Laser cladding with scanning optics

Scanning optics create different types of phenomena and limitation to cladding process compared to cladding with static optics. This work concentrates on identifying and explaining the special features of laser cladding with scanning optics. Scanner optics changes cladding process energy input mechanics. Laser energy is introduced into the process through a relatively small laser spot which moves rapidly back and forth, distributing the energy to a relatively large area. The moving laser spot was noticed to cause dynamic movement in the melt pool. Due to different energy input mechanism scanner optic can make cladding process unstable if parameter selection is not done carefully. Especially laser beam intensity and scanning frequency have significant role in the process stability. The laser beam scanning frequency determines how long the laser beam affects with specific place local specific energy input. It was determined that if the scanning frequency in too low, under 40 Hz, scanned beam can start to vaporize material. The intensity in turn determines on how large package this energy is brought and if the intensity of the laser beam was too high, over 191 kW/cm2, laser beam started to vaporize material. If there was vapor formation noticed in the melt pool, the process starts to resample more laser alloying due to deep penetration of laser beam in to the substrate. Scanner optics enables more flexibility to the process than static optics. The numerical adjustment of scanning amplitude enables clad bead width adjustment. In turn scanner power modulation (where laser power is adjusted according to where the scanner is pointing) enables modification of clad bead cross-section geometry when laser power can be adjusted locally and thus affect how much laser beam melts material in each sector. Power modulation is also an important factor in terms of process stability. When a linear scanner is used, oscillating the scanning mirror causes a dwell time in scanning amplitude border area, where the scanning mirror changes the direction of movement. This can cause excessive energy input to this area which in turn can cause vaporization and process instability. This process instability can be avoided by decreasing energy in this region by power modulation. Powder feeding parameters have a significant role in terms of process stability. It was determined that with certain powder feeding parameter combinations powder cloud behavior became unstable, due to the vaporizing powder material in powder cloud. Mainly this was noticed, when either or both the scanning frequency or powder feeding gas flow was low or steep powder feeding angle was used. When powder material vaporization occurred, it created vapor flow, which prevented powder material to reach the melt pool and thus dilution increased. Also powder material vaporization was noticed to produce emission of light at wavelength range of visible light. This emission intensity was noticed to be correlated with the amount of vaporization in the powder cloud.

Estudio experimental del aporte de material en forma de hilo por Laser Cladding

La competencia y la constante evolución del mercado de la Fabricación Aditiva, y en concreto del Laser Cladding, como en cualquier otro mercado industrial, demandan una alta productividad y una buena calidad de los recubrimientos. El objetivo principal de este trabajo, realizado en el Taller de Ingeniería Mecánica de la Universidad del País Vasco, es analizar estos dos factores basándose en el aporte de material en forma de hilo, y hacer una comparación de los resultados que se obtendrían con el aporte de polvo. Como indicador de la productividad se ha utilizado la tasa de aporte, y para analizar la calidad del aporte se han observado los defectos y el crecimiento de los cordones tanto en altura como en anchura. Otros factores como la dilución y la reducción de costes, también se han tenido en cuenta.

Laser cladding and its potential to reduce particulate matter emissions from the automotive and locomotive sector

Laser Cladding (LC) is an emerging technology which is used both for coating applications as well as near-net shape fabrication. Despite its significant advantages, such as low dilution and metallurgical bond with the substrate, it still faces issues such as process control and repeatability, which restricts the extension to its applications. The following thesis evaluates the LC technology and tests its potential to be applied to reduce particulate matter emissions from the automotive and locomotive sector. The evaluation of LC technology was carried out for the deposition of multi-layer and multi-track coatings. 316L stainless steel coatings were deposited to study the minimisation of geometric distortions in thin-walled samples. Laser power, as well as scan strategy, were the main variables to achieve this goal. The use of constant power, reduction at successive layers, a control loop control system, and two different scan strategies were studied. The closed-loop control system was found to be practical only when coupled with the correct scan strategy for the deposition of thin walls. Three overlapped layers of aluminium bronze were deposited onto a structural steel pipe for multitrack coatings. The effect of laser power, scan speed and hatch distance on the final geometry of coating were studied independently, and a combined parameter was established to effectively control each geometrical characteristic (clad width, clad height and percentage of dilution). LC was then applied to coat commercial GCI brake discs with tool steel. The optical micrography showed that even with preheating, the cracks that originated from the substrate towards the coating were still present. The commercial brake discs emitted airborne particles whose concentration and size depended on the test conditions used for simulation in the laboratory. The contact of LC cladded wheel with rail emitted significantly less ultra-fine particles while maintaining the acceptable values of coefficient of friction.

