elongation are observed for the vertically printed test sample, when compared to the horizontal one.

Parameter optimization, microstructural and mechanical properties of fiber laser lap welds of DP1200 steel sheets

In this research, the effects of laser power, laser welding speed and laser incidence angle were evaluated in terms of weld geometry, microstructure, microhardness, fracture surfaces and tensile shear load in fiber laser welding joints of DP1200 steel sheets. Response Surface Methodology (RSM) was utilized to derive mathematical relationships between the process parameters and the tensile shear load after the tensile test. The optimum combination of process parameters was a laser power of 2800 W, a laser welding speed of 40 mm/s, and a laser incidence angle of 70°. A thermal camera was used to record the laser welding process, and the cooling rates were evaluated by analyzing this data. The influence of cooling rate upon microstructure phase formation for DP1200 steel is investigated, with continuous cooling transformation (CCT) diagrams. Also, post-welding stress and displacement were simulated by Simufact Welding software. At high heat input (55.79 J/mm) occurred coarse dendritic martensitic lath growth while at low heat input (37.6 J/mm) fine dendritic martensitic structure was observed in the weld zone was obtained owing to the high rate of cooling. The microstructure consists of full martensite at a higher than 10 °C/s cooling rate. The findings reveal that the phases in FZ and HAZ, the morphology and martensite/bainite constituents differed related to the heat input and laser incidence angle, which ultimately affects the joint’s microhardness, fracture dynamics and tensile shear load.

High-Sensitivity Differential Helmholtz Photoacoustic System Combined with the Herriott Multipass Cell and Its Application in Seed Respiration.

A highly sensitive photoacoustic detection system using a differential Helmholtz resonator (DHR) combined with a Herriott multipass cell is presented, and its implementation to sub-ppm level carbon dioxide (CO2) detection is demonstrated. Through the utilization of erbium-doped optical fiber amplifier (EDFA), the laser power was amplified to 150 mW. Within the multipass cell, a total of 22 reflections occurred, contributing to an impressive 33.6 times improvement in the system sensitivity. The normalized noise equivalent absorption coefficient (NNEA) was 8.64 × 10-11 cm-1·W·Hz-1/2 [signal-to-noise ratio, (SNR) = 1] and according to the Allan variance analysis, a minimum detection limit of 500 ppb could be achieved for CO2 at 1204 s, which demonstrates the long-term stability of the system. The system was applied to detect the respiration of rice and upland rice seeds. It is demonstrated that the system can monitor and distinguish the respiration intensity and respiration rate of different seeds in real time.

Unidimensional and Bidimensional Beam Expander Effects on the Output Power and Spectral Bandwidth of a Dye Laser

Unidimensional and Bidimensional Beam Expander Effects on the Output Power and Spectral Bandwidth of a Dye Laser

High power and high efficiency yellow laser in Dy3+-doped single-mode double-clad structured waterproof fluoro-aluminate glass fiber

We demonstrated a single-mode yellow fiber laser using a Dy3+-doped single-mode double-clad structured weatherproof fluoro-aluminate glass fiber (Dy3+:SM-DC-WPFGF) and a 450-nm GaN laser diode (LD) as the excitation light. The power of 445 mW and the slope efficiency of 51.2% were achieved for the single-mode yellow fiber laser. The power level was approximately 20 times higher than our previous result due to improved efficiency of the focusing optics and increased Dy3+ doping concentration (10,000 ppm) in the fiber core. This yellow fiber laser shows particular promise for use in the medical field, e.g., for the treatment of melasma and telangiectasia.

