Laser Texturing Research Articles

Photocatalytic and antibacterial activity properties of Ti surface treated by femtosecond laser–a prospective solution to peri-implant disease

Laser texturing seems to be a promising technique for reducing bacterial adhesion on titanium implant surfaces. This work aims to demonstrate the possibility of obtaining a functionally orientated surface of titanium implant elements with a specific architecture with specific bacteriological and photocatalytic properties. Femtosecond laser-generated surface structures, such as laser-induced periodic surface structures (LIPSS, wrinkles), grooves, and spikes on titanium, have been characterised by XRD, Raman spectroscopy, and scanning electron microscopy (SEM). The photocatalytic activity of the titanium surfaces produced was tested based on the degradation effect of methylene blue (MB). The correlation between the photocatalytic activity of TiO2 coatings and their morphology and structure has been analysed. Features related to the size, shape, and distribution of the roughness patterns were found to influence the adhesion of the bacterial strain on different surfaces. On the laser-structurised surface, the adhesion of Escherichia coli bacteria were reduced by 80% compared to an untreated reference surface.

An innovative process chain for the production of antibiofouling polymer parts using ultrafast laser texturing

Polymers are versatile materials widely used in various industries, with significant applications in biomedicine where biofouling on polymer surfaces presents major health and economic challenges. Biofouling, initiated by bacterial adhesion, can be mitigated by modifying surface properties through laser micro- and nano-texturing, an approach that offers advantages over chemical treatments. This study introduces an economical mass production process for textured polymeric components using injection molding to replicate hierarchical textures. Testing revealed that all textured samples significantly reduced bacterial adhesion compared to untextured surfaces across different designs and bacteria types after 24 h of culture. The study examined factors like wettability, nanoscale roughness, and pattern dimensions to explain these outcomes, comparing them with existing studies. Despite all textured samples showing decreased wettability and roughness, these factors alone did not ensure reduced bacterial adhesion. The most effective anti-adhesive performance was observed in surfaces with parallel ridge patterns, which segmented the surface into isolated areas that limited bacterial interaction and hindered micro-colony formation, highlighting the importance of specific surface patterning in combating biofouling.

Superhydrophilic Surface Creation and Its Temporal Transition to Hydrophobicity on Copper via Femtosecond Laser Texturing

We analyzed a process to fabricate a superhydrophilic surface on copper by forming various laser-induced periodic surface structures (LIPSS) using a Ti/sapphire femtosecond laser. For these structured surfaces, the correlation between the surface structure and the wetting characteristics was analyzed by scanning electron microscopy, atomic force microscopy, and contact angle (CA) measurement. X-ray photoelectron spectroscopy (XPS) was also employed to analyze variation of the elemental composition of the surfaces. The laser treatment produced micro/nanostructures composed of ripples whose length and width are in microscale and nanoscale, respectively. At specific conditions, the CA of a water droplet was reduced to less than 1°. The superhydrophilcity is attributed to the effect of nanoholes and nanoclusters, which consist of copper (II) oxide and copper hydroxide, having a hydrophilic effect on LIPSS. However, the pristine superhydrophilic surface spontaneously became hydrophobic after being exposed to air at room temperature for about 10 days. According to XPS analysis, the surface’s transition to hydrophobic is attributed not only to the decomposition of Cu(OH)2 but also to the adsorption of oxygen molecules and/or airborne organic molecules containing carbon, which further influences the wettability.

The impact of pulsed Nd:YAG laser on the surface of n-Si and photo-electrical performance of silicon solar cells

Texturizing the surface of a silicon solar cell enhances performance by reducing reflection losses. Pyramidal texturization via wet chemical etching is standard in manufacturing, while plasma etching is often used for vertical hole texturization. Laser texturization offers a chemical-free, user-friendly alternative to plasma etching. Infrared (IR) transmission studies indicate that laser-textured samples transmit more IR light through n-Si than normally textured samples, suggesting that vertical grooves from laser texturization allow deeper light penetration. Analyses using cross-sectional Field Emission Scanning Electron Microscopy (FESEM), Energy Dispersion x-ray (EDX), and Energy Dispersive Spectroscopy (EDS) demonstrate the effects of laser texturization on the front surface of textured n-Si wafers. However, silicon solar cells with laser-textured surfaces demonstrated lower conversion efficiencies (1.20% to 4.30%) compared to conventionally textured cells (14.30%). The short-circuit current density (JSC) was also lower in laser-textured cells, below 17 mA cm−2, compared to 34.44 mA cm−2 in normally textured cells. At the same time, higher laser power (114 W) during texturization also led to the lowest JSC and open-circuit voltage (VOC), indicating that laser texturization may introduce defects and dislocations that degrade Si properties.

