Laser Shock Microforming of Thin Metal Sheets: Physical Principles, Modelling and Experimental Implementation

The increasing demands in MEMS fabrication are leading to new requirements in production technology. Especially the packaging and assembly require high accuracy in positioning and high reproducibility in combination with low production costs. Conventional assembly technology and mechanical adjustment methods are time consuming and expensive. Each component of the system has to be positioned and fixed. Also adjustment of the parts after joining requires additional mechanical devices that need to be accessible after joining. Accurate positioning of smallest components represents an up-to-date key assignment in micro-manufacturing. It has proven to be more time and cost efficient to initially assemble the components with widened tolerances before precisely micro-adjusting them in a second step.

Induction of through-thickness compressive residual stress fields in thin Al2024-T351 plates by laser shock processing

Laser Shock Processing (LSP) has been demonstrated as an emerging technique for the induction of RS’s fields in subsurface layers of relatively thick specimens. However, the LSP treatment of relatively thin specimens brings, as an additional consequence, the possible bending in a process of laser shock forming. This effect poses a new class of problems regarding the attainment of specified RS’s depth profiles in the mentioned type of sheets, and, what can be more critical, an overall deformation of the treated component. The analysis of the problem of LSP treatment for induction of tentatively through-thickness RS’s fields for fatigue life enhancement in relatively thin sheets in a way compatible with reduced overall workpiece deformation due to spring-back self-equilibration is envisaged in this paper. The coupled theoretical-experimental predictive approach developed by the authors has been applied to the specification of LSP treatments for achievement of RS's fields tentatively able to retard crack propagation on normalized specimens. A convergence between numerical code results and experimental results coming from direct RS's measurement is presented as a first step for the treatment of the normalized specimens under optimized conditions and verification of the crack retardation properties virtually induced.

High-brightness all semiconductor laser at 1.57 µm for space-borne lidar measurements of atmospheric carbon dioxide: device design and analysis of requirements

The availability of suitable laser sources is one of the main challenges in future space missions for accurate measurement of atmospheric CO2. The main objective of the European project BRITESPACE is to demonstrate the feasibility of an all-semiconductor laser source to be used as a space-borne laser transmitter in an Integrated Path Differential Absorption (IPDA) lidar system. We present here the proposed transmitter and system architectures, the initial device design and the results of the simulations performed in order to estimate the source requirements in terms of power, beam quality, and spectral properties to achieve the required measurement accuracy. The laser transmitter is based on two InGaAsP/InP monolithic Master Oscillator Power Amplifiers (MOPAs), providing the ON and OFF wavelengths close to the selected absorption line around 1.57 µm. Each MOPA consists of a frequency stabilized Distributed Feedback (DFB) master oscillator, a modulator section, and a tapered semiconductor amplifier optimized to maximize the optical output power. The design of the space-compliant laser module includes the beam forming optics and the thermoelectric coolers.The proposed system replaces the conventional pulsed source with a modulated continuous wave source using the Random Modulation-Continuous Wave (RM-CW) approach, allowing the designed semiconductor MOPA to be applicable in such applications. The system requirements for obtaining a CO2 retrieval accuracy of 1 ppmv and a spatial resolution of less than 10 meters have been defined. Envelope estimated of the returns indicate that the average power needed is of a few watts and that the main noise source is the ambient noise.

Random-modulation cw lidar system for space-borne carbon dioxide remote sensing based on a high-brightness semiconductor laser

In this paper, we report on the progresses of the BRITESPACE Consortium in order to achieve space-borne LIDAR measurements of atmospheric carbon dioxide concentration based on an all semiconductor laser source at 1.57 ?m. The complete design of the proposed RM-CW IPDA LIDAR has been presented and described in detail. Complete descriptions of the laser module and the FSU have been presented. Two bended MOPAs, emitting at the sounding frequency of the on- and off- IPDA channels, have been proposed as the transmitter optical sources with the required high brightness. Experimental results on the bended MOPAs have been presented showing a high spectral purity and promising expectations on the high output power requirements. Finally, the RM-CW approach has been modelled and an estimation of the expected SNR for the entire system is presented. Preliminary results indicate that a CO2 retrieval precision of 1.5 ppm could be achieved with an average output power of 2 W for each channel.

Laser induced forward transfer of silver pastes for printing of fingers in c-si cells.