Microstructure and properties nonuniformity of Ti6Al4V component fabricated by high-power laser melting deposition

High-power laser melting deposition provides an efficient solution for the fabrication of large-sized titanium alloy components. In this study, Ti6Al4V blocks with well-formed structures were prepared using a 7 kW laser power, and their internal defect distribution, microstructure along the deposition direction, tensile properties, and fatigue performance were investigated. The results showed that the density of the as-deposited Ti6Al4V blocks could reach 99.94%, and the main internal defects were cavities, primarily spherical and dispersed, with a maximum diameter of 326.7 μm. Among them, 65.53% of cavities had a diameter smaller than 100 μm, and 92.76% had a diameter smaller than 200 μm. The microstructure at the top region of the specimen consisted of a needle-shaped α phase, the middle region had a mixture of needle-shaped and lamellar α-phase, and the bottom region showed a lamellar α-phase structure. With an increase in deposition height, the aspect ratio of α-phase increased, and the average width decreased from 3.22 μm to 0.88 μm. The internal structure was mainly composed of a basket-weave structure, with a small amount of Widmanstätten structure present at grain boundaries. Hardness and tensile properties exhibited significant non-uniformity along the deposition height. The tensile strength and yield strength at the top region were approximately 50 MPa higher than those in the middle and bottom regions, while the elongation was about 2% lower. The top region's tensile fracture surface displayed a sawtooth pattern, whereas the middle and bottom regions exhibited fractures along the 45° direction of the principal stress. The length of α-bundles and the interface density within the bundles were crucial factors affecting crack propagation. In the top region, α bundles were the longest, and the interface density was the highest. During crack propagation, when the crack extended perpendicular to the α bundles, it encountered high resistance, and when it extended non-perpendicular, it rapidly propagated along the bundle boundaries, exhibiting high strength and low plasticity. The fatigue performance of the Ti6Al4V specimens fabricated by high-power laser melting deposition showed significant dispersion, with cracks originating from subsurface lack of fusion defects. At different stages of fatigue crack propagation, the role of α phase laths varied: during the fatigue source region, cracks primarily propagated along the boundaries of α laths, displaying significant cleavage fracture characteristics. In the fatigue propagation region, crack propagation velocity was mainly influenced by the direction of the laths, and in the fatigue final rupture region, ductile fracture was predominant. Α laths parallel to the tensile direction exhibited the best plasticity, promoting the formation of large dimples and high tear ridges.

Optimization of process parameters of selective laser melted nickel-based superalloy for densification by random forest regression algorithm and response surface methodology

In this study, Random Forest Regression (RFR) and Response Surface Methodology (RSM) were employed to predict the optimized processing parameters to achieve the highest densification of a nickel-based superalloy Mar-M247LC fabricated by selective laser melting (SLM). The RFR model considered input processing parameters such as laser power, hatch distance, and scanning speed. A dataset of 223 samples, was used to train the RFR model. As a result, the RFR model exhibited accuracy of 99.57 %, R2 value of 0.976, Mean Square Error (MSE) of 0.402, and Mean Absolute Percentage Error (MAPE) of 0.426 % on testing set. In addition to the RFR model, this study also employed Central Composite Design (CCD) and RSM to optimize the processing parameter sets. Subsequently, this study conducted Box-Behnken Design (BBD) to experimentally validate the accuracy of this RFR model. In the end, a set of the optimal processing parameters was tested and resulted a sample densification of 99.959 %, outperformed that in the original database before building the RFR model, which was 99.734 %. In summary, the RFR models was able to predict densification with accuracy, and by coupling with RSM, the optimal processing parameter could be obtained, so better densification of the build could be achieved.

The effects of 3D printing parameters, structural design and post-processing on the mechanical properties and corrosion resistance of SLMed ZK60 porous scaffolds

High-quality porous Mg alloy scaffolds show promise in repairing large segmental bone defects. In this study, the authors prepared porous ZK60 scaffolds using the selective laser melting (SLM) method with three different model structures: Gyroid (G), Diamond (D), and Dodecahedral (Do). The researchers investigated the structural refinement, mechanical properties, and corrosive properties of SLM-ed ZK60 by adjusting the 3D printing parameters, specifically the scanning speed and laser power. The results show that, with optimized process parameters of a scanning speed of 400 mm/s and a laser power of 110 W, the relative density of the prepared samples was higher than 97 %. After post-processing with electrolytic polishing, the G model scaffolds showed a smooth structural transition and the largest surface area compared to the other two models. The electrolytic polishing treatment also improved the structural refinement of the 70 % designed porosity, with an error of only 4.3 %. Additionally, the Do model scaffolds exhibited the best mechanical properties, with a yield strength of up to 24 MPa and an elastic modulus of up to 425 MPa. Furthermore, after coating treatment, the corrosion rate decreased from 5.67 mm/year to 1.34 mm/year after 48 h. These results demonstrate the potential of SLM-ed porous scaffolds for biomedical applications.