Diamond coatings on copper surfaces through interface engineering

To address the challenges posed by the significant thermal stress and limited affinity of diamond coatings on copper (Cu) substrates, we developed a method combining femtosecond (fs) laser texturing with the application of a nickel (Ni) interlayer. This technique was utilized for adhesion enhancement of diamond coatings on Cu. By varying the deposition duration and microgrid depth through multiple fs laser scanning passes, it is possible to attain well-adhered diamond coatings on Cu substrates. These coatings demonstrate an outstanding quality factor of 93.4% and an average grain size of 5.5 μm. The enhanced adhesion results from the synergistic reinforcement of the mechanical interlock and anchoring mechanisms facilitated by the textured surface, further bolstered by the presence of the Ni interlayer. Moreover, the shape of the texture significantly influences the deposition outcome. Single-crystal diamonds with an average grain size of 10 μm were achieved on sharp microgrids at a substrate temperature of 550 °C. This work is expected to offer a general approach for deposition of diamond coatings on metallic materials with enhanced adhesion.

Influence of laser texturing on the properties of fusion joints between aluminum alloys and carbon fiber reinforced thermoplastic composites

Laser texturing is an effective method to enhance the fusion joining of aluminum alloy (Al) to carbon fiber reinforced thermoplastics composite (CFRTP). The enhancement effect is related to the morphology and spacing of the microstructures on Al surface. However, because of the correlation between the morphology and the spacing of the microstructures, excessive dense microstructures change the morphology, leading to a reduction in the enhancement effect, while sparse microstructures are also difficult to significantly enhance the joint. To this end, this paper proposes an improved laser texturing process to enhance fusion joints, through the investigation of the recast layer formation process during laser texturing on the Al surface, which comprehensively reveals the synergistic effects of microstructural morphology and spacing on joint properties. The results indicated that the increase of the number of laser processes and the microstructure spacing increased the height of the recast layer, with the difference that the microstructure spacing had less effect after increasing to a certain value. With the increase of microstructure spacing, the morphology of the microstructure on the Al surface transformed from the serrated microstructure to the double-scale microstructure, and finally to the independent microstructure, affected by the recast layer on sides of the microstructure. Once the dual-scale microstructures were formed on the Al surface, the shear strength of the Al/CFRTP fusion joint was the highest with a value of 25.05 MPa. The findings could provide a basis for laser texturing pretreatment for fusion joining.

Molten CMAS resistance strategy for PS-PVD TBCs based on laser textured and Al-modified bionic structure

Plasma spray-physical vapor deposition (PS-PVD) is a promising third-generation thermal barrier coatings (TBCs) technique. Feather-like columnar TBCs with excellent strain tolerance and low thermal conductivity can be achieved using PS-PVD. However, molten CMAS (CaO–MgO–Al2O3–SiO2) can penetrate coatings and accelerate PS-PVD TBCs failure due to the feather-like columnar structure. Hence, a strategy is proposed to alleviate molten CMAS corrosion. The super-hydrophobicity structure is fabricated via laser texturing on the surface of PS-PVD TBCs to repel molten CMAS wetting and spreading. Then, a thin layer of the Al-film is deposited on the laser-textured surface. Next, the Al-modified layer is in situ synthesized after vacuum heat treatment, preventing the infiltration of molten CMAS into the TBCs and reducing the coating damage. The results show that the contact angle of laser textured and Al-modified PS-PVD TBCs (LT-Al) at room temperature increased from 12.3° to 168.8°. The wetting and spreading behavior of molten CMAS of as-sprayed (AS), laser textured (LT), and LT-Al coatings is observed in situ at 1230 °C for 1800 s. The LT-Al coatings exhibited excellent CMAS corrosion resistance, attributed to the laser-textured micro-nano structures and Al-modified layer protection. The findings may be an effective approach for solving the disadvantage of PS-PVD feather-like columnar structure TBCs.