The main objective of this work is to adapt the Laser Induced Forward Techniques (LIFT), a well- known laser direct writing technique for material transfer, to define metallic contacts (fingers and busbars) onto c-Si cells. The silver paste (with viscosity around 30-50 kcPs) is applied over a glass substrate using a coater. The thickness of the paste can be control changing the deposit parameters. The glass with the silver paste is set at a controlled gap over the c-Si cell. A solid state pulsed laser (532 nm) is focused at the glass/silver interface producing a droplet of silver that it is transferred to the c-Si cell. A scanner is used to print lines. The process parameters (silver paste thickness, gap and laser parameters -spot size, pulse energy and overlapping of pulses) are modified and the morphology of the lines is studied using confocal microscopy. Long lines are printed and the uniformity (in thickness and height) is studied. Some examples of metallization of larger areas (up to 10 cm x 10 cm) are presented.

Laser remote sensing applications (LiDAR) in forest hydrology and the management of river ecosystems.

La utilización de sensores láser desde plataformas aéreas (LiDAR) ofrece nuevas posibilidades en el cartografiado de sistemas fluviales, tanto en áreas densamente cubiertas por vegetación, como en aquellas que presentan una escasa cubierta. La información topográfica de alta resolución que se obtiene a partir de las medidas láser puede ser utilizada en el análisis y estimación de diversas variables hidrológicas, y en el estudio de diferentes componentes del medio fluvial. Entre éstas, cabe citar la vegetación riparia, la morfología fluvial, el régimen hidrológico o el grado de alteración de los ecosistemas debido a las presiones de origen antrópico. La gestión del medio fluvial puede ser mejorada en gran medida gracias a la precisión y fiabilidad de esta información. En muchas ocasiones, el escaso relieve de los valles fluviales y la densa cubierta vegetal que existe en ellos han dificultado la aplicación de otras técnicas de teledetección. Sin embargo, los datos obtenidos mediante altimetría láser son especialmente aconsejables para estos trabajos, mediante análisis numéricos o a través de la simple interpretación de las imágenes obtenidas. Este artículo muestra las posibilidades de uso de los datos LiDAR en hidrología forestal y en la gestión de zonas húmedas, a lo largo de tramos con condiciones climáticas bien diferenciadas. En todas ellas, se comparan los resultados obtenidos mediante la aplicación de distinto software, con el fin de mostrar la mejor metodología de tratamiento de la información láser. Asimismo, se muestra la diferencia con otras técnicas de teledetección, y se muestra la fácil integración de los datos LiDAR con otras herramientas y metodologías de estudio de las variables citadas.

Deciduous tree reconstruction algorithm based on cylinder fitting from mobile terrestrial laser scanned point clouds

Vector reconstruction of objects from an unstructured point cloud obtained with a LiDAR-based system (light detection and ranging) is one of the most promising methods to build three dimensional models of orchards. The cylinder fitting method for woody structure reconstruction of leafless trees from point clouds obtained with a mobile terrestrial laser scanner (MTLS) has been analysed. The advantage of this method is that it performs reconstruction in a single step. The most time consuming part of the algorithm is generation of the cylinder direction, which must be recalculated at the inclusion of each point in the cylinder. The tree skeleton is obtained at the same time as the cluster of cylinders is formed. The method does not guarantee a unique convergence and the reconstruction parameter values must be carefully chosen. A balanced processing of clusters has also been defined which has proven to be very efficient in terms of processing time by following the hierarchy of branches, predecessors and successors. The algorithm was applied to simulated MTLS of virtual orchard models and to MTLS data of real orchards. The constraints applied in the method have been reviewed to ensure better convergence and simpler use of parameters. The results obtained show a correct reconstruction of the woody structure of the trees and the algorithm runs in linear logarithmic time

Relationship between residual stresses and mechanical behavior in ceramic composites

