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11 pages, 41628 KiB

Open AccessArticle

Blue Diode Laser Welding of Commercially Pure Titanium Foils

by Tim Pasang, Pai-Chen Lin, Wojciech Z. Misiolek, Jia-Yuan Wei, Shinichiro Masuno, Masahiro Tsukamoto, Eiji Hori, Yuji Sato, Yuan Tao, Danang Yudhistiro and Salahuddin Yunus

Quantum Beam Sci. 2022, 6(3), 24; https://0-doi-org.brum.beds.ac.uk/10.3390/qubs6030024 - 18 Jul 2022

Cited by 1 | Viewed by 2631

Abstract

The need for thin foil welding is increasing significantly, particularly in the electronic industries. The technologies that are currently available limit the joining processes in terms of materials and their geometries. In this paper, a series of trials of fusion welding (bead-on- plate) [...] Read more.

The need for thin foil welding is increasing significantly, particularly in the electronic industries. The technologies that are currently available limit the joining processes in terms of materials and their geometries. In this paper, a series of trials of fusion welding (bead-on- plate) of commercially pure titanium (CPTi) foils were conducted using a blue diode laser (BDL) welding method. The power used was 50 W and 100 W for 0.1 mm and 0.2 mm thick foils, respectively. Following welding, various samples were prepared to examine the weld profiles, microstructures, hardness, tensile strength, and fracture surface characteristics. The results showed that the base metal (BM) had an annealed microstructure with equiaxed grains, while the weld zones contained martensite (α’) with large grains. The hardness increased in both regions, from around 123 HV to around 250 HV, in the heat-affected zone (HAZ) and fusion zone (FZ) areas. The tensile tests revealed that the strengths of the welded samples were slightly lower than the unwelded samples, i.e., UTS = 300–350 MPa compared with 325–390 MPa for the unwelded samples. Fracture took place within the BM area. All of the samples, welded and unwelded, showed identical fracture mechanisms, i.e., microvoid coalescence or ductile fracture. The weld zone experienced very small strains (elongation) at fracture, which indicates a good weld quality. Full article

(This article belongs to the Special Issue Laser Assisted Manufacturing)

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13 pages, 2981 KiB

Open AccessArticle

Laser Cleaning as Novel Approach to Preservation of Historical Books and Documents on a Paper Basis

by Vadim Parfenov, Alexander Galushkin, Tatiana Tkachenko and Vladimir Aseev

Quantum Beam Sci. 2022, 6(3), 23; https://0-doi-org.brum.beds.ac.uk/10.3390/qubs6030023 - 30 Jun 2022

Cited by 4 | Viewed by 2204

Abstract

The purpose of this work is the study of laser cleaning of historical paper. The effect of laser exposure of the paper reflectance, fracture resistance and acidity was investigated. The paper surface roughness before and after laser treatment was analyzed by optical and [...] Read more.

The purpose of this work is the study of laser cleaning of historical paper. The effect of laser exposure of the paper reflectance, fracture resistance and acidity was investigated. The paper surface roughness before and after laser treatment was analyzed by optical and scanning electron microscopy. It was shown that use of multi-pulse micromachining in combination with high-speed scanning of laser beams provides high safety for paper cleaning. The optimal parameters of laser radiation for effective and safe cleaning are a power density of about 2 × 105 W/cm² at a wavelength of 1.06 μm, pulse repetition rate is 20 kHz; and a beam scanning speed of 200 mm/s–500 mm/s. The selective laser cleaning method for books and documents was proposed. Selective cleaning is achieved by means of high-precision control of the trajectory of movement of laser beams. Full article

(This article belongs to the Special Issue Laser Assisted Manufacturing)

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15 pages, 21008 KiB

Open AccessArticle

Effect of Process Parameters on Laser Powder Bed Fusion of Al-Sn Miscibility Gap Alloy

by Chiara Confalonieri, Riccardo Casati and Elisabetta Gariboldi

Quantum Beam Sci. 2022, 6(2), 17; https://0-doi-org.brum.beds.ac.uk/10.3390/qubs6020017 - 25 Apr 2022

Cited by 4 | Viewed by 2336

Abstract

Al-Sn binary system is a miscibility gap alloy consisting of an Al-rich phase and a Sn-rich phase. This system is traditionally applied in bearings and more recently found application as form-stable phase change material (PCM) exploiting solid-liquid phase transition of Sn. A careful [...] Read more.