Performance and compensation method of first-order liquid crystal beam-steering system under continuous wave laser irradiation

The effects of laser irradiation thermal deposition on the performance degradation of liquid crystal (LC) devices in high-power laser systems are extremely vital. In this study, the first-order beam-steering system (FBS) was developed using a passive liquid crystal polarization grating (LCPG) and liquid crystal adjustable wave-plate (LCAW). The LCPG was prepared by holographic exposure technology, and the LCAW was prepared using the standard LC cell preparation process. We investigated the influences of diffraction efficiency of FBS under a 1070-nm continuous-wave (CW) laser irradiation. The energy is concentrated in the −1st order at first. When the half-wave retardation was reached, all the energy is concentrated in the +1st order (∼97 %), and the beam is deflected. Once the phase retardation decreases below the half-wave retardation, the energy gradually reconcentrates in the −1st order. When the LCAW fails, the diffraction the energy is refocused to the −1st order by the LCPG. The results indicated that both thermal deposition and driving voltage reduce the phase retardation of the LCAW, generating a variation of energy between in ±1st orders. By reducing the driving voltage, this half-wave retardation can be recovered under a certain half-wave voltage and laser power density, and the diffraction efficiency of the +1st order can be compensated to ∼97 %. If the reduced phase retardation is not less than half-wave, the FBS can still be modulated in high-power continuous lasers. Our research provides a reference for the development of beam-steering technology based on LC materials in high-power laser systems.

A multi-sensor based online monitoring system for laser hot-wire surface cladding process

A multi-sensor online monitoring system, including a high-speed camera, a spectrometer, and an infrared camera, was developed to enhance the laser hot wire cladding process. This innovative process feeds a preheated wire, using a hot-wire power supply, into a shallow molten pool formed on the substrate surface by a rectangular diode laser beam. This study assesses the capability of the monitoring system to detect variations in cladding process conditions that significantly influence the geometry and quality of the clad layer. Specifically, the study involved four sets of laser hot-wire cladding experiments, altering substrate surface conditions, substrate thicknesses, laser powers, and scanning speeds. The real-time data from the three sensors were synchronized and analyzed in depth, focusing on the morphology and microhardness of the clad layers. A laser vision sensor was employed to examine the surface profile and roughness of the clads. The findings indicated that the crucial role of surface preparation in influencing the dynamics of the molten pool, subsequently affecting the geometry, dilution depth, and microhardness of the clads. The sensors demonstrated increased sensitivity to changes in surface conditions compared to variations in other conditions like substrate thickness, laser power, and scanning speed. A significant correlation was found between the dilution depth, clad height, surface roughness, and microhardness of the clad layer. These correlations are in response to adjustments in laser power, scanning speed, and surface preparation and can be reliably and rapidly detected by the multi-sensor system.

Relating laser powder bed fusion process parameters to (micro)structure and to soft magnetic behaviour in a Fe-based bulk metallic glass

This work aims to establish fundamental processing-(micro)structure-property links in a commercial Fe-based Kuamet6B2 bulk metallic glass (BMG) processed by laser powder bed fusion (LPBF). With that purpose, amorphous powders were processed using a pulsed-wave system and a simple meander strategy. The laser power, the scan speed, and the hatch distance were varied over wide intervals within the conduction regime. The processability window leading to samples with good dimensional accuracy and mechanical stability was determined. Within this window, the manufactured samples were crystalline/amorphous composites and the crystalline regions were formed by equiaxed ultrafine and nanograins with random orientations. Processing parameters yielding the densest prints caused severe crystallization while, conversely, parameter sets allowing the material to retain a high amorphous fraction led to significant lack-of-fusion defects and residual cracking along directions perpendicular to crystalline/amorphous interfaces. Comparatively, for a fixed hatch distance, the scanning speed had a stronger effect than the laser power in the resulting amorphous fraction due to its stronger influence on the melt pool size and, in turn, on the corresponding HAZ volume. The saturation magnetization and the coercive field were inversely related to the amorphous fraction. This work allows to derive fundamental guidelines for the successful additive manufacturing of soft magnetic Fe-based bulk metallic glasses (BMGs) by laser powder bed fusion (LPBF).

