Local Energy Input Research Articles

Influence of complex geometries on the properties of laser-hardened surfaces

Laser surface hardening provides for many advantages in terms of flexible production due to very localized and controlled energy input into the material. Laser processing offers the possibility to treat surfaces in order to locally strengthen the areas that are prone to fatigue cracking. It is well known that laser energy absorption depends on many parameters, e.g., the surface structure and the surface orientation. The incident angle of the laser beam plays a key role in this regard. When complex geometries like crankshaft fillets are treated, the surface cannot be considered a series of flat surfaces. Obviously, this leads to locally varying degrees of energy absorption. In the present work, curved surface structures were chosen in order to analyze the impact of the geometrical characteristics on surface and subsurface material properties after laser treatment. Microstructure evolution generally was found to be similar for flat and curved geometries. However, even if higher absorption in the groove due to the illumination at larger incident angles was expected, the outer parts of the curved geometry were not fully hardened. Thus, the increased effective length of the complex geometry-treated and the larger heat-affected volume are expected to have a more dominant influence on the final appearance of the subsurface microstructure. Eventually, for austenitization of the complete illuminated surface volume, the energy density needs to be increased.

Energy storage in steady states under cyclic local energy input.

We study periodic steady states of a lattice system under external cyclic energy supply using simulation. We consider different protocols for cyclic energy supply and examine the energy storage. Under the same energy flux, we found that the stored energy depends on the details of the supply, period, and amplitude of the supply. Further, we introduce an adiabatic wall as an internal constraint into the lattice and examine the stored energy with respect to different positions of the internal constrain. We found that the stored energy for constrained systems is larger than its unconstrained counterpart. We also observe that the system stores more energy through large and rare energy delivery, comparing to small and frequent delivery.

Experimental observation of stress formation during selective laser melting using in situ X-ray diffraction

Despite the ongoing success of metal additive manufacturing and especially the selective laser melting (SLM) technology, process-related defects, distortions and residual stresses impede its usability for fracture-critical applications. In this paper, results of in situ X-ray diffraction experiments are presented that offer insights into the strain and stress formation during the manufacturing of multi-layer thin walls made from Inconel 625. Using different measuring modes and laser scanning parameters, several experimental observations are discussed to validate and extend theoretical models and simulations from the literature. As a sample is built-up layer by layer, the stress state changes continuously up until the last exposure. The localized energy input leads to a complex stress field around the heat source that involves alternating tensile and compressive stresses. The correlation of temperature and yield strength results in a stress maximum at a certain distance to the top layer. The present study demonstrates the potential of high-energy synchrotron radiation diffraction for in situ SLM research.

Improving process reliability by means of detection of weld seam irregularities in copper via thermographic process monitoring

Laser beam welding plays an important role in automotive industry as it offers a number of advantages. These include contactless joining, localized energy input, thermally and mechanically durable welds and low electrical contact resistance of the bonded connections. The latter is exploited in the laser beam welding of copper contacts as used for electrical connections in e-mobility. However, copper entails a higher susceptibility to seam defects due to the metallurgical properties compared to, for example, car body materials which in many cases are processed by laser beam as well. In order to meet the high standards of the automotive industry an inline validation of the connections is essential. A suitable method is the monitoring of the welding process by means of thermography which has already proven itself for other metals and joining techniques but has not yet been investigated in detail for laser beam welding of copper. Consequently, this paper deals with the possibilities of thermographic process monitoring in laser beam welding of copper components. It examines the extent to which defects can be registered; so far pores have been detected reliably up to a minimal diameter of 0.5 mm.