Evaporation of a water droplet on composite materials Cu-SiC, Cu/G and alloy AlMg3: Modeling the wettability of a metal-matrix composite with MDS

Composite materials are widely used in technology. The choice of exact composite material depends on its purpose, functional properties, stability of parameters over time, and specific conditions of use. In this work, the wettability of various materials was studied. The materials used were processed in two ways: polishing and laser texturing with and without craters. The surface wettability using molecular dynamics methods was modeled when changing the concentration of the reinforcing component in the composite. The crystalline grain orientation and surface roughness of the Cu-SiC composite after texturing is different from Cu, which is important to consider when modeling the wettability. The sensitivity of the wettability of various materials to the surface temperature (Δθ0/ΔTw) was studied experimentally. The maximum sensitivity of the contact angle to temperature was found for the superhydrophobic surface. The minimum sensitivity was observed for polished AlMg3 surface. Power-law dependences of the evaporation rate of water droplet on the contact angle were obtained for various materials in the temperature range of 25–90 °С. As the droplet diameter increases, the influence of the wetting diameter on the evaporation rate decreases, while that of convection increases. The data obtained can be useful for the development of composite materials technologies and optimization of their functional properties.

Anti-Corrosion Flocking Surface with Enhanced Wettability and Evaporation.

The corrosion protection of tool steel surfaces is of significant importance for ensuring cutting precision and cost savings. However, conventional surface protection measures usually rely on toxic organic solvents, posing threats to the environment and human health. In this regard, an integrated process of laser texturing and electrostatic flocking is introduced as a green anti-corrosion method on a high-speed steel (HSS) surface. Drawing from the principles of textured surface energy barrier reduction and fiber array capillary water evaporation enhancement, a flocking surface with a synergistic optimization of surface wettability and evaporation performance was achieved. Then, contact corrosion tests using 0.1 mol/L of NaCl droplets were performed. Contact angles representing wettability and change in droplet mass representing evaporation properties were collected. The elements and chemical bonds presented on the corroded surfaces were characterized by X-ray photoelectron spectroscopy (XPS). The results revealed that the flocking surface exhibited the lowest degree of corrosion when compared with smooth and textured surfaces. Corrosion resistance of the flocking surface was achieved through the rapid spread and evaporation of droplets, which reduced the reaction time and mitigated electrochemical corrosion. This innovative flocking surface holds promise as an effective treatment in anti-corrosion strategies for cutting tools.

An investigation into the use of incoherent UV light to augment IR nanosecond pulsed laser texturing of CFRP composites for improved adhesion

The preparation of Carbon Fibre Reinforced Polymers (CFRP) surfaces for adhesive bonding has been widely reported. Such reports include laser texturing using both near-infrared (IR) lasers and ultraviolet (UV) lasers. In this report, we present, for the first time, findings showing that surface treatment of CFRP using incoherent UV light, at 254 nm wavelength, can increase the adhesive bonding strength of CFRP by 75 % compared to non-treated samples. It is also around 10 % stronger than NIR laser-textured samples. However, combination treatments, where the UV irradiation is conducted either before or after laser texturing did not give a significant benefit over the laser-textured samples. A germicidal 46 W 254 nm UV lamp was used for the UV light treatment, while an IR nanosecond pulsed fibre laser operating at 1064 nm was used for the laser texturing treatment. The material tested was an autoclave-cured T700 CFRP composite.The wettability of the treated CFRP surfaces and the adhesive bonding were quantitatively assessed. This study concludes that low-cost incoherent UV treatment effectively reduces the water contact angle of the CFRP surface and activates CFRP surfaces. All treatments led to bonding strengths at least 50% greater than for the untreated surfaces.The predominant failure mode for UV-treated samples was Cohesive Substrate Failure (CSF), indicating that the adhesion strength exceeded the interlaminar shear strength of the CFRP material. All samples treated with the laser (including combined treatment with UV) exhibited Light Fibre Tear Failure.

