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Efficiently shaping femtosecond, transverse Gaussian laser beams to flat-top beams with flat wavefronts is critical for large-scale material processing and manufacturing. Existing beam shaping devices fall short either in final beam homogeneity or efficiency. We present an approach that uses refractive optics to perform the majority of the beam shaping and then uses a fine-tune device (spatial light modulator) to refine the intensity profile. For the beam that we selected, circularly asymmetric with intensity fluctuations, our method achieved a uniformity of 0.055 within 90% of the beam area at 92% efficiency. The optimization involved an iterative beam shaping process that converged to optimum within 10 iterations.

Car manufacturers increasingly aid high-strength aluminum alloys for their advantageous weight-to-strength ratio, but their limited formability poses challenges in plastic deformation processes. Tailored heat-treated blanks (THTBs) are a propitious approach to improve formability. Surface laser treatment is the predominant technology for obtaining THTB. To design this process quickly and accurately, without material waste, the use of physical simulation is increasingly promising. It allows replicating the process on a lab-scale and studying posttreatment mechanical and metallurgical properties. By adopting Gleeble® physical simulator, this study investigates the softening effects of local surface laser heat treatment on a EN AW 6082 T6 aluminum alloy blank. Two laser movement strategies—single linear path and multiple rectangular paths—were investigated at two treatment speeds for each. A finite element (FE) model was developed for simulating the process under all explored conditions. FE-derived thermal cycles were reproduced by means of physical simulation. After physical tests, alloy mechanical properties were evaluated. Results show that these properties depend on both the peak temperature thermal cycle and the interaction time between the laser source and the material surface. The comparison between the two strategies revealed that the multiple rectangular paths strategy allows to achieve a wider softened area at comparable interaction times. [ABSTRACT FROM AUTHOR]

A parameter study of ultrashort pulse laser‐induced modifications in the bulk of ZnS crystals is reported. Experimental results on these modifications and their dependence on the pulse energy, writing speed, and depth are presented, with an emphasis on cross‐sectional morphology and induced refractive index changes. Localized permanent material modifications have been inscribed in the bulk of the crystal using a laser with a center emission wavelength of 2.09 μm and a pulse duration of ≈4 ps. The morphology strongly depends on the laser and optical focusing parameters, in particular, on the pulse energy and processing speed, with a significant shift in depth dependence for short pulse‐to‐pulse separations. Depending on the applied pulse energy, distortions of the lateral profile of the refractive index changes appear in the form of oscillatory features in the transverse plane relative to the inducing laser beam. The true extent of the modified material is revealed by the alternating lateral profile with largest induced negative refractive index change, Δn, of −3.88 × 10−2 ± 0.18. Such parametric insight is of critical importance for the understanding and optimization of the fabrication process and for realizing compact 3D photonic devices in the bulk of materials in a reproducible manner. [ABSTRACT FROM AUTHOR]

This article discusses recent advancements in the Laser Surface Transformation Hardening (LSTH) process applied to industrial metals. It focuses on examining the microstructure of the metal surface layer and explores different methods of performing LSTH to evaluate mechanical and surface properties. The study also investigates the utilization of various industrial lasers and simulation software for the LSTH process. The careful analysis of heat transfer and temperature control during LSTH aims to prevent the generation of surface defects like micro-cracks and surface melting. Finite element method (FEM) software effectively simulates the LSTH process. The research provides a comprehensive overview of recent developments in LSTH, categorized based on different metals and subsequent testing, highlighting its applications in the automotive industry. Electrochemical, wear, and microhardness tests are investigated to assess the potential applications of automotive metals. [ABSTRACT FROM AUTHOR]

Very recently, the synthesis of 2D MoS2 and WS2 through pulsed laser-directed thermolysis can achieve wafer-scale and large-area structures, in ambient conditions. In this paper, we report the synthesis of MoS2 and MoS2 oxides from (NH4)2MoS4 film using a visible continuous-wave (CW) laser at 532 nm, instead of the infrared pulsed laser for the laser-directed thermolysis. The (NH4)2MoS4 film is prepared by dissolving its crystal powder in DI water, sonicating the solution, and dip-coating onto a glass slide. We observed a laser intensity threshold for the laser synthesis of MoS2, however, it occurred in a narrow laser intensity range. Above that range, a mixture of MoS2 and MoO2 is formed, which can be used for a memristor device, as demonstrated by other research groups. We did not observe a mixture of MoS2 and MoO3 in the laser thermolysis of (NH4)2MoS4. The laser synthesis of MoS2 in a line pattern is also achieved through laser scanning. Due to of the ease of CW beam steering and the fine control of laser intensities, this study can lead toward the CW laser-directed thermolysis of (NH4)2MoS4 film for the fast, non-vacuum, patternable, and wafer-scale synthesis of 2D MoS2. [ABSTRACT FROM AUTHOR]