Time and power dependence of laser-induced photodamage on human sperm revealed by longitudinal rolling measurement using optical tweezers.

Lasers are widely applied in assisted reproductive technologies, including sperm fixation, sperm selection and intracytoplasmic sperm injections, to reduce procedure time and improve consistency and reproducibility. However, quantitative studies on laser-induced photodamage of sperm are lacking. In this study, we demonstrated that, by using optical tweezers, the kinematic parameters of freely swimming sperm are correlated with the frequency as well as the percentage of pausing duration of longitudinal rolling of the same sperm head in the optical trap. Furthermore, by trapping individual sperm cells using 1064-nm optical tweezers, we quantitatively characterized the time-dependence of longitudinal rolling frequency and percentage of pausing duration of sperm under different laser powers. Our study revealed that, as trapping time and the laser power time increase, the longitudinal rolling frequency of the optically trapped sperm decreases with an increasing percentage of pausing duration, which characterizes the effect of laser power and duration on the photodamage of individual sperm cells. Our study provides experimental basis for the optimization of laser application in assisted reproductive technology, which may reduce the photodamage-induced biosafety risk in the future.

Spatially Resolved Raman Spectroscopic Investigation of Uranyl Fluoride: A Case Study in the Importance of Instrument Optimization.

Raman spectroscopy is an emerging technique for rapid and nondestructive analysis of nuclear materials for forensic and nonproliferation applications as it is a powerful tool for distinguishing multiple chemical forms of materials with similar stoichiometries. Recent developments in spectroscopic software have enabled rapid data collection with high-speed Raman spectroscopic mapping capabilities. However, some uranium-rich materials are susceptible to degradation in humid air and/or laser-induced phase transformations. To mitigate environmental or measurement-related sample degradation of potential samples of interest, we have taken a systematic approach to define optimized data collection parameters for high-throughput measurements of uranyl fluoride (UO2F2), which is an important intermediate material in the nuclear fuel cycle. First, we systematically describe the influence of optical magnification (5× to 100×), laser power, and exposure time on obtained signal for identical particles of UO2F2 and find that at low laser power and exposure times, comparable signal is obtained regardless of optical magnification. Second, we ensure sample integrity during data collection, and third, collect spectroscopic maps that employ optimized parameters to reduce the time required to obtain spatially resolved spectroscopic information. Reductions of 90% and 99% in measurement times are discussed as they relate to differences in resolving spectroscopic features of particles in identical mapping areas. During this work, we found that additional data processing options were needed and thus developed a customized Python script for importing, processing, analyzing, and visualizing Raman spectroscopic map data.

Symmetry-Reduction Enhanced Polarization-Sensitive Photoresponse Based on One-Dimensional van der Waals Materials.

Designing high-performance polarization-sensitive photodetectors is essential for photonic device applications. Anisotropic one-dimensional (1D) van der Waals (vdW) materials have provided a promising platform to that end. Despite significant advances in 1D vdW photonic devices, their performance is still far from delivering practical potential. Herein, we propose the design of high-performance polarization-sensitive photodetectors using unique 1D vdW materials. By leveraging the chemical vapor transport technique, we successfully fabricate high-quality 1D vdW Nb2Pd1-xSe5 (x = 0.29) nanowires. The 1D vdW Nb2Pd1-xSe5 photodetector exhibits a high mobility of ∼56 cm2/(V s) and superior photoresponse performance, including a high responsivity of 1A/W and an ultrafast response time of ∼8 μs under 638 nm illumination. Moreover, the 1D vdW Nb2Pd1-xSe5 photodetector demonstrates excellent polarization-sensitive photoresponse with a degree of linear polarization (DOLP) up to 0.85 and can be modulated by adjusting the gate voltage, laser power density, and wavelength. Those exceptional performance are believed to be relevant to the symmetry-reduction induced by the partial occupation of Pd sites. This study offers feasible approaches to enhance the anisotropy of 1D vdW materials and the modulation of their polarization-sensitive photoresponse, which may provide deep insights into the physical origin of anisotropic properties of 1D vdW materials.