LASER SURFACE TEXTURING TO IMPROVE THE TRIBOLOGICAL PROPERTIES OF Ti ALLOYS

Friction and wear requirements in the aerospace/space industry or in biomedical applications are governed by life-limiting challenges: the wide range of contact stresses and sliding speeds in movable parts and operating conditions such as extreme temperature changes, humidity and abrasive wear caused by electrostatically attracted dust. Surface modification by laser texturing has been introduced to adjust the surface characteristics of the base material to overcome its tribological limitations of use via different surface topographies, allowing for the ability of lubricant retention. Laser surface texturing is therefore effective in enhancing the tribological performance of materials via controllable surface topographies acting as traps for wear debris and lubricant reservoirs, leading to reduced abrasion. This paper reviews the tribological behaviour of a laser-textured Ti6Al4V alloy with different textures: lines, crosshatch and dimples. The fiction and wear characteristics for dry sliding are discussed and compared.

Innovative construction of high-strength tungsten-copper joint through laser texture and nano-activation

Tungsten-copper (W-Cu) joints hold immense promise as plasma-facing materials in fusion reactors. However, the inherent immiscibility of W-Cu poses significant challenges in joint fabrication. Here, we introduce an innovative methodology that incorporates laser texture, W surface nano-activation, and subsequent diffusion bonding to fabricate W-Cu joints. Remarkably, the joints achieved exhibit unparalleled mechanical properties, with a peak tensile strength of 201 MPa and a shear strength of 141 MPa, surpassing previously reported W-Cu joints. To gain insights into the underlying mechanisms, we conducted a multiscale analysis utilizing scanning electron microscopy (SEM), high-resolution transmission electron microscopy (HRTEM), and density-functional theory (DFT) calculations. Our findings reveal a unique embedded structure and a metallurgically bonded interface at the W-Cu junction. Furthermore, the diffusion zone at the interface exhibits a fascinating hybrid crystal structure, maintaining a body-centered cubic (BCC) structure in certain regions while displaying a tetragonal crystal structure (with lattice parameters a=b=2.8617, c=3.44) in others. This tetragonal crystal structure formation within the W-Cu diffusion zone remains unexplored in previous literature. In summary, this novel W-Cu bonding approach not only offers a cutting-edge solution for modern manufacturing and fusion energy applications but also lays a solid theoretical foundation for understanding the intricate microstructure-property relationships in W-Cu systems.

Enhancing Bactericidal Properties of Ti6Al4V Surfaces through Micro and Nano Hierarchical Laser Texturing.

Orthopedic and dental implants made from Ti6Al4V are widely used due to their excellent mechanical properties and biocompatibility. However, the long-term performance of these implants can be compromised by bacterial infections. This study explores the development of hierarchically textured surfaces with enhanced bactericidal properties to address such challenges. Hierarchical surface structures were developed by combining microscale features produced by a microsecond laser and superimposed submicron features produced using a femtosecond laser. Microscale patterns were produced by the pulsed laser surface melting process, whereas submicrometer laser-induced periodic surface structures were created on top of them by femtosecond laser processing. Escherichia coli bacterial cells were cultured on the textured surface. After 24 h, a staining analysis was performed using SYTO9 and PI dyes to investigate the samples with a confocal microscope for live dead assays. Results showed bacterial colony formation onto the microscale surface textures with live bacterial cells, whereas the hierarchical surface textures display segregated and physically damaged bacterial cell attachments on surfaces. The hierarchical surface textures showed ∼98% dead bacterial cells due to the combined effect of its multiscale surface features and oxide formation during the laser processing steps. The efficacy of hierarchical surface textures in enhancing the antibacterial behavior of Ti6Al4V implants is evident from the conducted research. Such laser-based surface treatments can find potential applications in different industrial sectors.

A high bonding tensile strength of CFRP ultrafast laser surface texturing method for surface damage repair

Carbon fiber reinforced polymer composite (CFRP) has a wide range of applications in aerospace, but it can cause varying degrees of damage in harsh service environments. Seeking a high-performance repair method is an effective way to save costs and ensure the service performance of CFRP components. In this study, a high bonding tensile strength of CFRP surface ultrafast laser texturing method for damage repair was proposed, which achieved complete removal of surface resin while retaining intact exposed fiber filaments. The difference in groove processing under unidirectional scanning and cross-scanning modes at different angles was explored. When the groove spacing was 0.2 mm and 0.4 mm, the surface resin was completely removed, the carbon fiber remained intact, and no debris was inside the groove. The groove morphology has a significant impact on the contact zone of the surface, which in turn affects the mechanical properties of the bonded joint. Cross-scanning can effectively improve surface roughness to increase the contact surface area. However, there is more fiber breakage, manifested as a groove weakening effect, which limits the improvement of bonding strength. In the 0° unidirectional scanning mode, the tensile performance of the joint is the best, improved by 61.6 % compared to manual processing.