This paper investigates an Extended Kalman Filter (EKF) based Sensor Fusion approach for robot tool center point (TCP) position estimation using a sensing unit consisting of multiple sensors. Data from an inertial measurement unit, axis encoders and two new optical sensors for relative speed estimation in the context of laser material processing is recorded. Performance of the approach is tested experimentally. Three different test trajectories are chosen to evaluate estimation performance, including an adaption of ISO 9283 trajectory for robot accuracy. Estimation results are compared to position measurements of a Laser Tracker system with measurement accuracy of +-28µm and position estimation of the robot controller of the used Universal Robots UR5e. [ABSTRACT FROM AUTHOR]

In recent years, the topic of beam shaping for improved laser material processing has rapidly grown influencing metal laser powder bed fusion (PBF-LB/M). Given the need to reduce the cost and improve control of the PBF-LB/M process to make it more competitive with traditional manufacturing methods, increasing productivity of PBF-LB/M is critical. When research reports a new beam profile (e.g. ring profile) to improve productivity on a specific material, it is often generalised, and assumed to have the capability to improve productivity in PBF-LB/M across the board. In this work, we use both low-fidelity simulations and experimental work to investigate the difference between Gaussian and ring/spot beam profiles on metals with very different thermal properties (a stainless steel and an aluminium alloy). We show that the two materials have opposite responses to the change in beam profile (both in terms of melt pool dimensions and thermal gradients); further, the most beneficial intensity distribution is dependent on the energy input to the material. This exemplifies yet another way in which the PBF-LB/M process is non-linear and contradicts the idea that a ring/spot laser profile is beneficial for all laser processing technologies. This highlights the need for further research into the non-linear effect of varying intensity distributions on laser processing before the benefits of dynamic beam shaping can be truly realised.

Lasers are widely used for structuring metallic surfaces by ablating material. An alternative approach for laser structuring is surface structuring by laser remelting (WaveShape), which is based onthe continuous remelting of a thin surface layer using laser radiation while simultaneously modulating the laser power. The structures are generated by redistribution of the molten material. The structure height and the structure wavelength of periodic structures created using WaveShape can be precisely adjusted by the adaption of various process parameters. However, the structures produced are mostly asymmetrical. An asymmetric structure refers to a structure that is not symmetrical and is inclined in or against the scanning direction. In the context of this work, the asymmetry of the structures was significantly reduced through two different process adaptations. As a first adaption, a compensation term is added to the laser power modulation, which is calculated from the difference profile between a target profile and a structured profile. With this adaption, the shape deviation of an asymmetrical structure could be decreased by 66 %. Asymmetry can be reduced efficiently, although the difference profile required must be determined from a preliminary process step. As a second adaption, a modulation of the scanning speed is investigated with which shape deviation can be decreased by 40 %. Asymmetry is not as effectively prevented as when using the first adaption, but the adaption can be performed without the difference profile. Another aim was to investigate the destructuring, i.e. the removal and therefore smoothing, of asymmetric structures. Using the inverse laser power modulation for destructuring, the structure height of a symmetrical structure can be reduced by 91 % while the structure height of an asymmetric structure can be reduced by 68 %. To increase the efficiency of destructuring of an asymmetrical structure, iterative destructuring was investigated. With two iterations of destructuring, the structure height was reduced by 90 %. As a second approach for more efficient destructuring of asymmetric structures an adaption of the laser power modulation via a compensation term was investigated. The structure height could be reduced by 86 %. In summary, results show that asymmetry can be prevented when structuring with WaveShape and that asymmetric structures can be destructured efficiently.

In this paper, a high‐throughput on‐the‐fly laser processing system for the manufacture of silicon solar cells is proposed. Industrial laser processing machines are systematically limited in a trade‐off between throughput and focal spot size. Additionally, today's laser power and repetition rates cannot be fully utilized because of limited galvanometer scan speeds. This work aims to overcome this using a polygon scanner in an on‐the‐fly laser processing operation. Unlike conventional approaches, this setup does not use high‐precision positioning systems, but reduces wafer transport to a simple conveyor belt to optimize system cost, space, integrability, and cycle rate. The concept is implemented in a demonstrator setup. Applying a laser contact opening process, a throughput of 10 000 wafers per hour is demonstrated. A potential throughput of 13400 wafers per hour is calculated, considering the utilization of more powerful lasers. Inaccuracies due to the unevenness of the surface as well as transport speed oscillations are analyzed and shown not to have an impact on the efficiency of the cells processed with this setup. The throughput is increased five times compared to the theoretical upper‐throughput limitation for the same structure processed by a galvanometer‐driven laser system. [ABSTRACT FROM AUTHOR]