En este trabajo, materiales de tipo alúmina/Y-TZP (ZrO2 tetragonal, estabilizada con 3 mol. % Y2O3), como sistema cerámico popular por sus mejoradas propiedades mecánicas en comparación con las cerámicas de alúmina puras, han sido estudiados en términos de propiedades mecánicas y tensiones residuales. El novedoso método de colado en cinta, consistente en el apilamiento de cintas de cerámica verde a temperatura ambiente y el uso de bajas presiones, se ha escogido para la presente investigación con el fin de poder aprovechar al máximo el futuro desarrollo de materiales laminados de alúmina-óxido de circonio. Se han determinado las propiedades de los materiales obtenidos por este nuevo método de procesamiento comparándolas con las de los materiales obtenidos por “slip casting”, con el fin de analizar si el método propuesto afecta a la microestructura y, por tanto, a las propiedades mecánicas y tensiones residuales propias de estos materiales. Para analizar la idoneidad del proceso de fabricación, utilizado para evitar la presencia de discontinuidades en las intercaras entre las láminas así como otros fenómenos que puedan interferir con las propiedades mecánicas, se estudiaron materiales cerámicos con la misma composición en cintas. Por otra parte también se analizó el efecto de la adición de óxido de circonio sobre la aparición de tensiónes residuales en cerámicas Al2O3/Y-TZP, teniendo en cuenta su notable influencia sobre las propiedades microestructurales y mecánicas de los materiales, así como el requisito de co-sinterización de capas con diferentes materiales compuestos en materiales laminados. La caracterización del material incluye la determinación de la densidad, el análisis de la microestructura, la obtención de las propiedades mecánicas (módulo de elasticidad, dureza, resistencia a la flexión y tenacidad de fractura) así como de las tensiones residuales. En combinación con otros métodos de medida tradicionales, la nanoindentación también se empleó como una técnica adicional para la medida del módulo de elasticidad y de la dureza. Por otro lado, diferentes técnicas de difracción con neutrones, tanto las basadas en longitud de onda constante (CW) como en tiempo de vuelo (TOF), han sido empleadas para la medición fiable de la deformación residual a través del grosor en muestras a granel. Las tensiones residuales fueron determinadas con elevada precisión, aplicando además métodos de análisis apropiados, como por ejemplo el refinamiento de Rietveld. Las diferentes fases en cerámicas sinterizadas, especialmente las de zirconia, se examinaron con detalle mediante el análisis de Rietveld, teniendo en cuenta el complicado polimorfismo del Óxido de Zirconio (ZrO2) así como las posibles transformaciones de fase durante el proceso de fabricación. Los efectos del contenido de Y-TZP en combinación con el nuevo método de procesamiento sobre la microestructura, el rendimiento mecánico y las tensiones residuales de los materiales estudiados (Al2O3/Y-TZP) se resumen en el presente trabajo. Finalmente, los mecanismos de endurecimiento, especialmente los relacionados con las tensiones residuales, son igualmente discutidos. In present work, Alumina/Y-TZP (tetragonal ZrO2 stabilized with 3 mol% Y2O3) materials, as an popular ceramic system with improved mechanical properties compared with the pure alumina ceramics, have been studied in terms of mechanical properties and residual stresses. The novel tape casting method, which involved the stacking of green ceramics tapes at room temperature and using low pressures, is selected for manufacturing and investigation, in order to take full advantage of the future development of alumina-zirconia laminated materials. Features of materials obtained by the new processing method are determined and compared with those of materials obtained by conventional slip casting in a plaster mold, in order to study whether the proposed method of processing affects microstructure and thereby the mechanical properties and residual stresses characteristics of materials. To analyse the adequacy of the manufacturing process used to avoid the presence of discontinuities at the interfaces between the sheets and other phenomena that interfere with the mechanical properties, ceramic materials with the same composition in tapes were investigated. Moreover, the effect of addition of zirconia on residual stress development of Al2O3/Y-TZP ceramics were taken into investigations, considering its significantly influence on the microstructure and mechanical properties of materials as well as the requirement of co-sintering of layers with different composites in laminated materials. The characterization includes density, microstructure, mechanical properties (elastic modulus, hardness, flexure strength and fracture toughness) and residual stresses. Except of the traditional measurement methods, nanoindentation technique was also used as an additional measurement of the elastic modulus and hardness. Neutron diffraction, both the constant-wavelength (CW) and time-of-flight (TOF) neutron diffraction techniques, has been used for reliable through-thickness residual strain measurement in bulk samples. Residual stresses were precisely determined combined with appropriate analysis methods, e.g. the Rietveld refinement. The phase compositions in sintered ceramics especially the ones of zirconia were accurately examined by Rietveld analysis, considering the complex polymorph of ZrO2 and the possible phase transformation during manufacturing process. Effects of Y-TZP content and the new processing method on the microstructure, mechanical performance and residual stresses were finally summarized in present studied Al2O3/Y-TZP materials. The toughening mechanisms, especially the residual stresses related toughening, were theoretically discussed.

