Laser Surface Modification Research Articles

Advancements in surface treatments for aluminum alloys in sports equipment

Abstract This review examines recent advancements in surface treatment technologies for aluminum alloys used in sports equipment. We discuss conventional methods like chemical conversion coatings and anodizing, as well as emerging techniques such as plasma electrolytic oxidation, physical vapor deposition, and laser surface modification. The replacement of toxic hexavalent chromium with eco-friendly alternatives is highlighted as a key development. We also explore the potential of smart, self-healing coatings to extend equipment lifespan. Our analysis reveals that while significant progress has been made in enhancing corrosion resistance and mechanical properties, challenges remain in scaling up advanced treatments for industrial implementation. The review concludes that continued innovation in surface treatments will be crucial for improving the performance, safety, and sustainability of aluminum alloys in sports applications, ultimately benefiting athletes and manufacturers alike.

Improving the Bio-Tribological Properties of Ti6Al4V Alloy via Combined Treatment of Femtosecond Laser Nitriding and Texturing

This paper presents a compound laser surface modification strategy to enhance the tribological performance of biomedical titanium alloys involving femtosecond laser nitriding and femtosecond laser texturing. First, high-repetition-rate femtosecond pulses (MHz) were used to melt the surface under a nitrogen atmosphere, forming a wear-resistant TiN coating. Subsequently, the TiN layer was ablated in air with low-repetition-rate femtosecond pulses (kHz) to create squared textures. The effects of the combined nitriding and texturing treatment on bio-tribological performance was investigated. Results show that compared with the untreated samples, the single femtosecond laser nitriding process increased the surface hardness from 336 HV to 1455 HV and significantly enhanced the wear resistance of titanium, with the wear loss decreasing from 9.07 mg to 3.41 mg. However, the friction coefficient increased from 0.388 to 0.655, which was attributed to the increased hardness, roughness within the wear scars, and the formation of hard debris. After combined treatment, the friction coefficient decreased to 0.408 under the optimal texture density of 65%. The mechanisms for the improvement in friction behavior are the reduction in contact area and the trapping of hard debris.

Dual-Function Femtosecond Laser: β-TCP Structuring and AgNP Synthesis via Photoreduction with Azorean Green Tea for Enhanced Osteointegration and Antibacterial Properties.

β-Tricalcium phosphate (β-TCP) is a well-established biomaterial for bone regeneration, highly regarded for its biocompatibility and osteoconductivity. However, its clinical efficacy is often compromised by susceptibility to bacterial infections. In this study, we address this limitation by integrating femtosecond (fs)-laser processing with the concurrent synthesis of silver nanoparticles (AgNPs) mediated by Azorean green tea leaf extract (GTLE), which is known for its rich antioxidant and anti-inflammatory properties. The fs laser was employed to modify the surface of β-TCP scaffolds by varying scanning velocities, fluences, and patterns. The resulting patterns, formed at lower scanning velocities, display organized nanostructures, along with enhanced roughness and wettability, as characterized by Scanning Electron Microscopy (SEM), optical profilometry, and contact angle measurements. Concurrently, the femtosecond laser facilitated the photoreduction of silver ions in the presence of GTLE, enabling the efficient synthesis of small, spherical AgNPs, as confirmed by UV-vis spectroscopy, Transmission Electron Microscopy (TEM), and Fourier Transform Infrared Spectroscopy (FTIR). The resulting AgNP-embedded β-TCP scaffolds exhibited a significantly improved cell viability and elongation of human bone marrow mesenchymal stem cells (hBM-MSCs), alongside significant antibacterial activity against Staphylococcus aureus (S. aureus). This study underscores the transformative potential of combining femtosecond laser surface modification with GTLE-mediated AgNP synthesis, presenting a novel and effective strategy for enhancing the performance of β-TCP scaffolds in bone-tissue engineering.