To study the influence pattern of femtosecond laser scanning path on the welding effect of skin tissue, this experiment analyzed the influence of scanning path on the surface morphology, degree of thermal damage, tensile strength, and microstructure of skin samples after skin attachment by designing nine scanning paths to weld skin tissue. The results showed that the skin samples connected by interrupted parallel mattress eversion sewing method with d = 0.2 mm showed no obvious color changes in morphology, the skin samples were connected on both front and back sides, the tensile strength was the highest, reaching 12.80 N/cm2, the thermal damage parameter was low at 1.08 × 10−2, the microstructure had obvious directionality, and the texture was clear and uniformly distributed. [ABSTRACT FROM AUTHOR]

Laser-based production systems have become more and more popular in recent years due to their potential to achieve high precision and accuracy in a wide range of different applications. However, the kinematic systems used for laser materials processing (LMP) are often inherited from other production technologies such as milling. The use of mobile robots (MRs) equipped with laser processing optics could disprove the current paradigm of adapted kinematic systems: scaling the size of the material processing system with the size of the components being processed and, thus, the resources used. The trend of autonomous MRs replacing classical kinematic systems in the field of material handling in industrial applications has been evident for years due to their higher flexibility, efficiency, and lower operating costs. In this paper, the prototype of a corresponding MR system is presented. In addition, the general design of the MR is presented. One challenge is the accuracy of an MR; for a common LMP such as laser cutting, the MR must be able to follow a predefined trajectory as accurately as possible. For this purpose, two different measurement systems are presented and compared. To demonstrate the potential of the mobile robot, an exemplary LMP process is also performed and evaluated. Finally, possibilities for improvement or further development, such as integration of scanner optics or the use of several autonomous MRs to increase productivity, are shown. [ABSTRACT FROM AUTHOR]

Featured Application: Additive remanufacturing of cutting tools on the example of flat broach by Coaxial Laser Wire Deposition technology. The recently introduced Coaxial Laser Wire Deposition technology can become a new promising method for remanufacturing high-complexity and expensive cutting tools (e.g., flat broach), which will have a significant impact on their service life. In addition, it is an innovative approach to tool management. An analysis of the feasibility of processing cobalt-added HSS powder steels was carried out for single clads and multilayer structures. The effect of process parameters (laser, beam power, travel speed, wire feed rate) on geometric properties, hardness and microstructure was discussed. In order to avoid cracking during multilayer deposition, an additional preheating to 320 °C was applied. Two sets of process parameters with high and low heat input were obtained. Both sets lead to crack-free structures that fulfill geometric (≥2.5 mm in height) and hardness (≥700 HV) requirements. [ABSTRACT FROM AUTHOR]

The stability and repeatability of laser metal deposition is particularly important when processing multiple layers or depositing material on complex component surfaces, and requires the use of process parameter control including the stand-off distance between the laser head and the substrate. The system proposed in this paper for correcting the stand-off parameter is based on a chromatic confocal sensor integrated into a laser head. Then, the spectral signal acquired from the measurement system is processed by using the developed application to compensate for the movement of an additional axis of the kinematic system. This study used an independent verification system based on the digital image correlation method. The validation tests were carried out using the system for correcting the stand-off parameter with different control algorithms and given motion trajectories and substrate materials. The results demonstrate that the developed system can be useful for laser metal deposition. [ABSTRACT FROM AUTHOR]

In the last decade, methods for relief fabrication on the metal surfaces by using the same base metal itself have appeared. The fabrication of surface relief by the laser remelting process is based on the relocation of the molten state of the base material instead of its removal. Since remelting is a thermally driven process, significant differences on the mechanical characteristics after surface structuring can be expected due to their thermophysical properties. Such operations are usually performed with high power radiation sources and in environments enriched with protective gases. In this paper, we have used relatively affordable low power equipment for relief formation on the carbon steel surface in air at room temperature. Within the framework of our investigation, we researched two means of relief formation based on the displacement of the liquid phase during laser irradiation. We found that the process of laser relief formation is accompanied by the generation of high amounts of oxide. This compromises the mechanical characteristics of the relief. Moreover, in this paper a multipass technique that enables the formation with a low amount of oxides is proposed. [ABSTRACT FROM AUTHOR]