Microstructure and fatigue performance of SLM-fabricated Ti6Al4V alloy after different stress-relief heat treatments

Abstract The main interest in Additive Manufacturing (AM) technology relates to its ability to produce complex components with relatively reduced weight that are difficult to produce or cannot be produced by other conventional technologies. Selective laser melting (SLM) is extensively used, as one of the AM technologies to fabricate metallic parts. This advanced method allows to produce various parts with complex geometries with high three-dimensional (3D) accuracy from fusion powders in a layer-by-layer style. Ti6Al4V alloy is a widely used material for structural applications in aerospace and biomedical due to high specific fatigue strength. SLM processing makes this alloy attractive when weight reduction is a design objective. The SLM Ti6Al4V microstructure is influenced by process parameters and build orientation. The localized high energy input during very short interaction times leads to the formation of very fine structures and to the generation of internal stresses. Therefore, the SLM parts are heat treated to decrease or completely remove residual stresses. The present study aims at evaluating the effect of stress-relief heat treatments on the microstructure, the mechanical properties and the fatigue performance of SLM Ti6Al4V alloy. Ti6Al4V alloy specimens were manufactured according to the SLM process with an EOS M290 system. Post fabrications heat treatments at different temperatures (i.e. 740˚C vs. 900˚C) resulted in different structure and mechanical properties that were identified and measured. Fatigue testing of specimens with as-built surfaces was performed at room temperature on modified Schenk-type fatigue testing machine applying a pulsating plane bending (load cycle ratio R = 0) to the specimens at a frequency f = 15 Hz.

Mass spectrometric comparison of swift heavy ion-induced and anaerobic thermal degradation of polymers

The study of polymers irradiated by highly energetic ions and the resulting radiation-induced degradation is of major importance for space and particle accelerator applications. The mechanism of ion-induced molecular fragmentation of polyethylene, polyethyleneimine and polyamide was investigated by means of mass spectrometry and infrared spectroscopy. The results show that the introduction of nitrogen and oxygen into the polymer influences the stability rendering aliphatic polymers with heteroatoms less stable. A comparison to thermal decomposition data from literature reveals that ion-induced degradation is different in its bond fracture mechanism. While thermal degradation starts at the weakest bond, which is usually the carbon-heteroatom bond, energetic ion irradiation leads in the first step to scission of all types of bonds creating smaller molecular fragments. This is due to the localized extreme energy input under non-equilibrium conditions when the ions transfer kinetic energy onto electrons. These findings are of relevance for the choice of polymers for long-term application in both space and accelerator facilities.

Mode Selection in Compressible Active Flow Networks.

Coherent, large-scale dynamics in many nonequilibrium physical, biological, or information transport networks are driven by small-scale local energy input. Here, we introduce and explore an analytically tractable nonlinear model for compressible active flow networks. In contrast to thermally driven systems, we find that active friction selects discrete states with a limited number of oscillation modes activated at distinct fixed amplitudes. Using perturbation theory, we systematically predict the stationary states of noisy networks and find good agreement with a Bayesian state estimation based on a hidden Markov model applied to simulated time series data. Our results suggest that the macroscopic response of active network structures, from actomyosin force networks to cytoplasmic flows, can be dominated by a significantly reduced number of modes, in contrast to energy equipartition in thermal equilibrium. The model is also well suited to study topological sound modes and spectral band gaps in active matter.

A new test procedure to evaluate the performance of substations for collective heating systems

The overall heat demand of a single dwelling, existing out of space heating and domestic hot water production, decreases due to higher insulation rates. Because of this, investing in efficient and renewable heat generation becomes less interesting. Therefore, to incorporate renewables or residual heat on a larger scale, district heating or collective heating systems grow in importance. Within this set-up, the substation is responsible for the interaction between local demand for comfort and overall energy performance of the collective heating system. Many different configurations of substations exist, which influence both local comfort and central system performance. Next to that, also hybrids exist with additional local energy input. To evaluate performance of such substations, a new experimental-based test procedure is developed in order to evaluate these different aspects, characterized by the two roles a substation has, namely as heat generator and as heat consumer. The advantage of this approach is that an objective comparison between individual and central systems regarding performance on delivering local comfort can be executed experimentally. The lab set-up consists out of three different subsystems, namely the central system, the domestic hot water consumption and the local space heating. The central system can work with different temperature regimes and control strategies, as these aspects have proven to have the largest influence on actual performance. The domestic hot water system is able to generate similar tap profiles according to eco-design regulation for domestic hot water generation. The space heating system is able to demand a modular heat load.