Al-Sn binary system is a miscibility gap alloy consisting of an Al-rich phase and a Sn-rich phase. This system is traditionally applied in bearings and more recently found application as form-stable phase change material (PCM) exploiting solid-liquid phase transition of Sn. A careful choice of production process is required to avoid macro-segregation of the two phases, which have different densities and melting temperatures. In the present study, the additive manufacturing process known as laser powder bed fusion (LPBF) was applied to an Al-Sn alloy with 20% volume of Sn, as a rapid solidification process. The effect of process parameters on microstructure and hardness was evaluated. Moreover, feasibility and stability with thermal cycles of a lattice structure of the same alloy were experimentally investigated. An Al-Sn lattice structure could be used as container for a lower melting organic PCM (e.g., a paraffin or a fatty acid), providing high thermal diffusivity thanks to the metallic network and a “safety system” reducing thermal diffusivity if the system temperature overcomes Sn melting temperature. Even if focused on Al-Sn to be applied in thermal management systems, the study offers a contribution in view of the optimization of manufacturing processes locally involving high solidification rates and reheat cycles in other miscibility gap alloys (e.g., Fe-Cu) with similar thermal or structural applications. Full article

(This article belongs to the Special Issue Laser Assisted Manufacturing)

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10 pages, 3791 KiB

Open AccessArticle

Use of 3D Laser Scanning and Additive Technologies for Reconstruction of Damaged and Destroyed Cultural Heritage Objects

by Vadim Parfenov, Sergei Igoshin, Dmitriy Masaylo, Alexey Orlov and Dzmitry Kuliashou

Quantum Beam Sci. 2022, 6(1), 11; https://0-doi-org.brum.beds.ac.uk/10.3390/qubs6010011 - 03 Mar 2022

Cited by 15 | Viewed by 7460

Abstract

Three-dimensional laser scanning is a novel measurement technique that is frequently used for the documentation of cultural heritage (CH) objects. In the process of 3D scanning, one can obtain computing 3D models of artworks to be documented. It allows one to produce detailed [...] Read more.

Three-dimensional laser scanning is a novel measurement technique that is frequently used for the documentation of cultural heritage (CH) objects. In the process of 3D scanning, one can obtain computing 3D models of artworks to be documented. It allows one to produce detailed digitized archives of important CH objects. Moreover, the use of 3D scanning enables the digital reconstruction of architectural fragments, sculptures, and other artworks. One more important application of this technique relates to the creation of molds and replicas for replacements of outdoor CH objects in case their preservation requirements do not allow them to remain in their original place due to the influence of environmental factors. One of the most effective ways of creating replicas is the use of laser additive technologies. Therefore, the combination of 3D scanning and additive technologies is a very promising way of preservation of CH. This paper describes several case studies concerned with the combined usage of 3D laser scanning and additive technologies for digital reconstruction and replication and of outdoor sculptures in St. Petersburg city. One of them is the reconstruction of the zinc sculpture “Eva at the fountain” (XIX century, England), which was destroyed during WWII. Its replica was created by means of laser stereolithography. Eventually, one more project is related to the reconstruction of the fragment of the sufficiently damaged cast-iron XIX century monument. This object was reconstructed using two laser technologies: direct metal laser sintering (DMLS), and laser cladding (LC). Full article

(This article belongs to the Special Issue Laser Assisted Manufacturing)

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10 pages, 3749 KiB

Open AccessArticle

Laser Treatment as a New Approach to the Passivation of Iron-Based Historical Monuments

by Iuliia Ruzankina, Vadim Parfenov, Oleg Vasiliev, Oleg Zotov and Alexandra Zotova

Quantum Beam Sci. 2022, 6(1), 9; https://0-doi-org.brum.beds.ac.uk/10.3390/qubs6010009 - 16 Feb 2022

Cited by 3 | Viewed by 2632

Abstract

This article is devoted to the study of the possibility of the passivation of iron-based metallic materials. The experimental results obtained for the laser treatment of carbon steel model samples by the radiation of repetitively pulsed and continuous-wave 1.064 µm Nd:YAG lasers are [...] Read more.