The tooling industry is one of the sectors that demands the deployment of advanced manufacturing techniques, like-laser directed energy deposition (LDED) for building customized tools. D2 tool steel, a high-carbon high-chromium alloy, is among the various alloys used for tooling applications, but LDED processing of D2 tool steel is challenging due to its higher hot cracking susceptibility. In the present work, a full factorial experiment is carried out to identify process window for building defect-free D2 tool steel structures, and thereafter, microstructural and mechanical properties of the bulk D2 tool steel structures are characterized in as-built and the heat-treated conditions. The LDED built D2 bulk structures at identified process parameters are found to be crack-free with high relative area density (> 99.9%). It is observed that the heat-treatment of LDED built D2 tool steel leads to formation of cementite (Fe3C) phase along with retained austenite and other eutectic phases. This leads to an increase in the micro-hardness, wear-resistance and compressive yield strength of heat-treated D2 tool steel at room temperature. However, reduction in the wear resistance at elevated temperatures is observed in the heat-treated sample. This study establishes LDED as a fabrication technique for defect-free processing of D2 tool steel for potential tooling applications. [ABSTRACT FROM AUTHOR]

This paper provides an overview of Professor Jyoti Mazumder's contribution in modeling of laser-matter interaction during materials processing over the past four decades, particularly in the area of laser-based metal additive manufacturing of metallic components, followed by the work at The University of Manchester in modeling and simulation of powder/wire-feeding laser additive manufacturing, in-space laser additive manufacturing, high deposition rate laser metal deposition, and multiple-material laser powder bed fusion additive manufacturing processes. Future challenges and opportunities in this field are discussed. [ABSTRACT FROM AUTHOR]

We report the fine periodic nanostructure formation process on metal and semiconductor surfaces in air with few-cycle 7-fs laser pulses and its physical mechanism. Using appropriate peak power densities and scanning speeds for the laser pulses, nanostructures could be formed on stainless steel and gallium arsenide (GaAs) with periods of 60–110 nm and 130–165 nm, respectively, which are 1/5–1/4 of the period of nanostructures formed with 100-fs laser pulses. The periodicity can be explained as arising from the excitation of short-range propagating surface plasmon polaritons, and the observed periods are in good agreement with the model calculation results.

This article discusses recent advancements in the Laser Surface Transformation Hardening (LSTH) process applied to industrial metals. It focuses on examining the microstructure of the metal surface layer and explores different methods of performing LSTH to evaluate mechanical and surface properties. The study also investigates the utilization of various industrial lasers and simulation software for the LSTH process. The careful analysis of heat transfer and temperature control during LSTH aims to prevent the generation of surface defects like micro-cracks and surface melting. Finite element method (FEM) software effectively simulates the LSTH process. The research provides a comprehensive overview of recent developments in LSTH, categorized based on different metals and subsequent testing, highlighting its applications in the automotive industry. Electrochemical, wear, and microhardness tests are investigated to assess the potential applications of automotive metals.

Very recently, the synthesis of 2D MoS2 and WS2 through pulsed laser-directed thermolysis can achieve wafer-scale and large-area structures, in ambient conditions. In this paper, we report the synthesis of MoS2 and MoS2 oxides from (NH4)2MoS4 film using a visible continuous-wave (CW) laser at 532 nm, instead of the infrared pulsed laser for the laser-directed thermolysis. The (NH4)2MoS4 film is prepared by dissolving its crystal powder in DI water, sonicating the solution, and dip-coating onto a glass slide. We observed a laser intensity threshold for the laser synthesis of MoS2, however, it occurred in a narrow laser intensity range. Above that range, a mixture of MoS2 and MoO2 is formed, which can be used for a memristor device, as demonstrated by other research groups. We did not observe a mixture of MoS2 and MoO3 in the laser thermolysis of (NH4)2MoS4. The laser synthesis of MoS2 in a line pattern is also achieved through laser scanning. Due to of the ease of CW beam steering and the fine control of laser intensities, this study can lead toward the CW laser-directed thermolysis of (NH4)2MoS4 film for the fast, non-vacuum, patternable, and wafer-scale synthesis of 2D MoS2.

Since several years the need for realizing small and smart devices composed of functional materials is constantly increasing. Among this advanced materials, shape memory alloys (SMAs) are some of the most important functional materials in several applications, including in the biomedical and aerospace fields. Nowadays, laser cutting is probably the most widespread cutting technology for realising SMA mini- and micro-devices for several applications. The present manuscript reviews the scientific literature on the performance of laser-cut elements, in NiTi SMA, under different points of view. The literature was systematically analysed, according with a technological, metallurgical, functional and device/prototypal approaches. It can be highlighted that a relevant correlation between design, process condition and material performances can promote the realization of advanced smart devices made in NiTi SMA.