Advanced Laser Techniques for the Development of Nature-Inspired Biomimetic Surfaces Applied in the Medical Field

This review focuses on the innovative use of laser techniques in developing and functionalizing biomimetic surfaces, emphasizing their potential applications in the medical and biological fields. Drawing inspiration from the remarkable properties of various natural systems, such as the water-repellent lotus leaf, the adhesive gecko foot, the strong yet lightweight spider silk, and the unique optical structures of insect wings, we explore the potential for replicating these features through advanced laser surface modifications. Depending on the nature and architecture of the surface, particular techniques have been designed and developed. We present an in-depth analysis of various methodologies, including laser ablation/evaporation techniques, such as Pulsed Laser Deposition and Matrix-Assisted Pulsed Laser Evaporation, and approaches for laser surface structuring, including two-photon lithography, direct laser interference patterning, laser-induced periodic surface structures, direct laser writing, laser-induced forward transfer, and femtosecond laser ablation of metals in organic solvents. Additionally, specific applications are highlighted with the aim of synthesizing this knowledge and outlining future directions for research that further explore the intersection of laser techniques and biomimetic surfaces, paving the way for advancements in biomedical applications.

تأثير استعمال ليزر النيوديميوم ياك (Nd-YAG) على البنية الدقيقة وصلابة سطح الفولاذ AISI1012

The unique characteristics of the laser beam such as directionality, monochromaticity, and brightness make it a very important tool in the surface treatment engineering. The concentrated heat in the laser beam can be precisely directed toward the processed region on the surface. The laser beam power, beam size, and scanning velocity are easily controlled during the different processing methods. Laser surface modifications of metallic materials, such as laser surface melting, laser surface alloying, and laser cladding are some of the most important methods to improve the mechanical properties of the processed layer on the surface. A pulsed Nd-YAG laser surface melted specimens of low carbon steel with a maximum power of 90W at different processing parameters. The rapid melt and solidification of the treated layer produced a refinement in the microstructure. The original microstructure of this steel (Ferrite + Pearlite) has been transformed to new phases of martensitic and bainitic structures. The melted layer consists of the melted pool, the heat affected zone, and the substrate. The maximum hardness of the laser melted layer is more than 400 HV. The effect of different lasers such as high power CW CO2 laser on the mechanical properties and corrosion resistance of steel alloys will be carried out in future studies. Keywords: Nd-Yag Laser, Laser surface treatment, Microstructure and hardness of AISI1012 steel

Tunable zinc corrosion rate by laser surface modification for implants with controllable degradation direction

Tunable zinc corrosion rate by laser surface modification for implants with controllable degradation direction

Investigation of residual stresses measured during laser surface modification of tantalum coated steel substrates

Investigation of residual stresses measured during laser surface modification of tantalum coated steel substrates

Laser processing effects on Ti−45Nb alloy surface, corrosive and biocompatible properties

The Ti−45Nb (wt.%) alloy properties were investigated in relation to its potential biomedical use. Laser surface modification was utilized to improve its performance in biological systems. As a result of the laser treatment, (Ti,Nb)O scale was formed and various morphological features appeared on the alloy surface. The electrochemical behavior of Ti−45Nb alloy in simulated body conditions was evaluated and showed that the alloy was highly resistant to corrosion deterioration regardless of additional laser surface modification treatment. Nevertheless, the improved corrosion resistance after laser treatment was evident (the corrosion current density of the alloy before laser irradiation was 2.84×10−8 A/cm2, while that after laser treatment with 5 mJ was 0.65×10−8 A/cm2) and ascribed to the rapid formation of a complex and passivating bi-modal surface oxide layer. Alloy cytotoxicity and effects of the Ti−45Nb alloy laser surface modification on the MRC-5 cell viability, morphology, and proliferation were also investigated. The Ti−45Nb alloy showed no cytotoxic effect. Moreover, cells showed improved viability and adherence to the alloy surface after the laser irradiation treatment. The highest average cell viability of 115.37% was attained for the alloy laser-irradiated with 15 mJ. Results showed that the laser surface modification can be successfully utilized to significantly improve alloy performance in a biological environment.