This article is devoted to the study of the possibility of the passivation of iron-based metallic materials. The experimental results obtained for the laser treatment of carbon steel model samples by the radiation of repetitively pulsed and continuous-wave 1.064 µm Nd:YAG lasers are described. It is shown that the laser treatment allows the formation of dense protection films, 62–77 microns thick, on the steel surface. The films enhance the anticorrosion properties of the metal. Exposure to laser radiation reduces the surface roughness (from R_a = 0.53 µm to R_a = 0.38 µm). Laser radiation power densities of 10.2 × 10⁵ W/cm² and 10.7 × 10⁵ W/cm² for these two laser generating modes, respectively, correspond to the optimum (in terms of the degree of corrosion resistance) modes of steel treatment. The conducted studies show that the application of Nd: YAG lasers is a promising method for the surface passivation of artworks created from steel and cast iron. One of the most promising applications of the proposed method for the anticorrosion protection of iron is the passivation of the surface of iron-based historical monuments. Full article

(This article belongs to the Special Issue Laser Assisted Manufacturing)

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10 pages, 2665 KiB

Open AccessArticle

Laser Peening Analysis of Aluminum 5083: A Finite Element Study

by Ali Tajyar, Noah Holtham, Nicholas Brooks, Lloyd Hackel, Vincent Sherman, Ali Beheshti and Keivan Davami

Quantum Beam Sci. 2021, 5(4), 34; https://0-doi-org.brum.beds.ac.uk/10.3390/qubs5040034 - 07 Dec 2021

Cited by 2 | Viewed by 3093

Abstract

In this research, a finite element (FE) technique was used to predict the residual stresses in laser-peened aluminum 5083 at different power densities. A dynamic pressure profile was used to create the pressure wave in an explicit model, and the stress results were [...] Read more.

In this research, a finite element (FE) technique was used to predict the residual stresses in laser-peened aluminum 5083 at different power densities. A dynamic pressure profile was used to create the pressure wave in an explicit model, and the stress results were extracted once the solution was stabilized. It is shown that as power density increases from 0.5 to 4 GW/cm², the induced residual stresses develop monotonically deeper from 0.42 to 1.40 mm. However, with an increase in the power density, the maximum magnitude of the sub-surface stresses increases only up to a certain threshold (1 GW/cm² for aluminum 5083). Above this threshold, a complex interaction of the elastic and plastic waves occurring at peak pressures above ≈2.5 Hugoniot Elastic Limit (HEL) results in decreased surface stresses. The FE results are corroborated with physical experiments and observations. Full article

(This article belongs to the Special Issue Laser Assisted Manufacturing)

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Review

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12 pages, 1621 KiB

Open AccessReview

A Survey of Process Monitoring Using Computer-Aided Inspection in Laser-Welded Blanks of Light Metals Based on the Digital Twins Concept

by Ahmad Aminzadeh, Sasan Sattarpanah Karganroudi, Mohammad Saleh Meiabadi, Dhanesh G. Mohan and Kadiata Ba

Quantum Beam Sci. 2022, 6(2), 19; https://0-doi-org.brum.beds.ac.uk/10.3390/qubs6020019 - 16 May 2022

Cited by 12 | Viewed by 3466

Abstract

The benefits of laser welding include higher production values, deeper penetration, higher welding speeds, adaptability, and higher power density. These characteristics make laser welding a superior process. Many industries are aware of the benefits of switching to lasers. For example, metal-joining is migrating [...] Read more.

The benefits of laser welding include higher production values, deeper penetration, higher welding speeds, adaptability, and higher power density. These characteristics make laser welding a superior process. Many industries are aware of the benefits of switching to lasers. For example, metal-joining is migrating to modern industrial laser technology due to improved yields, design flexibility, and energy efficiency. However, for an industrial process to be optimized for intelligent manufacturing in the era of Industry 4.0, it must be captured online using high-quality data. Laser welding of aluminum alloys presents a daunting challenge, mainly because aluminum is a less reliable material for welding than other commercial metals such as steel, primarily because of its physical properties: high thermal conductivity, high reflectivity, and low viscosity. The welding plates were fixed by a special welding fixture, to validate alignments and improve measurement accuracy, and a Computer-Aided Inspection (CAI) using 3D scanning was adopted. Certain literature has suggested real-time monitoring of intelligent techniques as a solution to the critical problems associated with aluminum laser welding. Real-time monitoring technologies are essential to improving welding efficiency and guaranteeing product quality. This paper critically reviews the research findings and advances for real-time monitoring of laser welding during the last 10 years. In the present work, a specific methodology originating from process monitoring using Computer-Aided Inspection in laser-welded blanks is reviewed as a candidate technology for a digital twin. Moreover, a novel digital model based on CAI and cloud manufacturing is proposed. Full article