Investigation of open air and under water laser surface texturing on surface roughness and wettability of Al-Mg alloy

Aluminum-Magnesium (Al-Mg) alloy is widely used in aerospace and marine related applications due to its high corrosion resistance, tensile strength and ductility properties. However, due to hydrophilic nature, its applications are restricted in areas where water absorption may cause problems like corrosion. In this research work, high speed laser texturing was carried out on Al-Mg alloy (AA5754) to improve hydrophobic properties of the material surface. Four different types of pattern, namely lines, grids, concentric circles and concentric rectangles were created on the material surface using a nanosecond fiber laser. Scanning speed was varied at two levels i.e., 500 mm/s and 1000 mm/s. Line density of texture designs was also varied at two levels of 10 lines per mm and 15 lines per mm. The texturing process was carried out in two different processing environment namely open air and in underwater condition. Distilled water with 1 mm thickness above the surface was used during underwater texturing condition. Surface morphology, surface roughness and wettability of all the surfaces were studied for all the experimental conditions. It was observed that lower scanning speed of 500 mm/s resulted in higher values of surface roughness and contact angles. Also, larger texture density leads to lower surface roughness and contact angles for all the pattern designs. Among all the studied texture patterns, grid structures, textured at 500 mm/s of scanning speed resulted in largest surface roughness and surface hydrophobicity.

Combining Ultrafast Laser Texturing and Laser Hardening to Enhance Surface Durability by Improving Hardness and Wear Performance

Aluminum alloy 7075 is utilized widely across marine, aerospace, and automotive sectors. However, its surface wear resistance has hindered its application in certain tribological environments. Addressing this challenge, the current study examines a hybrid laser method to increase surface wear resistance by combining two techniques: ultrafast laser texturing and laser‐based surface hardening. Ultrafast laser processing is conducted using 3 W laser power, 100 kHz pulse repetition rate, 4 mm s−1 scanning speed, and three different scan patterns. After the texturing operation, laser‐based surface hardening is then performed on these textures using a continuous wave laser. The laser heat treatment is conducted using laser powers of 400 and 500 W with three different scan speeds of 1, 2, and 3 mm s−1. Microhardness evaluations show a notable increase in hardness, with the hardest sample exhibiting a 17.8% increase compared to the pristine sample. The laser‐textured and laser heat‐treated samples exhibit a significant reduction in the average coefficient of friction and wear volumes compared to samples that were laser‐textured but not laser heat‐treated. The investigated laser processing strategy offers a promising approach for surface modification, enhancing both mechanical properties and wear resistance of aluminum alloy 7075 surfaces.

Dynamics of acoustically levitated ice impacts on smooth and textured surfaces: Effects of surface roughness, elasticity, and structure

Atmospheric ice collisions on exposed outdoor infrastructure are a rarely explored surface design challenge. A primary obstacle to realistic ice particles in the laboratory setting is freezing a droplet without a solid surface present and then allowing it to impact a substrate without physical intervention. Using acoustically levitated ice formation with subsequent release onto a controlled area, a third class of ice-countering system called “ice-impacting” is introduced. Stainless steel 316 (SS), epoxy resin-coated (ER), and laser-textured (LT) surfaces with known surface roughness, hardness, and structural characteristics were subjected to 40 ice droplet impacts each. The impact effect on surface properties and the effect of these properties on solid-solid interfacial impact dynamics, in turn, were examined using an analysis framework based on fundamental conservation laws. Elasticity was the most significant factor in droplet behaviour as the ER surface exhibited rebounding for 78 % of impacts, nearly double the rates of the stainless steel surfaces. However, surface roughness also played a role, particularly for droplets with rotational motion, as immobilization occurred for 66 % of impacts on the rougher LT surface. Moreover, the nanostructures on that textured surface resulted in droplet redirection perpendicular to the surface directionality. In contrast, the other surfaces experienced no consistent change in rebound angle. Elasticity also affected momentum retention: the ER surface had a translational restitution coefficient of 0.32 compared to 0.17 for the SS/LT surfaces. Surface roughness was a predominant aspect of energy retention, as the LT surface had a translational-to-rotational energy transfer coefficient of 0.07 (0.23 for the smoother surfaces), resulting in an overall energy retention coefficient of 0.09 compared to 0.28 for the SS and ER surfaces on average. The results show that the interplay between elasticity, roughness, and structure at a dynamic solid-solid interface must be considered to optimize their effectiveness when designing ice-countering surfaces.