Laser direct-write (LDW) methods offer the rapid, on-demand, and high-resolution patterning of a variety of nanocrystals (NCs). Out of the many LDW methods, the laser-induced modification method is an attractive method as NCs can be directly patterned on polymers without supplementary preparation steps. Previously, it has been indicated that the laser irradiation of polydimethylsiloxane results in composite structures composed of graphitic carbon crystals (GCs) and silicon carbide NCs (SiC-NCs). However, material properties distinctive of SiC-NCs have not been reported for the resulting structures owing to the low formation content relative to those of GCs. In this study by utilizing a high-repetition femtosecond laser, we demonstrate the controlled formation of GCs and SiC-NCs to achieve a composite structure exhibiting a measurable semiconducting behavior for the first time. Moreover, photoluminescence emissions distinctive of fluorescent molecular-sized SiC-NCs were observed from the resulting structures. The presented results will trigger a wave of ideas utilizing ultrashort-pulsed lasers for the laser-induced modification of polymers toward the fabrication of a wide range of electronic and photonic devices, such as memory storage devices, photovoltaics, and optical sensors. [ABSTRACT FROM AUTHOR]

Recently, the realization of the spiral mass transfer of matter has attracted the attention of many researchers. Nano- and microstructures fabricated with such mass transfer can be used for the generation of light with non-zero orbital angular momentum (OAM) or the sensing of chiral molecules. In the case of metals and semiconductors, the chirality of formed spiral-shaped microstructures depends on the topological charge (TC) of the illuminating optical vortex (OV) beam. The situation is quite different with polarization-sensitive materials such as azopolymers, azobenzene-containing polymers. Azopolymers show polarization-sensitive mass transfer both at the meso and macro levels and have huge potential in diffractive optics and photonics. Previously, only one-spiral patterns formed in thin azopolymer films using circularly polarized OV beams and double-spiral patterns formed using linearly polarized OV beams have been demonstrated. In these cases, the TC of the used OV beams did not affect the number of formed spirals. In this study, we propose to use two-beam (an OV and a Gaussian beam with a spherical wavefront) interference lithography for realization spiral mass transfer with the desired number of formed spirals. The TC of the OV beam allows for controlling the number of formed spirals. We show the microstructures fabricated by the laser processing of thin azopolymer films can be used for the generation of OAM light at the microscale with the desired TC. The experimentally obtained results are in good agreement with the numerically obtained results and demonstrate the potential of the use of such techniques for the laser material processing of polarization-sensitive materials. [ABSTRACT FROM AUTHOR]

In laser beam fusion cutting of metals, the interaction of the gas jet with the melt determines the dynamics of the melt extrusion and the quality of the resulting cutting kerf. The gas-dynamic phenomena occurring during laser beam cutting are not fully known, especially regarding temporal fluctuations in the gas jet. The observation of gas and melt dynamics is difficult because the gas flow is not directly visible in video recordings and access to the process zone for observation is limited. In this study, the problem of imaging the gas jet from the cutting nozzle is addressed in a novel way by utilizing the striation pattern formed at the cutting kerf as a background pattern for background-oriented Schlieren imaging (BOS). In this first feasibility study, jets of different gas nozzles were observed in front of a solidified cutting kerf, which served as a background pattern for imaging. The results show that imaging of the characteristic shock diamonds of cutting nozzles is possible. Furthermore, the resulting shock fronts from an interaction of the gas jet with a model of a cutting front can be observed. The possibility of high-speed BOS with the proposed method is shown, which could be suitable to extend the knowledge of gas-dynamic phenomena in laser beam fusion cutting. [ABSTRACT FROM AUTHOR]

The curvature feature makes the irradiance and absorptivity change, resulting in an uneven power density distribution, which affects the quality of composite parts. In this study, a theoretical model-based Super-Gaussian profile beam in the laser irradiation area was established to obtain the heat flux distribution on the curved surface. The effect of curvature on the surface scattering reflection, temperature distribution, and surface morphology were investigated and verified the validity of the theoretical model. Furthermore, the influence of the laser intensity distribution, laser inclination and curvature radius on the power density distribution and distribution uniformity were studied. Research indicated that the power density increases as the distance from the origin increase resulting from the variation of the irradiance and absorptance along the circumference. The flatter the intensity distribution of the laser beam in the height direction, the less uniform the power density distribution. Accordingly, the typical Gaussian profile beam significantly ameliorates the power density distribution. This research provides a novel understanding of using heat sources during laser heating thermoplastic tape placement. [ABSTRACT FROM AUTHOR]

The polarization sensitivity of azopolymers is well known. Therefore, these materials are actively used in many applications of photonics. Recently, the unique possibilities of processing such materials using a structured laser beam were demonstrated, which revealed the key role of the distribution of polarization and the longitudinal component of light in determining the shape of the nano- and microstructures formed on the surfaces of thin azopolymer films. Here, we present numerical and experimental results demonstrating the high polarization sensitivity of thin azopolymer films to the local polarization state of an illuminating structured laser beam consisting of a set of light spots. To form such arrays of spots with a controlled distribution of polarization, different polarization states of laser beams, both homogeneous and locally inhomogeneous, were used. The results obtained show the possibility of implementing a parallel non-uniform patterning of thin azopolymer films depending on the polarization distribution of the illuminating laser beam. We believe that the demonstrated results will not only make it possible to implement the simultaneous detection of local polarization states of complex-shaped light fields but will also be used for the high-performance fabrication of diffractive optical elements and metasurfaces. [ABSTRACT FROM AUTHOR]