Three-dimensional surface analysis of iron-based materials using synchrotron Mössbauer source

A novel three-dimensional surface analysis system for iron-based solid materials has been developed. This system is composed of a synchrotron Mössbauer source, an X-ray focusing device, a precision stage, a gas flow proportional counter for conversion electron measurements, and multiple multichannel scalers. The performance was evidenced by determining the spatial distribution of the iron oxide abundance on a laser-ablated iron foil surface. This system can be widely utilized as a powerful analytical tool in steel science for corrosion, welding, and laser surface modification.

Double laser two-step process for creating interconnected frame microstructures' superhydrophobic surface with dual scales

Superhydrophobic surfaces have garnered significant attention for their unique wettability and extensive applications across various critical fields. In this paper, a two-step laser processing technique, involving infrared nanosecond laser patterning and ultraviolet picosecond laser surface modification, was employed to fabricate interconnected frame surfaces with dual-scale microstructures on Ti6Al4V substrates. After that, the microstructure surface was chemically modified with 1H,1H,2H,2H-perfluorodecyl trimethoxy-silane to achieve a superhydrophobic surface. An L32 (47) orthogonal experiment was used to analyze the effect of seven main factors (including the structure size, scanning velocity and the fluence, number of scans of infrared nanosecond laser and ultraviolet picosecond laser) on the wettability of the interconnected frame microstructures surface. After optimization, the surface strongly corresponded with the Cassie-Baxter model and demonstrated a water contact angle of 153.22±1.64° and roll-off angle of 4.43±1.70°. The experiments demonstrated that the optimized surface possesses excellent mechanical stability and corrosion resistance. Additionally, the optimized surface exhibits anti-adhesion, effective self-cleaning, and anti-fouling properties, which hold promise for addressing issues of liquid adhesion and dust pollution in industrial machinery.

Improving energy harvesting through femtosecond laser surface modification of PVDF/ZnS composite nanofibrous nanogenerators for electronic applications

Surface modification in ceramic/polymer composites holds paramount importance for electronic devices applications. Laser is a versatile and flexible device for modifying the surface characteristics of various materials. Here, we propose a novel approach to enhance the energy harvesting efficiency of polyvinylidene fluoride (PVDF) and zinc sulfide (ZnS) composite nanofibrous membranes through femtosecond laser surface modification. The electrospinning technique is used to produce nanofibers with a high β-phase content in a single step. The PVDF membrane was further enriched with ZnS nanoparticles to enhance the β-phase content. The membranes were systematically investigated using scanning electron microscopy (SEM), transmission electron microscopy (TEM), Electron Energy Loss spectroscopy (EELS), and Fourier-transform infrared spectroscopy (FTIR) to characterize their morphological and chemical properties. Femtosecond laser was employed to induce controlled surface modifications, resulting in hierarchical microstructures and surface functionalization. The results showed patterned tracks on the fiber surface while preserving its inherent nature. To validate its utility as an energy harvesting device, the membrane's capability was assessed by measuring the open circuit voltage. The results revealing average output voltages for nanogenerators treated with laser fluences of 0.5 J/cm2, 0.7 J/cm2, and 0.9 J/cm2 are 15.6 V, 25 V, and 17 V, respectively. The maximum output voltage is observed for a laser fluence of 0.7 J/cm2, attributed to the deeper structure created, increasing the surface area of contact and deformation in the structure. This work offers promising avenues for enhancing energy harvesting efficiency and expanding the scope of electronic devices such as sensors and actuators.

Microstructure Characterization of Al-alloy AW 5454 Intended for Ecological Laser Hybrid Welding

The article deals with the presentation of the microstructure characterization of Al-alloy AW 5454, which is intended for laser hybrid welding. In the first part, the procedure of laser hybrid welding and comparison to other laser surface modification techniques is presented. In the following, the key methods of metallographic characterization and hardness measurements at selected locations of Al-alloy AW 5454 are presented, which made it possible to carry out a scientific evaluation of the obtained results. The goal of the research was to gain insight into the microstructure of Al-alloy AW 5454, which in the future will make it possible to determine those technological parameters of laser hybrid welding that have the greatest influence on the resulting final microstructure and thus on the properties of the weld.