Experimental study of picosecond laser-assisted grinding of GH4169 nickel-based superalloy

The nickel-based superalloy GH4169 exhibits excellent thermal stability and fatigue resistance, making it widely utilized in the aerospace and marine manufacturing industries. However, the high mechanical strength of the nickel-based superalloy GH4169 leads to issues such as high grinding forces during grinding and poor surface morphology of the material after grinding. To improve the processing quality of GH4169, this study employs ultrafast pulse laser texturing to create two distinct biomimetic structures on its surface. The study explores the impact of laser parameters on both the recast layer and surface hardness. Subsequently, grinding experiments are conducted on both structured and non-structured workpieces. The grinding forces and surface roughness during grinding are analyzed, and the surface morphology of the workpiece after grinding and the corrosion resistance of the material are also tested. According to the test results, the grinding forces of the fishbone-like and nacre-like structure workpieces are reduced compared with those of the non-structured workpieces, and the maximum tangential grinding forces are reduced by 38.54 % and 35.98 %, and the maximum normal grinding forces are reduced by 30.24 % and 29.6 %, respectively. In addition, the corrosion resistance of the surface of the structured workpieces after grinding is better compared to the non-structured workpieces, and the best corrosion resistance is obtained for the fishbone-like structure.

Picosecond Laser Texturing of Al current collector to improve cycling performances and simplify recycling of Lithium-ion batteries

Lithium-ion batteries (LIBs) are one of the main energy storage technologies currently in use and recycling them offers significant economic, environmental, and material recovery benefits. Despite various recycling processes, separating the metallic current collector from the electrode composite film remains a crucial challenge. In this framework, the present study focuses on laser texturing of aluminum current collectors (CCs) to introduce a microscale surface architecture. The asymmetric surface pattern facilitated a controlled and directional adhesion, enhancing attachment to manage the significant volume variation of the active material (NMC811) during charging and discharging cycles. Additionally, it enabled an easy separation of the electrode composite layer from the current collector, during recycling, by applying a force in a specific direction. As a result, the laser-treated cathodes displayed low electrode polarization and increased cycling performances, with a capacity retention of 67.6 % after 300 cycles at 1C, thanks to the increased interfacial adhesion that reduced the active material delamination from the current collector upon cycling.

Study on the Tribological Properties of Multilayer Concentric Hexagonal Laser Texturing on Rubber Surfaces of Screw Pumps.

Given the friction and drag reduction effects observed in various biological hexagonal structures in nature, a new design was implemented on the rubber surface of the stator of a submersible screw pump. This design featured a multilayer concentric hexagonal groove structure. Furthermore, a composite multilayer hexagonal structure integrating grooves and pits was also developed and applied. This study investigated the influence of groove layer number, groove depth, pit depth, and multilayer hexagonal groove texture arrangement on the rubber surface flow characteristics. Additionally, the pressure field state, the degree of influence on the oil film-bearing capacity, and the biomimetic and hydrodynamic lubrication theories were tested using the finite element analysis method. Tribological experiments were conducted on nanosecond laser-processed rubber textures under simulated liquid lubrication conditions, reflecting actual shale oil well experiments. These experiments aimed to investigate the influence of multilayer hexagonal shape parameters on the tribological characteristics of the stator-rotor friction pair of a submersible screw pump. The results indicated that with a constant overall size, a multilayer hexagonal structure with ~0.1 mm groove depth enhanced the oil film-bearing capacity, providing significant friction and drag reduction. For composite textures, a deeper pit depth within the study area enhanced the oil film-bearing capacity. Furthermore, a gradient arrangement of groove textures featuring wider outer grooves and shallower depth exhibited superior performance in terms of bearing capacity.