Deep learning-based prediction of thermal residual stress and melt pool characteristics in laser-irradiated carbon steel

Residual stress is a crucial factor that must be managed in laser manufacturing processes. Neglecting it can result in product failure or unsuitability for the intended use. In this article, we present the first surrogate deep learning model based on generative adversarial network that predicts thermal residual stress and melt pool characteristics on the cross-section of laser-irradiated carbon steel. The model was trained using simulation data obtained from the unified momentum equation approach-based numerical model. Our model was designed to predict various aspects of the laser melting process only from three scalar inputs of laser power, beam diameter, and irradiation time at two different points in time (immediately after the laser heating is finished and when the steel is completely cooled down) and successfully predicted the distributions of 12 variables, including residual stress and temperature. Prediction results were not only qualitatively very similar to their ground truth, but also quantitatively accurate with the R2 values ranging from 0.975 to 0.999 and the mean absolute errors between 0.0015 and 0.0126. We demonstrated that complex experiments can be quickly performed using the surrogate model because a single deep learning prediction took only 0.13 s, compared to the 2.5–8 h numerical simulation times.

Effect of process parameters on the mechanical behavior of Ti6Al4V alloys fabricated by laser powder bed fusion method

The parameters used in the production process in laser powder bed fusion (L-PBF) technology, one of the additive manufacturing methods, have a critical effect on the mechanical behavior and density properties of the product and can change the properties of the product. Therefore, this study examined the influence of laser power, scanning speed, hatch spacing and beam rotation angle on the tensile strength, impact energy, surface roughness, and porosity levels of Ti–6Al–4V produced through the L-PBF method. It was observed that the tensile strength changes directly proportional to the laser power. In addition, the tensile strength decreases significantly with a value of 645 MPa obtained at lowest 0.07 mm hatch spacing, 190 W laser power and 900 mm scanning speed. The lowest value of impact energy, with a value of 8.7 J, was reached at a rotation angle of 180°. It has been determined that surface roughness decreases significantly with increasing laser power, while it demonstrates an increase with higher scanning speeds. Surface roughness values of 8.9 μm parallel and 8.35 μm perpendicular to the building direction were achieved at a laser power level of 220 W. Laser power was identified as the most influential factor in determining the porosity ratio, with a high porosity rate 0.48% occurring at 160 W laser power. Furthermore, an increase in scanning speed resulted in a corresponding increase in the porosity rate.

Corrosion property investigation of laser-cladding copper coating in the simulated nuclear waste disposal solution

To explore the efficient corrosion protection for the nuclear waste storage containers, pure copper coatings were successfully prepared on the 20# steel pipe surface using an infrared laser system under different laser powers. The study was conducted on the copper coatings, encompassing the surface quality, defects, microstructure, elemental distribution, phase composition, and corrosion products. The electrochemical and immersion corrosion behavior of the copper coatings in simulated nuclear waste disposal solutions was analyzed. The pure copper coating prepared by 2800 W laser power has fewer amounts and smaller sizes of defects inside the coating with only a slight fusion of Cu and Fe elements at the interface, which exhibits the highest corrosion potential and the smallest self-corrosion current density. During the immersion corrosion process, pores and unfused defects inside the coating, as well as the pits formed by galvanic coupling corrosion, lead to enhanced acidity inside these defects, resulting in a higher corrosion rate. As the immersion time proceeds, the corrosion rate slows down gradually and the content of Cu2+ corrosion product increases significantly.