Modulating the corrosion performance of magnesium alloys through hydroxyapatite coating

Magnesium and its alloys have attracted attention as medical bone implant materials due to their excellent biocompatibility, bone-like mechanical properties, and degradability. However, the clinical application of magnesium is limited by the fact that it corrodes too quickly in body fluids, leading to premature mechanical failure. Surface hydroxyapatite coatings can significantly reduce the initial corrosion of magnesium alloys, but suffer from the problems of non-dense coatings, many defects and poor adhesion strength to the substrate. In this study, we propose femtosecond laser construction of microemulsion cone structures on the surface of magnesium alloys to significantly enhance the densities and thicknesses of the coatings, as well as to improve the bonding strength of the coatings to the substrate, which ultimately reduces the corrosion rate. The corrosion rate of modified hydroxyapatite coating in simulated body fluid is only 0.146 mm/y, and it has the ability to rapidly induce hydroxyapatite mineralization and promote osteoblast proliferation. Furthermore, the surface morphology, chemical composition, and wettability of the laser-modified Mg alloy were analyzed. It was demonstrated that the microstructure and thin oxide layer formed on the surface of the magnesium alloy could provide more sites for HA nucleation, which promotes the deposition and growth of HA and the existence of a mechanical interlocking effect with the substrate. The application of femtosecond laser surface modification represents a rapid and efficacious approach to enhance the quality of hydroxyapatite coatings. This method has successfully controlled the corrosion rate of magnesium alloys with excellent biocompatibility, thereby overcoming potential obstacles to the use of magnesium alloys in clinical applications.

The synergic effect of nanosecond fiber laser and drug-loaded electrospun PVA coating on metallurgical and biological characteristics of Ti-6Al-4 V alloy

Nowadays, titanium-based implants are widely used to replace damaged or missing body organs. Poor chemical bonding with the bone and infection caused by formation of biofilm on the implant surface are the most common problems with them. So, antibacterial properties and osteoblast adhesion improvement have been intended to address these issues. The aim of this research is cell adhesion improvement and prevention of bacterial infection using surface roughness and in-situ antibiotic drug release. Here, micromachining (nanoseconds) laser with a groove distance of 10, 30, and 50 µm, was used to surface modification. X-ray diffraction (XRD), field emission scanning electron microscope (FESEM), hardness, roughness, and wettability tests were used for physical and metallurgical characterization of surface-modified samples to find the optimum laser processing conditions. Roughness has increased as a result of laser surface modification and surface characteristics of alloy exhibit sensitivity to the groove distance. The lower groove distance indicated the higher roughness and wettability. Martensite phase, α phase, and, Ti3Al were observed in the fusion zone. Also, the dissolution of the beta phase has occurred in the fusion and the heat-affected zones. No oxidation was observed. All these occurred without any change in bulk. Then optimized sample surfaces were coated by the vancomycin-loaded polyvinyl alcohol solution using electrospinning process, and toxicity, cell adhesion, and drug release rate were evaluated. The results showed laser surface modification and coating did not hurt cell viability. Modified samples demonstrated high cell adhesion and improvement in drug release compared to the unmodified samples. The drug release rate was extended from 4 h to 25 h for modified samples. So, the modified implants could indicate a sustained release of antibiotics as well.