(This article belongs to the Special Issue Laser Assisted Manufacturing)

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48 pages, 11840 KiB

Open AccessReview

Femtosecond Laser-Based Additive Manufacturing: Current Status and Perspectives

by Atiq Basha Kaligar, Hemnath Anandan Kumar, Asghar Ali, Wael Abuzaid, Mehmet Egilmez, Maen Alkhader, Farid Abed and Ali Sami Alnaser

Quantum Beam Sci. 2022, 6(1), 5; https://0-doi-org.brum.beds.ac.uk/10.3390/qubs6010005 - 18 Jan 2022

Cited by 14 | Viewed by 6127

Abstract

The ever-growing interest in additive manufacturing (AM) is evidenced by its extensive utilisation to manufacture a broad spectrum of products across a range of industries such as defence, medical, aerospace, automotive, and electronics. Today, most laser-based AM is carried out by employing continuous-wave [...] Read more.

The ever-growing interest in additive manufacturing (AM) is evidenced by its extensive utilisation to manufacture a broad spectrum of products across a range of industries such as defence, medical, aerospace, automotive, and electronics. Today, most laser-based AM is carried out by employing continuous-wave (CW) and long-pulsed lasers. The CW and long-pulsed lasers have the downside in that the thermal energy imparted by the laser diffuses around the irradiated spot and often leads to the creation of heat-affected zones (HAZs). Heat-affected zones may degrade the material strength by producing micro-cracks, porous structures and residual stresses. To address these issues, currently, attempts are being made to employ ultrafast laser sources, such as femtosecond (fs) lasers, in AM processes. Femtosecond lasers with pulse durations in the order of

10^{- 15}

s limit the destructive laser–material interaction and, thus, minimise the probability of the HAZs. This review summarises the current advancements in the field of femtosecond laser-based AM of metals and alloys. It also reports on the comparison of CW laser, nanosecond (ns)/picosecond (ps) lasers with fs laser-based AM in the context of heat-affected zones, substrate damage, microstructural changes and thermomechanical properties. To shed light on the principal mechanisms ruling the manufacturing processes, numerical predictions are discussed and compared with the experimental results. To the best of the authors’ knowledge, this review is the first of its kind to encompass the current status, challenges and opportunities of employing fs lasers in additive manufacturing. Full article

(This article belongs to the Special Issue Laser Assisted Manufacturing)

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24 pages, 4750 KiB

Open AccessFeature PaperReview

Making Light Work of Metal Bending: Laser Forming in Rapid Prototyping

by Adam L. Bachmann, Michael D. Dickey and Nathan Lazarus

Quantum Beam Sci. 2020, 4(4), 44; https://0-doi-org.brum.beds.ac.uk/10.3390/qubs4040044 - 14 Dec 2020

Cited by 12 | Viewed by 5574

Abstract

Lasers can be used to bend 2D metal sheets into complex 3D objects in a process called ‘laser forming.’ Laser forming bends metal sheets by locally heating the sheets to generate plastic strains and is an established metal bending technology in the shipbuilding [...] Read more.

Lasers can be used to bend 2D metal sheets into complex 3D objects in a process called ‘laser forming.’ Laser forming bends metal sheets by locally heating the sheets to generate plastic strains and is an established metal bending technology in the shipbuilding industry. Recent studies have investigated the laser forming of thin metal parts as a complementary rapid prototyping technology to metal 3D printing. This review discusses the laser forming process, beginning with the mechanisms before covering various design considerations. Laser forming for the rapid manufacturing of metal parts is then reviewed, including the recent advances in process planning, before highlighting promising future research directions. Full article

(This article belongs to the Special Issue Laser Assisted Manufacturing)

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