Seasonal and Interannual Variations of the Energy Flux Equator and ITCZ. Part II: Zonally Varying Shifts of the ITCZ

Abstract The ITCZ lies at the ascending branch of the tropical meridional overturning circulation, where near-surface meridional mass fluxes vanish. Near the ITCZ, column-integrated energy fluxes vanish, forming an atmospheric energy flux equator (EFE). This paper extends existing approximations relating the ITCZ position and EFE to the atmospheric energy budget by allowing for zonal variations. The resulting relations are tested using reanalysis data for 1979–2014. The zonally varying EFE is found as the latitude where the meridional component of the divergent atmospheric energy transport (AET) vanishes. A Taylor expansion of the AET around the equator relates the ITCZ position to derivatives of the AET. To a first order, the ITCZ position is proportional to the divergent AET across the equator; it is inversely proportional to the local atmospheric net energy input (NEI) that consists of the net energy fluxes at the surface, at the top of the atmosphere, and zonally across longitudes. The first-order approximation captures the seasonal migrations of the ITCZ in the African, Asian, and Atlantic sectors. In the eastern Pacific, a third-order approximation captures the bifurcation from single- to double-ITCZ states that occurs during boreal spring. In contrast to linear EFE theory, during boreal winter in the eastern Pacific, northward cross-equatorial AET goes along with an ITCZ north of the equator. EFE and ITCZ variations driven by ENSO are characterized by an equatorward (poleward) shift in the Pacific during El Niño (La Niña) episodes, which are associated with variations in equatorial ocean energy uptake.

Dynamics of a vapor bubble inside a vertical rigid cylinder with and without a deposit rib

In this paper, the dynamics of a vapour bubble generated due to local energy input inside a vertical rigid cylinder and in the absence of buoyancy forces was investigated. Different ratios of the diameter of the rigid cylinder up to the maximum radius of the bubble were considered. The boundary integral equation method was employed for numerical simulation of the problem. The results show that during the collapse phase of the bubble inside a vertical rigid cylinder, two liquid micro jets are developed on the top and bottom sides of the vapor bubble and are directed inward. It is found that by increasing the ratio of the cylinder diameter to the maximum radius of the bubble, the rate of the growth and collapse phases of the bubble increases and the lifetime of the bubble decreases. The results also show that an increase in the thickness of the deposit rib inside a vertical rigid cylinder slightly decreases the lifetime of the bubble.

Numerical Simulation of the Thermal Efficiency During Laser Deep Penetration Welding

The advantages of laser beam welding, such as its high flexibility, its high local energy input, and its fast processing speed, led to a substantial increase of industrial applications of the technology. High losses can be observed during laser welding of materials with a high thermal conductivity, such as aluminum or copper. This is caused by the heat conduction losses in the surrounding area of the process zone and due to reflections. These energy losses lead to a reduced efficiency of the laser welding process.A numerical model based on a CFD simulation is presented, which enables to calculate the molten pool isotherms. The thermal efficiency is determined for different keyhole geometries and welding velocities. This efficiency is defined as the ratio between the energy which is required to melt the volume of metal in the fusion zone and the absorbed laser beam power.