Superhydrophobic synergistic antibacterial ZrO2-based surfaces with tertiary hierarchical structures fabricated by femtosecond laser texturing and surface modification

Zirconia (ZrO2) is a hard and brittle dental implant material without anti-infective property. This work reports the preparation of a tertiary micro-nano hierarchical structure on a ZrO2 surface via femtosecond laser texturing combined with magnetron sputtering deposition of an Ag layer (Ag/ZrO2), aiming to achieve a superhydrophobic synergistic antibacterial effect. Laser-scanning pitch and Ag layer thickness were systematically optimized for obtaining the tertiary hierarchical structure. The wettabilities, antibacterial properties and durabilities of various ZrO2 and stearic acid modified Ag/ZrO2 (S-Ag/ZrO2) surfaces were further tested and comparatively analyzed. The results revealed that the optimal process parameters were a laser-scanning pitch of 30 μm and an Ag layer thickness of 100 nm. The as-obtained S-Ag/ZrO2 sample displayed a tertiary micro-nano hierarchical structure, which was featured by a periodic regular conical micro-convex structure covered with ZrO2 nano-protrusions and Ag nanoparticles. This structure could not only greatly reduce the solid-liquid contact area to achieve outstanding superhydrophobicity and durability, it could also sustainably release bacteria-killing Ag+ to obtain an antibacterial ratio of 95.1 % and ensure a long-term antibacterial effect. In addition, the optimal S-Ag/ZrO2 sample having this structure showed a PC12 cell survival rate of up to 81.75 %, demonstrating its good biocompatibility. This work may be of great inspiration and reference for the expansion of the use of ZrO2 in dentistry.

Unsatisfactory CMAS resistance of Gd2Zr2O7 thermal barrier coatings and the solution strategy based on laser surface modification

Gd2Zr2O7 thermal barrier coatings (TBCs) were reported to be resistant to calcium-magnesium-aluminum-silicon (CMAS) corrosion, but is still unsatisfactory. In this study, laser surface modification is employed to further improve CMAS resistance of Gd2Zr2O7 coatings. The modification layer consists of a columnar microstructure, which is affected by the modification parameters such as pulse width and beam length. CMAS corrosion resistance of the as-fabricated and laser modified Gd2Zr2O7 coatings is compared. At 1250 °C for 1 h, a reaction layer forms between the Gd2Zr2O7 coating and CMAS which has some ability to suppress molten CMAS penetration. After prolonged corrosion (4 and 10 h), however, the reaction layer continues to thicken until no CMAS remains, which largely consumes the coating thickness and degrades the coating performance. Laser surface modification has solved this problem effectively due to its ability to reduce the melt penetration channels. Hence, laser-modified Gd2Zr2O7 coatings have enhanced CMAS resistance.

Surface microstructure and corrosion characterization of AZ31 magnesium alloys fabricated by laser surface-modification

This study aimed to improve the corrosion resistance of Mg alloys, and to this end, AZ31 Mg alloy was subjected to laser surface re-melting using a fiber laser. Subsequently, a comparative analysis was conducted on the microstructures of the re-melted surfaces under various laser power settings, and the influence of laser surface re-melting on corrosion characteristics was investigated through a potentiodynamic polarization test. The test results show that laser surface re-melting produced a distinct reduction in the crystallite size of magnesium, ranging from 11.23–15.80 μm within the laser-melted layers. The maximum melted layer thickness of 820 μm was achieved with a laser power of 2100 W. The process of laser surface re-melting notably heightened the hardness, particularly as the power increased, which was attributed to swift solidification. The most noteworthy hardness measurement of 92.1 HV0.02 was recorded at 2100 W. Thus, the study shows that laser surface re-melting significantly enhances the corrosion resistance of Mg alloys, primarily owing to the formation of a corrosion product. The smaller grain size on the surface contributes to the formation of a dense product film.

Enhancing interfacial bond strength between PEEK and inkjet-printed silver film through laser surface modification for additive manufacturing of electronics