In this article, we present an approach to fabricate conductive tracks on polymer substrates. Here, a digital printing process is used together with subsequent processing by a laser. For this purpose, a silver flake-based composite is printed onto a polycarbonate substrate using a jet-dispensing process. The printed tracks are then cured using a pyrometer-controlled laser beam source. The fabricated samples are analyzed for electrical resistivity and the cross-sectional area of the conductive tracks and compared to conventionally oven-cured samples. Four-point measurements and an optical measurement method are used for this purpose. Based on the resulting resistance, two different process regimes can be observed for the laser curing process. By using a laser instead of an oven for post-treatment, the achieved resistance of the conductive tracks can be reduced by a factor of 2. Moreover, the tracks produced in this way are more reproducible in terms of the resistance that can be achieved. [ABSTRACT FROM AUTHOR]

The appearance of the residual stress hole (RSH) phenomenon makes the otherwise perfect laser shock processing (LSP) method potentially defective. Residual compressive stress distribution appears in the areas irradiated by the laser beam while the central position of the laser beam pursues the residual tensile stress individually. This is prominently seen in the numerical simulation of LSP experiments. However, the authors find that the existence of RSHs is ill-defined in most published testing results. A hypothesis that the cavitation effect inhibits the formation of RSHs based on the application of water in the laser shock process can be proposed.

This study investigates the use of a low cost microphone combined with state-of-the-art machine learning (ML) algorithms as online process monitoring to differentiate various materials and process regimes of Laser-Powder Bed Fusion (LPBF). Three processing regimes (lack of fusion pores, conduction mode and keyhole pores) and three alloys (316L stainless steel, bronze (CuSn8), and Inconel 718) were selected. Three conventional ML algorithms and a Convolutional Neural Network (CNN) were chosen to perform the classification tasks resulting in five main findings. First, we proved that the AE features are related to the laser-material interaction and not from undesired machine or environmental noise. Second, the process regimes are classified with high accuracy (> 87%) regardless of the algorithms and materials. Third, it is possible to build a single model from the three materials and still reach high classification accuracy (>86%) of the different regimes. Forth, the AE features used for the classifications are material and regime dependent. Finally, with LPBF processing of multi-materials on the rise, a strategy for classifying the material and the process regimes simultaneously using a CNN multi-label architecture reached a very high classification accuracy (≈ 93%). The results demonstrate the potential of our approaches for online LPBF process monitoring of different materials and regimes.

Optimising the laser intensity distribution in high power laser processes, such as laser welding, laser cladding or laser hardening, can be used to tailor the local thermal fields and thermal cycles which, in turn, determine the final process results. Deformable Mirrors allow to dynamically shape the beam profile and previous studies showed their potential. However, only limited flexibility in achievable beam shapes is shown at higher power levels. In addition the relation between desired laser intensity profiles and required mirror surface profiles is nontrivial. In this work the design and implementation of a dynamic beam shaping system, capable of handling high laser powers (up to 1 kW), is presented and evaluated. To that end, several distinctly different laser intensity profiles are defined, corresponding mirror surfaces are determined and realised with the beam shaping system. Measurements of the laser intensity profiles were compared with laser intensity profiles simulated using a previously presented mathematical framework and showed a good agreement. From the measurements it was concluded that the setup is suitable for high laser powers (up to 1 kW) and is characterised by large depth of focus (< 14 % change in dimensions at a distance of 100 mm from the focal plane). • A Deformable Mirror based adaptive focusing optic was designed and implemented. • The design can handle high laser power and has large depth of focus. • Mirror profiles were derived to create various distinctive laser intensity profiles. • Experimental validation of intensity profiles shows good agreement with simulations. • Versatile and flexible tool for dynamic beam shaping in high power laser processing. [ABSTRACT FROM AUTHOR]

The recently introduced Coaxial Laser Wire Deposition technology can become a new promising method for remanufacturing high-complexity and expensive cutting tools (e.g., flat broach), which will have a significant impact on their service life. In addition, it is an innovative approach to tool management. An analysis of the feasibility of processing cobalt-added HSS powder steels was carried out for single clads and multilayer structures. The effect of process parameters (laser, beam power, travel speed, wire feed rate) on geometric properties, hardness and microstructure was discussed. In order to avoid cracking during multilayer deposition, an additional preheating to 320 °C was applied. Two sets of process parameters with high and low heat input were obtained. Both sets lead to crack-free structures that fulfill geometric (≥2.5 mm in height) and hardness (≥700 HV) requirements.

