
Metal Material Processing Using Femtosecond Lasers: Theories, Principles, and Applications.
Materials (Basel, Switzerland)
Metal material processing using femtosecond lasers is a useful technique, and it has been widely employed in many applications including laser microfabrication, laser surgery, and micromachining. The basic mechanisms of metal processing using femtosecond lasers are reviewed in this paper and the characteristics and theory of laser processing are considered. In addition to well-known processes, the recent progress relating to metals processing with femtosecond lasers, including metal material drilling, metal ablation thresholds, micro/nano-surface modification, printed circuit board (PCB) micromachining, and liquid metal (LM) processing using femtosecond lasers, is described in detail. Meanwhile, the application of femtosecond laser technology in different fields is also briefly discussed. This review concludes by highlighting the current challenges and presenting a forward-looking perspective on the future of the metal laser processing field.
10.3390/ma17143386
Selective Laser Melting of Aluminum and Its Alloys.
Wang Zhi,Ummethala Raghunandan,Singh Neera,Tang Shengyang,Suryanarayana Challapalli,Eckert Jürgen,Prashanth Konda Gokuldoss
Materials (Basel, Switzerland)
The laser-based powder bed fusion (LBPF) process or commonly known as selective laser melting (SLM) has made significant progress since its inception. Initially, conventional materials like 316L, Ti6Al4V, and IN-718 were fabricated using the SLM process. However, it was inevitable to explore the possible fabrication of the second most popular structural material after Fe-based alloys/steel, the Al-based alloys by SLM. Al-based alloys exhibit some inherent difficulties due to the following factors: the presence of surface oxide layer, solidification cracking during melt cooling, high reflectivity from the surface, the high thermal conductivity of the metal, poor flowability of the powder, low melting temperature, etc. Researchers have overcome these difficulties to successfully fabricate the different Al-based alloys by SLM. However, there exists no review dealing with the fabrication of different Al-based alloys by SLM, their fabrication issues, microstructure, and their correlation with properties in detail. Hence, the present review attempts to introduce the SLM process followed by a detailed discussion about the processing parameters that form the core of the alloy development process. This is followed by the current research status on the processing of Al-based alloys and microstructure evaluation (including defects, internal stresses, etc.), which are dealt with on the basis of individual Al-based series. The mechanical properties of these alloys are discussed in detail followed by the other important properties like tribological properties, fatigue properties, etc. Lastly, an outlook is given at the end of this review.
10.3390/ma13204564
Progress of laser surface treatment on magnesium alloy.
Frontiers in chemistry
Magnesium (Mg) metals have been widely used in various fields as one of the most promising lightweight structural materials. However, the low corrosion resistance and poor mechanical properties restrict its applications. Surface treatments are common approach to enhance the mechanical strength and corrosion resistance of Mg metals. Among them, laser surface treatment generates novel tissues and structures on the sample surface, thereby improving properties of mechanical strength and corrosion resistance. We briefly describe the changes in surface organization that arise after laser treatment of Mg surfaces, as well as the creation of structures such as streaks, particles, holes, craters, etc., and provide an overview of the reasons for the alterations. The effect of laser processing on wettability, hardness, friction wear, degradation, biocompatibility and mechanical properties were reviewed. At last, the limitations and development trend of laser treatment on Mg metals research were further pointed out.
10.3389/fchem.2022.999630
Laser Processing of Hard and Ultra-Hard Materials for Micro-Machining and Surface Engineering Applications.
Hazzan Kafayat Eniola,Pacella Manuela,See Tian Long
Micromachines
Polycrystalline diamonds, polycrystalline cubic boron nitrides and tungsten carbides are considered difficult to process due to their superior mechanical (hardness, toughness) and wear properties. This paper aims to review the recent progress in the use of lasers to texture hard and ultra-hard materials to a high and reproducible quality. The effect of wavelength, beam type, pulse duration, fluence, and scanning speed is extensively reviewed, and the resulting laser mechanisms, induced damage, surface integrity, and existing challenges discussed. The cutting performance of different textures in real applications is examined, and the key influence of texture size, texture geometry, area ratio, area density, orientation, and solid lubricants is highlighted. Pulsed laser ablation (PLA) is an established method for surface texturing. Defects include melt debris, unwanted allotropic phase transitions, recast layer, porosity, and cracking, leading to non-uniform mechanical properties and surface roughness in fabricated textures. An evaluation of the main laser parameters indicates that shorter pulse durations (ns-fs), fluences greater than the ablation threshold, and optimised multi-pass scanning speeds can deliver sufficient energy to create textures to the required depth and profile with minimal defects. Surface texturing improves the tribological performance of cutting tools in dry conditions, reducing coefficient of friction (COF), cutting forces, wear, machining temperature, and adhesion. It is evident that cutting conditions (feed speed, workpiece material) have a primary role in the performance of textured tools. The identified gaps in laser surface texturing and texture performance are detailed to provide future trends and research directions in the field.