Determination of the species generated in atmospheric-pressure laser-induced plasmas by mass spectometry techniques

We present temporal information obtained by mass spectrometry techniques about the evolution of plasmas generated by laser filamentation in air. The experimental setup used in this work allowed us to study not only the dynamics of the filament core but also of the energy reservoir that surrounds it. Furthermore, valuable insights about the chemistry of such systems like the photofragmentation and/or formation of molecules were obtained. The interpretation of the experimental results are supported by PIC simulations.

Caracterización de la cerámica para su empleo como material de enfriamiento evaporativo en la envolvente de los edificios = Ceramic characterization towards its application as evaporative cooling material in building envelopes

El presente trabajo de investigación determina las características de la cerámica que más eficientemente se comporta a evaporación y a enfriamiento. Con el objeto de ser empleado como material integrado en la envolvente de los edificios para reducir su carga de refrigeración. La cerámica es un buen material para ser empleado para la refrigeración por evaporación. Es un sólido poroso inerte que, tras ser sometido a cocción a temperaturas por encima de los 900ºC, resulta uno de los materiales que mejor se comportan como contenedor de agua en su red capilar para, posteriormente, ir liberándola por evaporación al mismo tiempo que se enfría su superficie. La metodología general de investigación, se divide en tres etapas: Búsqueda y análisis del estado de la técnica y de la investigación. Estudio teórico de la eficacia del enfriamiento evaporativo como estrategia de enfriamiento pasivo en la arquitectura. Etapa experimental, desarrollada en tres fases: una primera de definición de los parámetros determinantes del Enfriamiento Evaporativo en piezas cerámicas, una segunda de selección cerámica y diseño de ensayos experimentales y una tercera de caracterización de la cerámica bajo criterios de evaporación y de enfriamiento. El recorrido por el estado de la cuestión ha identificado las aplicaciones tecnológicas y las investigaciones científicas que emplean el Enfriamiento Evaporativo con piezas cerámicas como técnica de enfriamiento. Como resultado se ha obtenido una tabla de clasificación de sistemas de enfriamiento evaporativo y se ha constatado que el conjunto de las aplicaciones están centradas en el diseño de piezas o sistemas pero que, sin embargo, no existe una definición de las características de la cerámica para su empleo como material de enfriamiento por evaporación. El estudio teórico de la eficacia del empleo del enfriamiento evaporativo como estrategia de enfriamiento pasivo en la arquitectura se ha realizado mediante cálculos de porcentaje de ampliación de horas en confort con empleo de técnicas de enfriamiento evaporativo directo e indirecto (EED y EEI). Como resultado se obtienen unos mapas para el ámbito español de potencial de aplicación del EED y EEI. Los resultados permiten afirmar que mediante EE se puede llegar a confort en prácticamente la totalidad de las horas de los días más cálidos del año en muchas localidades. La metodología experimental se ha desarrollado en tres fases. En la fase inicial, se han definido los parámetros determinantes del enfriamiento evaporativo en un medio cerámico mediante ensayos experimentales de capacidad de evaporación y de caracterización. Se realizaron un total de 12 ensayos. Se determinó que el material cerámico tiene una gran influencia en la capacidad de evaporación y enfriamiento en las piezas cerámicas, apoyando la hipótesis inicial y la necesidad de caracterizar el material. La primera fase empírica se centró en la selección cerámica y el diseño de los ensayos experimentales de comportamiento hídrico. Se seleccionaron muestras de 5 tipos de cerámica. Se realizaron 4 tipos de ensayos de caracterización y 6 tipos de ensayos experimentales de comportamiento hídrico (total 123 muestras ensayadas). Los resultados obtenidos son de dos tipos, por un lado, se determinó cuál es el tipo de cerámica que más eficientemente se comporta a EE y, por otro, se rediseñaron los ensayos de la última fase experimental. Para la segunda fase experimental se seleccionaron cerámicas de fabricación manual abarcando el mayor número de localidades del ámbito español. Se realizaron ensayos de caracterización de 7 tipos y ensayos de comportamiento hídrico de 5 tipos (total 197 muestras ensayadas). Los resultados de caracterización han permitido aportar unos rangos de las características de la cerámica que más eficientemente se comporta en los ensayos de comportamiento hídrico. Al final de la investigación se ha caracterizado el material cerámico aportando características acerca de su porosidad, capacidad de absorción, color, rugosidad y mineralogía. Así como datos de referencia de su comportamiento hídrico. Además se ha desarrollado una metodología de ensayo específica que permite evaluar la capacidad de enfriamiento eficiente de una pieza cerámica. ABSTRACT The purpose of this research is to determine the characteristics of ceramic materials having the most efficient performance in terms of evaporation and cooling, so that they can be integrated in building envelopes to reduce cooling loads. Ceramics are suitable materials for cooling through passive evaporation. After being fired at temperatures over 900 °C (1,652 °F), the capillary network of this inert porous medium turns to be excellent to retain water, which is progressively liberated by evaporation while the material surface gets colder. Research methodology has involved the following steps: Search and analysis on the state of the art in technology and research. Theoretical study on the efficiency of evaporation as passive cooling strategies in buildings. Experimental stage developed in three phases, namely: definition of parameters determining evaporative cooling in ceramic elements; ceramic selection and design of experimental tests; characterization of ceramic materials under evaporation and cooling criteria. Search and analysis on the state of the art in this field have been useful to identify technology applications and scientific research where ceramics are employed for evaporative cooling. The resulting table shows that applications are wholly focused on the design of pieces and systems. Nonetheless, there is lack of definition of material characteristics in this scope. The theoretical study on efficiency of the passive strategy applied to buildings has been realized by calculation of the percentage increase in comfort hours through direct/indirect evaporative cooling techniques (DEC/IEC). The mapping of their potential application in Spain clearly shows that comfort conditions can be reached in almost all the hours of the hottest days in many towns. In the initial phase of the experimental stage, parameters determining evaporative cooling in ceramic media have been defined. For this purpose, characterization tests and evaporation and cooling rates experiments have been carried out; the number of samples tested amounted to 12. It has been concluded that material characteristics have great influence on these rates, which supports the initial hypothesis and the need for their characterization. The first empirical phase has focused on ceramic selection and design of water behaviour experimental methods. The samples covered five different kinds of ceramic materials. Four different characterization tests and six different water behaviour experiments were carried out; the number of samples tested amounted to 123. The experimental testing procedures served to determine the most efficient types of ceramic materials in terms of evaporative cooling efficiency and, at the same time, made it necessary to change the original designed experimental test for the last phase. In the second phase, a number of varied hand-made ceramic tiles have been selected. Seven different characterization tests and five different water behaviour tests were carried out; the number of samples amounted to 197. The results of characterization served to establish a range of features in ceramic materials according to their efficiency in water behaviour experiments. Finally, ceramic materials have been characterized according to porosity, water absorption, colour, surface roughness and mineralogy. Also, reference data regarding water behaviour have been included. Moreover, an innovative and specific experimental test to evaluate cooling efficiency of ceramic tiles has been developed.