The article presents development of a new heat transfer model for calculating temperature distribution in porous and non-porous materials during laser cutting. The novelty of this model lies in incorporating melting and vaporization progression of porous media during laser interaction. The modelling has been implemented through a transient finite difference scheme and the results have been validated against experimental data of cutting various materials by laser including rock and metals.

The stability and repeatability of laser metal deposition is particularly important when processing multiple layers or depositing material on complex component surfaces, and requires the use of process parameter control including the stand-off distance between the laser head and the substrate. The system proposed in this paper for correcting the stand-off parameter is based on a chromatic confocal sensor integrated into a laser head. Then, the spectral signal acquired from the measurement system is processed by using the developed application to compensate for the movement of an additional axis of the kinematic system. This study used an independent verification system based on the digital image correlation method. The validation tests were carried out using the system for correcting the stand-off parameter with different control algorithms and given motion trajectories and substrate materials. The results demonstrate that the developed system can be useful for laser metal deposition.

Today, the use of plastic lenses in processing optics for laser material processing is fundamentally limited to laser powers lower than 1 W. This is due to thermo-optical effects in the plastic material which primarily lead to a shift in the focus position. To overcome this laser power limitation, a design routine was developed for injection molded lenses, which simulates the optical properties of the lens in thermal equilibrium state during laser irradiation and which iteratively adapts the lens design for the manufacturing process in this way that the lens is compensated for thermal effects and manufacturing errors like shrinkage. The approach is demonstrated for an injection molded focusing lens used at an average laser power of 15 W. The focusing properties of the compensated manufactured lens are compared with the underlying simulations as well as with an uncompensated lens geometry used at the same laser power. [ABSTRACT FROM AUTHOR]

The realisation of sophisticated hierarchically patterned multiphase steels has the potential to enable unprecedented properties in engineering components. The present work explores the controlled creation of patterned multiphase steels in which the patterns are defined by two different crystal structures: face centre cubic or fcc (austenite) and body centre cubic or bcc (martensite). These austenite/martensite mesostructures are generated by solid–solid phase transformations during the application of localised laser heat treatments in a Fe-Ni-C alloy. In particular, four patterned configurations are analysed in this work consisting of one or two horizontal austenite line structures imprinted in a base of as-quenched or tempered martensite. Digital image correlation analysis during tensile testing of the developed materials showed that both the strength of the base martensite and the mesostructure at the gauge have a strong effect on the resulting properties. Clear differences were observed among the configurations in strain partitioning, hardening of the different constituents and failure. The uniform elongation and tensile strength are increased with respect to that of the reference martensite and austenite, respectively. Concepts explored in this work can be extended to more complex patterns and other base microstructures, opening novel strategies to engineer properties in steel and other alloys.

Femtosecond laser pulses were spatially modulated with fast reconfiguration of computer-generated holograms (CGHs) using a ferroelectric liquid-crystal-on-silicon spatial light modulator (FLCoS-SLM). Reconfiguration was executed at a frame rate of more than 1 kHz while changing the CGH every frame. The CGHs were designed as binary phases because the FLCoS-SLM can represent only binary values. The optimization method was modified by the weighted iterative Fourier transform algorithm (IFTA) to make the binary phase. The fundamental performance of the CGH reconstruction and femtosecond laser processing with 6.3 kHz pulse-to-pulse spatial light modulation was demonstrated. The reconfiguration speed will drastically change the applicability to science and industrial fields and open a door for new CGH applications. • Femtosecond pulses were modulated with CGH reconfiguration of 6.3kHz using FLCoS-SLM. • To our knowledge, this is the highest frame rate for laser processing using LCoS-SLM. • To make the binary phase mask, the weighted IFTA was modified. • The fast reconfiguration speed will be useful for next-generation laser processing. [ABSTRACT FROM AUTHOR]

This study investigates the use of a low cost microphone combined with state-of-the-art machine learning (ML) algorithms as online process monitoring to differentiate various materials and process regimes of Laser-Powder Bed Fusion (LPBF). Three processing regimes (lack of fusion pores, conduction mode and keyhole pores) and three alloys (316L stainless steel, bronze (CuSn8), and Inconel 718) were selected. Three conventional ML algorithms and a Convolutional Neural Network (CNN) were chosen to perform the classification tasks resulting in five main findings. First, we proved that the AE features are related to the laser-material interaction and not from undesired machine or environmental noise. Second, the process regimes are classified with high accuracy (> 87%) regardless of the algorithms and materials. Third, it is possible to build a single model from the three materials and still reach high classification accuracy (>86%) of the different regimes. Forth, the AE features used for the classifications are material and regime dependent. Finally, with LPBF processing of multi-materials on the rise, a strategy for classifying the material and the process regimes simultaneously using a CNN multi-label architecture reached a very high classification accuracy (≈ 93%). The results demonstrate the potential of our approaches for online LPBF process monitoring of different materials and regimes. [ABSTRACT FROM AUTHOR]