10.3390/mi12080895
Femtosecond Laser Microfabrication of Porous Superwetting Materials for Oil/Water Separation: A Mini-Review.
Frontiers in chemistry
Frequent oil-leakage accidents and large quantities of oil-bearing wastewater discharge cause severe environmental pollution and huge economic losses. Recently, superwetting porous materials are successfully utilized to separate oil/water mixture (OWM) based on the different interfacial behavior of water and oil. Here, we summarize the recent development of efficient oil/water separation (OWS) based on the femtosecond laser-induced superwetting materials. The typical wettability-based separation manners (including "oil-removing" and "water-removing") and the characteristic of the femtosecond laser are introduced as background. Various laser-structured porous sheets with either superhydrophobicity or underwater superoleophobicity are successfully used to separate different OWMs. The laser processing methods, surface wettability, separation process, and separation mechanism of these laser-structured separation materials are reviewed. Finally, the current challenges and prospects in achieving OWS by femtosecond laser microfabrication are discussed.
10.3389/fchem.2020.585723
Critical Review of Comparative Study of Selective Laser Melting and Investment Casting for Thin-Walled Parts.
Materials (Basel, Switzerland)
Thin-walled structures are a significant and growing portion of engineering construction, with a wide range of applications, including storage vessels, industrial buildings, warehouses, aircraft, automobiles, bridges, ships, and oil rigs. Thin-walled components with minimum thickness without compromising strength and other quality characteristics are the desire of modern industry. Reducing wall thickness not only aids in lowering the cost of production. It also improves the effectiveness of engineering systems, resulting in lower fuel consumption and lower emissions of hazardous gases to the environment. Nowadays, even though thin-walled parts are demanded, the constraints of the production process, quality, and reliability are the concerns of current research and development. The ability to produce parts with intricate geometries and tight dimensional tolerances are important criteria for advanced manufacturing processes. In the early days of society, investment casting was used to produce jewelry, weapons, and statues. In modern industry, investment casting is still used to produce thin-walled and intricate parts such as turbine blades. The current advancements in SLM, which has the capacity to produce thin-walled and intricate parts, have recently attracted attention due to several benefits, such as the supreme degree of design freedom and the viability of tool-free production directly from CAD data. However, the current technological applications of SLM and investment casting are crucial for producing parts at the desired quality and reliability. This review article focuses on comparative studies of SLM and investment casting at the current technology level. The basis of comparison via systematic approach is mechanical characterization; quality in terms of porosity, microstructure, surface roughness and dimensional accuracy; and residual stress. Therefore, the latest open scientific sources published are considered to obtain sufficient literature coverage. Better tensile strength and fine microstructure are found in SLM, while better surface quality, fatigue load resistance, ductility, and residual stress are found in investment casting. The research gap for further investigation is indicated.
10.3390/ma16237346
Femtosecond Laser Processing Technology for Anti-Reflection Surfaces of Hard Materials.
Micromachines
The anti-reflection properties of hard material surfaces are of great significance in the fields of infrared imaging, optoelectronic devices, and aerospace. Femtosecond laser processing has drawn a lot of attentions in the field of optics as an innovative, efficient, and green micro-nano processing method. The anti-reflection surface prepared on hard materials by femtosecond laser processing technology has good anti-reflection properties under a broad spectrum with all angles, effectively suppresses reflection, and improves light transmittance/absorption. In this review, the recent advances on femtosecond laser processing of anti-reflection surfaces on hard materials are summarized. The principle of anti-reflection structure and the selection of anti-reflection materials in different applications are elaborated upon. Finally, the limitations and challenges of the current anti-reflection surface are discussed, and the future development trend of the anti-reflection surface are prospected.
10.3390/mi13071084
Improving the Wear and Corrosion Resistance of Aeronautical Component Material by Laser Shock Processing: A Review.
Materials (Basel, Switzerland)
Since the extreme service conditions, the serious failure problems caused by wear and corrosion are often encountered in the service process for aeronautical components. Laser shock processing (LSP) is a novel surface-strengthening technology to modify microstructures and induce beneficial compressive residual stress on the near-surface layer of metallic materials, thereby enhancing mechanical performances. In this work, the fundamental mechanism of LSP was summarized in detail. Several typical cases of applying LSP treatment to improve aeronautical components' wear and corrosion resistance were introduced. Since the stress effect generated by laser-induced plasma shock waves will lead to the gradient distribution of compressive residual stress, microhardness, and microstruture evolution. Due to the enhancement of microhardness and the introduction of beneficial compressive residual stress by LSP treatment, the wear resistance of aeronautical component materials is evidently improved. In addition, LSP can lead to grain refinement and crystal defect formation, which can increase the hot corrosion resistance of aeronautical component materials. This work will provide significant reference value and guiding significance for researchers to further explore the fundamental mechanism of LSP and the aspects of the aeronautical components' wear and corrosion resistance extension.
10.3390/ma16114124
Research Progress of Laser Cladding on the Surface of Titanium and Its Alloys.