Reduction of front-metallization grid shading in concentrator cells through laser micro-grooved cover glass

Concentrator solar cell front-grid metallizations are designed so that the trade-off between series resistance and shading factor (SF) is optimized for a particular irradiance. High concentrator photovoltaics (CPV) typically requires a metallic electrode pattern that covers up to 10% of the cell surface. The shading effect produced by this front electrode results in a significant reduction in short-circuit current (I SC) and hence, in a significant efficiency loss. In this work we present a cover glass (originally meant to protect the cell surface) that is laser-grooved with a micrometric pattern that redirects the incident solar light towards interfinger regions and away from the metallic electrodes, where they would be wasted in terms of photovoltaic generation. Quantum efficiency (QE) and current (I)-voltage (V) characterization under concentration validate the proof-of-concept, showing great potential for CPV applications

Analysis by finite element calculations of light scattering in laser-textured AZO films for PV thin-film solar cells

In the thin-film photovoltaic industry, to achieve a high light scattering in one or more of the cell interfaces is one of the strategies that allow an enhancement of light absorption inside the cell and, therefore, a better device behavior and efficiency. Although chemical etching is the standard method to texture surfaces for that scattering improvement, laser light has shown as a new way for texturizing different materials, maintaining a good control of the final topography with a unique, clean, and quite precise process. In this work AZO films with different texture parameters are fabricated. The typical parameters used to characterize them, as the root mean square roughness or the haze factor, are discussed and, for deeper understanding of the scattering mechanisms, the light behavior in the films is simulated using a finite element method code. This method gives information about the light intensity in each point of the system, allowing the precise characterization of the scattering behavior near the film surface, and it can be used as well to calculate a simulated haze factor that can be compared with experimental measurements. A discussion of the validation of the numerical code, based in a comprehensive comparison with experimental data is included.