Laser material processing enables precise machining of a wide variety of materials. In order to prevent an excessive heat input, which leads to irreversible material damage, the process parameters have to be adapted to the processed material. To keep the heat load as low as possible, the potential of femtosecond laser technology is exploited. The processing of semi-finished products using femtosecond laser technology is highly depending on the processed material. In this regard, we established a workflow and basic parameters for the processing of polymeric material. The performed parameter study varying cutting speed, cutting gas pressure and pulse energy to optimize the manufacturing process. Scanning electron microscopy (SEM) was utilized to analyze the cutting results, such as cut edge quality or possible melted areas. The established parameter set is also suitable for processing of very filigree material structures as used in innovative medical devices. The SEM analysis of the established parameter set showed that a homogeneous, nonwavy cut edge was created along the kerf.

As a high-quality thick glass separation method, multifocus technology has proven its superiority. For a certain thickness of glass, there must be an optimal multifocus distance. But, the positions of the foci cannot be adjusted flexibly in current multifocus schemes without changing the energy proportions; the influence of thermal stress distribution on the quality of thick glass separation has not been systematically studied. An adjustable multifocus laser scheme has been proposed in this paper and proved by optical design, ray tracing, and experiment. First, finite element simulations have been performed to analyze the thermal stress distribution inside 20 mm glass. The simulation results show that thermal tensile stress exceeds the fracture threshold only at the upper and lower sides of the glass but not in the middle; the maximum thermal tensile stress reduces inside the glass when the symmetrical focal distance increases. Then, a series of separation experiments of 20, 22, and 25 mm thick soda lime glass have been carried out, which have adjusted foci positions to control the thermal stress distribution. The experimental results show that the deviation length decreases with an increase of the foci distances, and the optimal symmetrical foci distances reduce as the glass thickness increases. [ABSTRACT FROM AUTHOR]

Fluid dynamics models for laser material processing with metal fusion in conduction mode generally assume a constant absorptivity. This parameter is known to govern the process. However, it used to be pre-set by extrapolating absorptance measurements made at different conditions or adjusted to reproduce experimental bead shapes. In this study a new approach is developed. It consists in predicting the absorptance as a function of local surface conditions, including the surface temperature. The proposed absorptance model is applied to the metal alloy Ti-6Al-4V. It is found that the absorptance of this alloy changes with surface temperature over a wide range of beam incidence angles. Thermo-fluid simulations with tracking of the free-surface deformation are performed for conduction mode beam welding test cases with a Yb fibre laser and different travel speeds. It is found that the absorptivity coefficient commonly used for this process clearly underestimates the absorptance and the melt pool geometry predicted for the process conditions of this study. The computational results are also compared against experimental results and good quantitative agreement of the melt pool depth, width, length, free surface contour geometry, and the curvature of the end depression left after re-solidification at the laser switch-off location is obtained. The results show that the absorptance field predicted depends on the melt pool development stage, on the spatial location within the beam spot, and on the process conditions. [ABSTRACT FROM AUTHOR]

Despite extensive research efforts in the field of laser welding, the imperfect repeatability of the weld quality still represents an open topic. Indeed, the inherent complexity of the underlying physical phenomena prevents the implementation of an effective controller using conventional regulators. To close this gap, we propose the application of Reinforcement Learning for closed-loop adaptive control of welding processes. The presented system is able to autonomously learn a control law that achieves a predefined weld quality independently from the starting conditions and without prior knowledge of the process dynamics. Specifically, our control unit influences the welding process by modulating the laser power and uses optical and acoustic emission signals as sensory input. The algorithm consists of three elements: a smart agent interacting with the process, a feedback network for quality monitoring, and an encoder that retains only the quality critic events from the sensory input. Based on the data representation provided by the encoder, the smart agent decides the output laser power accordingly. The corresponding input signals are then analyzed by the feedback network to determine the resulting process quality. Depending on the distance to the targeted quality, a reward is given to the agent. The latter is designed to learn from its experience by taking the actions that maximize not just its immediate reward, but the sum of all the rewards that it will receive from that moment on. Two learning schemes were tested for the agent, namely ${Q}$ -Learning and Policy Gradient. The required training time to reach the targeted quality was 20 min for the former technique and 33 min for the latter.