Electronic 3D printing is a very promising technology, which is widely used in the manufacturing of conformal antennas, flexible electronics and sensors. Polyether ether ketone (PEEK) is one of the most popular substrate materials for electronic 3D printing due to its superior fatigue resistance, heat tolerance, chemical resistance, and mechanical properties. However, the deficient bond between the PEEK substrate and the conductive ink leads to the peeling and shedding of the conductive pattern. This paper investigated the enhancement of the bond strength between the PEEK substrate and the conductive layer through PEEK surface modification. A 355 nm ns solid-state laser was used to treat the PEEK surface with different values of laser scanning spacing (S) and spot overlap rate (R). The surface microstructure, surface roughness, wettability, and functional groups of the treated substrates have been measured. Then the nanoparticle silver ink was printed and cured on the treated substrate. After that, the bonding strength was measured using a pull-off adhesion tester. Results showed that regular grooves were generated and the content of active oxygen atoms was increased on the PEEK surface through laser modification. The mechanical interlocking between the grooves and silver particles and hydrogen bonds induced by the active oxygen atoms and the hydroxyl groups contribute to the enhancement of bond strength between PEEK and silver film. The bond strength for the laser treated PEEK reached the maximum of 1.9 MPa, which was 413.51% higher than that of the untreated PEEK. The laser modification can effectively enhance the interfacial bond strength for additive manufacturing of reliable electronics.

Comparison of Zirconia Implant Surface Modifications for Optimal Osseointegration.

Zirconia ceramic implants are commercially available from a rapidly growing number of manufacturers. Macroscopic and microscopic surface design and characteristics are considered to be key determining factors in the success of the osseointegration process. It is, therefore, crucial to assess which surface modification promotes the most favorable biological response. The purpose of this study was to conduct a comparison of modern surface modifications that are featured in the most common commercially available zirconia ceramic implant systems. A review of the currently available literature on zirconia implant surface topography and the associated bio-physical factors was conducted, with a focus on the osseointegration of zirconia surfaces. After a review of the selected articles for this study, commercially available zirconia implant surfaces were all modified using subtractive protocols. Commercially available ceramic implant surfaces were modified or enhanced using sandblasting, acid etching, laser etching, or combinations of the aforementioned. From our literature review, laser-modified surfaces emerged as the ones with the highest surface roughness and bone-implant contact (BIC). It was also found that surface roughness could be controlled to achieve optimal roughness by modifying the laser output power during manufacturing. Furthermore, laser surface modification induced a very low amount of preload microcracks in the zirconia. Osteopontin (OPN), an early-late osteogenic differentiation marker, was significantly upregulated in laser-treated surfaces. Moreover, surface wettability was highest in laser-treated surfaces, indicating favorable hydrophilicity and thus promoting early bone forming, cell adhesion, and subsequent maturation. Sandblasting followed by laser modification and sandblasting followed by acid etching and post-milling heat treatment (SE-H) surfaces featured comparable results, with favorable biological responses around zirconia implants.

Superhydrophobic Surface of Ti6Al4V using Direct Nanosecond Laser Texturing

This study aims to investigate the impact of laser parameters, including laser power, laser frequency, laser scan speed, and hatches line distance, on Ti6Al4V to create superhydrophobic surfaces. Surface profile and roughness play vital roles in achieving superhydrophobicity, and existing laser surface modification methods are time-consuming and lack subsequent steps for optimizing desired characteristics. A factorial design was implemented, varying laser power (12 and 18 W), laser frequency (40 and 60 kHz), laser scan speed (180 and 220 mm/s), and hatch line distance (0.25 and 0.45 mm). Surface morphology and topological properties were analyzed for surface characterization. The results demonstrate a significant increase in surface roughness profiles such as Sa and Sq by 6 and 5 times, respectively, compared to the untextured surface. These modifications also led to enhancements in surface topological properties. Regression analysis revealed the importance of controlling the surface profile for achieving superhydrophobicity. Statistical analysis indicated that laser power, laser frequency, and laser speed were the most significant parameters contributing to superhydrophobicity. The optimum laser parameters for superhydrophobic surfaces were determined as 18 W laser power, 40 kHz laser frequency, and 220 mm/s laser scan speed. In conclusion, this study emphasizes the critical role of surface topological properties in creating superhydrophobic surfaces on Ti6Al4V. Laser texturing techniques successfully improved surface roughness and profile, facilitating the development of superhydrophobic surfaces. These findings offer valuable insights for advancing surface engineering, with potential applications in the aerospace, automotive, and biomedical industries.