Entrainment and mixed layer dynamics of a surface-stress-driven stratified fluid

AbstractWe consider experimentally an initially quiescent and linearly stratified fluid with buoyancy frequency $N_{Q}$ in a cylinder subject to surface-stress forcing from a disc of radius $R$ spinning at a constant angular velocity ${\rm\Omega}$. We observe the growth of the disc-adjacent turbulent mixed layer bounded by a sharp primary interface with a constant characteristic thickness $l_{I}$. To a good approximation the depth of the forced mixed layer scales as $h_{F}/R\sim (N_{Q}/{\rm\Omega})^{-2/3}({\rm\Omega}t)^{2/9}$. Generalising the previous arguments and observations of Shravat et al. (J. Fluid Mech., vol. 691, 2012, pp. 498–517), we show that such a deepening rate is consistent with three central assumptions that allow us to develop a phenomenological energy balance model for the entrainment dynamics. First, the total kinetic energy of the deepening mixed layer $\mathscr{E}_{KF}\propto h_{F}u_{F}^{2}$, where $u_{F}$ is a characteristic velocity scale of the turbulent motions within the forced layer, is essentially independent of time and the buoyancy frequency $N_{Q}$. Second, the scaled entrainment parameter $E={\dot{h}}_{F}/u_{F}$ depends only on the local interfacial Richardson number $Ri_{I}=(N_{Q}^{2}h_{F}l_{I})/(2u_{F}^{2})$. Third, the potential energy increase (due to entrainment, mixing and homogenisation throughout the deepening mixed layer) is driven by the local energy input at the interface, and hence is proportional to the third power of the characteristic velocity $u_{F}$. We establish that internal consistency between these assumptions implies that the rate of increase of the potential energy (and hence the local mass flux across the primary interface) decreases with $Ri_{I}$. This observation suggests, as originally argued by Phillips (Deep-Sea Res., vol. 19, 1972, pp. 79–81), that the mixing in the vicinity of the primary interface leads to the spontaneous appearance of secondary partially mixed layers, and we observe experimentally such secondary layers below the primary interface.

Numerical study on the oscillation of a transient bubble near a confined free surface for droplet generation

In the present work, the oscillation of a spark-created bubble near a confined water–air interface and the ensuing droplet generation and ejection are studied numerically using the boundary element method. The interface is accorded by the top opening of either one of the following symmetrical configurations, which are distinguished by the value of angle between their vertical symmetry axis and lateral wall (i.e., θ): (i) a centrally perforated horizontal flat plate (θ = 90°) and (ii) vertically placed cylinder (θ = 0°), nozzle (θ > 0°) and diffuser (θ < 0°). Furthermore, the influences of the effective parameters such as the strength parameter (i.e., the intensity of local energy input), the bubble-free surface distance (standoff distance) and the nozzle size on the bubble dynamics and droplet formation and ejection processes are investigated. It was found that the moment at which the bubble attained its maximum volume was advanced as θ increased. In addition, by decreasing θ the attraction of the bubble toward the free surface during its expansion phase and its migration from the free surface during its contraction phase became stronger. Furthermore, for the nozzle case, by increasing θ, the volume of the droplet was increased. It was also found that by increasing the strength parameter, the volume of the droplet increased and its pinch-off happened earlier. Finally, as the standoff distance was increased, the volume of the droplet increased and its pinch-off was delayed.

Laser cladding with scanning optics: Effect of scanning frequency and laser beam power density on cladding process

Scanning optics is an effective way to manipulate a laser beam for laser cladding. The numerical adjustment of the scanner gives a great deal of flexibility to the cladding process. However, the effect of the scanned beam on the cladding process itself has not been studied very thoroughly so far. This study concentrates on explaining how the scanning frequency and power density of the laser beam affect the stability of the cladding process. The results showed that both of these factors significantly influence the process stability and the outcome of the cladding process. If the local specific energy input was over 2.46 J/mm2, the process was noticed to be unstable. This limit was cross when scanning frequency was under 40 Hz. Power density's limit value for stable process was found to be 191 kW/cm2 and higher power densities than this was found to produce unstable process. If the cladding process was found to be unstable, dilution increased significantly and process started to resemble more laser alloying.

Perfect plastic deformation of a circular thin metal plate due to pulsation of a vapour bubble

In this paper dynamics of a vapour bubble generated due to a local energy input in the vicinity of a thin metal plate in the absence of the buoyancy forces is investigated. The bubble is initially generated in different distances from the surface and during its growth and collapse phases, it deforms the plate. The boundary Integral Equation Method is employed for numerical simulation of the problem. The fluid is assumed to be incompressible, inviscid and irrotational and the surface tension on the bubble boundary is neglected. Furthermore, the thin metal plate is assumed to have perfectly plastic behaviour. Results show that displacement of the thin metal plate has considerable effect on the dynamics of its nearby vapour bubble. It is also found that the collapse rate of the bubble in the vicinity of a deformable thin metal plate is higher than that of a rigid boundary and consequently the lifetime of the bubble near a deformable thin metal plate is shorter than the life time of the bubble near a rigid boundary. Deformation of the thin metal plate depends on the properties of the its nearby surface and the energy that has been imported by its nearby vapour bubble. Decreasing the density and the yield point stress of the plate, more plate deformation takes place.