Influence of laser powder bed fusion parameters on microstructure and mechanical properties of Co–Cr dental alloy

This research investigates the impact of three process parameters of Laser Powder Bed Fusion (LPBF) - laser power, scanning speed, and base plate preheating temperature on the structure and mechanical properties of the EOS CoCr SP2 dental alloy. The LPBF process was used to fabricate dental Co–Cr alloy specimens for microstructural analysis and mechanical properties testing. Light and electron microscopy were used to determine microstructural parameters, including porosity, inclusions, and cracks. The material's chemical composition was analysed by EDS, while XRD and EBSD methods were used to determine the presence of microstructural phases and the crystallographic orientation of individual grains. The mechanical properties were evaluated through a static tensile test (Rp0.2, ε), a toughness test (KVa), and a three-point bending test to determine the flexural strength (Rms). In the microstructure, differences were observed that reflected statistically significant differences in mechanical properties (one-way analysis of variance (ANOVA) and Scheffé post hoc test (α = 0.05)) Using the base plate preheating temperature ϑp = 310 °C with a constant scanning speed v = 900 mm/s in combination with increasing laser power P from 160 W to 250 W the proportion of porosity decreased while the mechanical properties of toughness (KVa) and flexural strength (Rms) increase to maximum values.

The effect of biomimetic laser surface treatment on the wear performance of high manganese steel

High manganese steel finds widespread applications in diverse friction and wear environments. The poor wear resistance of high manganese steel at low stress levels has prompted researchers globally to focus on studying its wear performance. Drawing inspiration from the protective features of pangolin scales, this study employed a pulsed radiation mode CO2 laser to conduct biomimetic laser surface treatment (BLST) on Mn13 high manganese steel. The BLST generated a biomimetic surface morphology consisting of tiny scales on the high manganese steel specimens. Subsequently, the biomimetic laser surface-treated (BLSTed) specimens underwent tests for surface morphology, microstructure, microhardness, and surface roughness. These tests employed metallographic microscopy, scanning electron microscopy, a microhardness tester, and a surface profilometer, respectively. A ring block friction and wear testing machine was utilized to evaluate the wear performance of the BLSTed specimens. Changes in laser power, laser frequency, and laser scanning velocity were found to alter the surface morphology of BLSTed specimens. The experimental results revealed that the microstructure of the BLSTed specimen surface comprised needle-like martensite. The increment in surface hardness and surface roughness of BLSTed specimens contributed to an elevation in their average friction coefficient. Furthermore, the surface hardness and wear performance of BLSTed specimens exhibited varying degrees of improvement with the increase in laser power, laser frequency, and laser scanning velocity. The tiny biomimetic scales, created through BLST, provided protection to high manganese steel akin to the protective scales on the body of pangolins. Finally, the study unveiled the wear resistance mechanism of BLSTed specimens.

Plasmon-driven substitution of 4–mercaptophenylboronic acid to 4-nitrothiophenol monitored by surface-enhanced Raman spectroscopy

Plasmon-driven reactions on plasmonic nanoparticles (NPs) occur under significantly different conditions from those of classical organic synthesis and provide a promising pathway for enhancing the efficiency of various chemical processes. However, these reactions can also have undesirable effects, such as 4-mercaptophenylboronic acid (MPBA) deboronation. MPBA chemisorbs well to Ag NPs through its thiol group and can subsequently bind to diols, enabling the detection of various biological structures by surface-enhanced Raman scattering (SERS), but not upon its deboronation. To avoid this reaction, we investigated the experimental conditions of MPBA deboronation on Ag NPs by SERS. Our results showed that the level of deboronation strongly depends on both the morphology of the system and the excitation laser wavelength and power. In addition, we detected not only the expected products, namely thiophenol and biphenyl-4,4-dithiol, but also 4-nitrothiophenol (NTP). The crucial reagent for NTP formation was an oxidation product of hydroxylamine hydrochloride, the reduction agent used in Ag NP synthesis. Ultimately, this reaction was replicated by adding NaNO2 to the system, and its progress was monitored as a function of the laser power, thereby identifying a new reaction of plasmon-driven −B(OH)2 substitution for –NO2.