Materials (Basel, Switzerland)
Titanium (Ti) and its alloys have been widely employed in aeronautical, petrochemical, and medical fields owing to their fascinating advantages in terms of their mechanical properties, corrosion resistance, biocompatibility, and so on. However, Ti and its alloys face many challenges, if they work in severe or more complex environments. The surface is always the origin of failure for Ti and its alloys in workpieces, which influences performance degradation and service life. To improve the properties and function, surface modification becomes the common process for Ti and its alloys. The present article reviews the technology and development of laser cladding on Ti and its alloys, according to the cladding technology, cladding materials, and coating function. Generally, the laser cladding parameters and auxiliary technology could influence the temperature distribution and elements diffusion in the molten pool, which basically determines the microstructure and properties. The matrix and reinforced phases play an important role in laser cladding coating, which can increase the hardness, strength, wear resistance, oxidation resistance, corrosion resistance, biocompatibility, and so on. However, the excessive addition of reinforced phases or particles can deteriorate the ductility, and thus the balance between functional properties and basic properties should be considered during the design of the chemical composition of laser cladding coatings. In addition, the interface including the phase interface, layer interface, and substrate interface plays an important role in microstructure stability, thermal stability, chemical stability, and mechanical reliability. Therefore, the substrate state, the chemical composition of the laser cladding coating and substrate, the processing parameters, and the interface comprise the critical factors which influence the microstructure and properties of the laser cladding coating prepared. How to systematically optimize the influencing factors and obtain well-balanced performance are long-term research issues.
10.3390/ma16083250
Research Progress and Challenges in Laser-Controlled Cleaning of Aluminum Alloy Surfaces.
Materials (Basel, Switzerland)
Aluminum alloys have been widely utilized in automobiles, aircraft, building structures, and high-speed railways industries due to their excellent structural and mechanical properties. Surface oxide film removal prior to aluminum alloy welding and old paint removal prior to repainting aluminum alloy surfaces are critical factors in ensuring the welding quality and service life of aluminum alloy products. Because of its unique advantages, such as environmental protection and precision control, laser-controlled cleaning has great application potential as a surface cleaning technology in removing oxide films and paint layers on aluminum alloy surfaces. In this paper, the mechanism of laser cleaning of oxide films and paint layers on aluminum alloy is discussed. Furthermore, the impact of various processing parameters such as laser beam power, energy density, scanning speed, and so on is analyzed in detail. After laser cleaning, the corrosion resistance, welding performance, adhesive performance, and other properties of the aluminum alloy are optimized. This paper also discusses several real-time detection technologies for laser cleaning. A summary and the development trend are provided at the end of the paper.
10.3390/ma15165469
Femtosecond laser hybrid processing strategy of transparent hard and brittle materials.
Frontiers in chemistry
With high hardness, high thermal stability, chemical inertness and excellent optoelectronic properties, transparent hard and brittle materials have drawn significant attentions in frontier domains such as aerospace, photoelectric detection, and high-intensity lasers. Femtosecond laser processing technology demonstrates great potential for transparent hard and brittle materials processing due to its outstanding advantages such as non-contact, true 3D processing and programmable design. However, high-energy laser ablation usually causes severe damage to the surface of the materials, resulting in low processing accuracy, low processing efficiency and poor surface quality. Femtosecond laser hybrid processing strategies have been proven to be an effective solution to solve the above problems. This mini-review summarizes the fundamentals and research progress of femtosecond laser hybrid processing strategies of transparent hard and brittle materials in recent years. Moreover, the challenges and application prospects of these techniques are discussed.
10.3389/fchem.2022.1082738
Development of Laser Processing Carbon-Fiber-Reinforced Plastic.
Sensors (Basel, Switzerland)
Due to its exceptional advantages, such as high specific strength, high specific modulus, and good fatigue resistance, carbon-fiber-reinforced plastic (CFRP) is frequently utilized in aerospace, aviation, automotive, rail transportation, and other areas. Composite components typically need to be joined and integrated. In the equipment manufacturing industry, the most used methods for processing composite components are cutting, drilling, and surface treatment. The quality of CFRP is significantly impacted by traditional mechanical processing, causing flaws like delamination, burrs, and tears. Laser processing technology has emerged as a crucial method for processing CFRP for its high quality, non-contact, simple control, and automation features. The most recent research on the laser processing of CFRP is presented in this paper, supporting scientists and engineers who work in the field in using this unconventional manufacturing technique. This paper gives a general overview of the key features of laser processing technology and the numerous machining techniques available. The concepts and benefits of laser processing technology are discussed in terms of the material properties, mode of operation, and laser characteristics, as well as the methods to achieve high efficiency, low damage, and high precision. This paper reviews the research development of laser processing of carbon-fiber-reinforced plastics, and a summary of the factors affecting the quality of CFRP laser processing. Therefore, the research content of this article can be used as a theoretical basis for reducing thermal damage and improving the processing quality of laser-processed composite materials, while, on this basis, we analyze the development trend of CFRP laser processing technology.
10.3390/s23073659