Deposition of ultrathin polymeric multilayers down to the Ångström level

Polymer layers on surfaces have a high relevance in both academic and technical systems. Deposition of polymers on surfaces is either spontaneous or can be achieved unselectively by evaporation of the solvent. Here we report the regioselective deposition of ultrathin polymer films from aqueous solution by local mechanical energy input. We demonstrate that water soluble polymers can be literally nailed – or, rather, ironed – onto a silicon wafer surface by the mechanical impact of an atomic force microscope (AFM) tip. Each layer has a controllable height from 10 nm down to a few Angstroms. Moreover, we demonstrate that it is possible to stack multiple layers of equally charged polycarboxylate chains and their counterions, in contrast to the alternating deposition of anionic and cationic polymers by the well-known layer-by-layer (LBL) technique. Although the polymer used in this study is water-soluble, the layers do not re-dissolve again. As a tentative explanation, we suggest that the longevity of the multilayers must be caused by chemisorption in combination with an unfavorable entropy penalty upon dissolution of the polymers fixed to the surface.

Pulsed Nd:YAG laser cutting of NiTi shape memory alloys—Influence of process parameters

Shape memory alloys (SMAs), in particular Nitinol (NiTi), are of increasing interest in research and industry due to their outstanding properties, e.g. the shape memory effect (SME) and high biocompatibility. Obviously, it is necessary to machine these elements from NiTi sheet materials using suitable processing methods that provide high precision and retain the shape memory effect. Pulsed Nd:YAG laser cutting of 1 mm thick NiTi shape memory alloys for medical applications (SMA-implants) has been investigated. Due to the local energy input only small heat-affected zones (HAZ) occur and the shape memory properties remain. The influence of key parameters like pulse energy, pulse width, and spot overlap on the cut geometry, roughness and HAZ is shown.

The relationship between sea surface temperature anomaly and wind energy input in the Pacific Ocean

The relationship between sea surface temperature anomaly (SSTA) and wind energy input in the Pacific Ocean over the period of 1949–2003 is studied by using daily-mean NOAA/NCEP wind stress and monthly mean Reynolds SST data. The results indicate the strong negative correlation between SSTA and local wind energy input to surface waves in most of the domain at low and middle latitudes. The SST is low (high) during the years with more (less) wind energy input. The correlation coefficients are high in the central and eastern tropical Pacific and the central midlatitude North Pacific at the decadal scale, and in the central tropical Pacific at the interannual scale. Vertical mixing processes in the upper ocean are closely associated with wind energy input, indicating that wind energy input may play an important role in interannual and decadal variability in the Pacific Ocean via regulating vertical mixing.

Fluid dynamics of self-propelled microorganisms, from individuals to concentrated populations

Nearly close-packed populations of the swimming bacterium Bacillus subtilis form a collective phase, the “Zooming BioNematic” (ZBN). This state exhibits large-scale orientational coherence, analogous to the molecular alignment of nematic liquid crystals, coupled with remarkable spatial and temporal correlations of velocity and vorticity, as measured by both novel and standard applications of particle imaging velocimetry. The appearance of turbulent dynamics in a system which is nominally in the regime of Stokes flow can be understood by accounting for the local energy input by the swimmers, with a new dimensionless ratio analogous to the Reynolds number. The interaction between organisms and boundaries, and with one another, is modeled by application of the methods of regularized Stokeslets.

Excimer laser annealing of silicon nanowires

Nanowires can potentially be used with low-cost flexible plastic substrates for applications such as large-area displays and sensor arrays. However, high temperature processing steps such as thermal annealing that are incompatible with plastic substrates are still a major hindrance. Laser annealing permits localized energy input without affecting the underlying substrate and can help overcome this problem. In this study, the excimer laser annealing of silicon nanowires is demonstrated to be an efficient means of activating implanted dopants. The optical absorption of the nanowires is discussed and the effect of parameters such as fluence and number of pulses is investigated.