Kulutus- korroosionkestävien materiaalien laserpinnoitus

Diplomityössä tutkitaan kulutus- ja korrosionkestävien materiaalien laserpinnoitusta. Laserpinnoituksessa sulatetaan uutta materiaalia työkappaleen pintaan lasersäteen avulla. Tarkoituksena on yleensä parantaa pinnan korroosion, kulumisen tai pintapaineen kestävyyttä. Laserpinnoitukseen liittyy useita etuja verrattuna konventionaalisiin päällehitsausprosesseihin. Työssä tutkittavat pinnoitemateriaalit ovat kobolttipohjaiset Stellite 1 ja Stellite 6, työkaluteräkset WR 4 ja WR 6 sekä metallimatriisikomposiitti Anval50/50+30 % Cr3C2. Pinnoitettavat perusaineet ovat hiiliteräs Fe 52, ruostumaton teräs AISI 316 ja valurauta GRP 500. Työn tavoitteena on löytää kunkin pinnoite/perusaine-yhdistelmän pinnoitusparametrit. Pinnoituskokeissa käytettiin LTKK:n 6 kW:n CO2-laseria. Pinnoitetuille koekappeleille tehtiin kovuusmittaukset ja kulutuskokeet. Pinnoitteiden mikrorakenteet analysoitiin ja sekoittumisasteet laskettiin. Virheitä tutkittiin silmämääräisesti sekä radiografisella kuvauksella. Optimiparametreja pinnoitemateriaaleille ei löydetty. Pinnoitteiden sekoittumisasteet muodostuivat suuriksi liiallisen lasertehon ja/tai huonon lisäaineen kohdistuksen vuoksi. Suuri sekoittuminen alensi pinnoitteiden kovuutta ja kulumiskestävyyttä. Pinnoitusparametreja arvioidaan koetulosten perusteella ja niille annetaan korjausehdotuksia. Lopuksi esitetään suosituksia tutkimusprojektin jatkotoimille.

Potkurilaitteen ohjausputken laserpinnoitus

Laserpinnoitus on additiivinen prosessi, jossa lasertehon avulla sulatetaan pinnoitusainetta pinnoitettavan kappaleen pintaan. Laserpinnoituksella on mahdollista aikaansaada tiivis sekä kova, kulutusta ja korroosiota kestävä pinnoite kappaleen pintaan. Tässä työssä kohteena oli potkurilaitteen ohjausputken laserpinnoitus. Kyseisessä kohteessa pinnoitteelta vaaditaan hyvää korroosion- ja kulumisen kestoa. Työn tavoitteena oli lisätä tietoisuutta laserpinnoitusprosessista ja siinä vaikuttavista tekijöistä. Myös materiaaliominaisuuksien vaikutuksia sekä pinnoitus- että pinnoitettavien aineiden osalta selvitettiin. Työhön sisältyi myös kokeellinen osuus, jossa tavoitteena oli löytää kustannustehokkain pinnoiteaine tutkittuun kohteeseen. Kokeissa ohjausputki- sekä levyaihioon tehtiin koepinnoituksia. Kokeiden ja edelleen materiaalitutkimuksien avulla tutkittiin neljää eri pinnoitusainetta, jotka olivat Stellitti 21, Inconel 625, AISI 316L ja AISI 431. Kovuus- ja taivutuskokeiden perusteella kyseisistä aineista vain Stelliitti 21 täytti ohjausputken pinnoitteelle asetetut vaatimukset. Näin ollen Stelliitti 21 valikoitui kustannustehokkaimmaksi pinnoitusaineeksi ohjausputkien laserpinnoitukseen.

Weld joint characteristics by nano-materials addition

The need for industries to remain competitive in the welding business, has created necessity to develop innovative processes that can exceed customer’s demand. Significant development in improving weld efficiency, during the past decades, still have their drawbacks, specifically in the weld strength properties. The recent innovative technologies have created smallest possible solid material known as nanomaterial and their introduction in welding production has improved the weld strength properties and to overcome unstable microstructures in the weld. This study utilizes a qualitative research method, to elaborate the methods of introducing nanomaterial to the weldments and the characteristic of the welds produced by different welding processes. The study mainly focuses on changes in the microstructural formation and strength properties on the welded joint and also discusses those factors influencing such improvements, due to the addition of nanomaterials. The effect of nanomaterial addition in welding process modifies the physics of joining region, thereby, resulting in significant improvement in the strength properties, with stable microstructure in the weld. The addition of nanomaterials in the welding processes are, through coating on base metal, addition in filler metal and utilizing nanostructured base metal. However, due to its insignificant size, the addition of nanomaterials directly to the weld, would poses complications. The factors having major influence on the joint integrity are dispersion of nanomaterials, characteristics of the nanomaterials, quantity of nanomaterials and selection of nanomaterials. The addition of nanomaterials does not affect the fundamental properties and characteristics of base metals and the filler metal. However, in some cases, the addition of nanomaterials lead to the deterioration of the joint properties by unstable microstructural formations. Still research are ongoing to achieve high joint integrity, in various materials through different welding processes and also on other factors that influence the joint strength.

Determining the elastic-plastic properties of metallic materials through instrumented indentation

En los últimos años, y asociado al desarrollo de la tecnología MEMS, la técnica de indentación instrumentada se ha convertido en un método de ensayo no destructivo ampliamente utilizado para hallar las características elástico-plásticas de recubrimientos y capas delgadas, desde la escala macroscópica a la microscópica. Sin embargo, debido al complejo mecanismo de contacto debajo de la indentación, es urgente proponer un método más simple y conveniente para obtener unos resultados comparables con otras mediciones tradicionales. En este estudio, el objetivo es mejorar el procedimiento analítico para extraer las propiedades elástico-plásticas del material mediante la técnica de indentación instrumentada. La primera parte se centra en la metodología llevada a cabo para medir las propiedades elásticas de los materiales elásticos, presentándose una nueva metodología de indentación, basada en la evolución de la rigidez de contacto y en la curva fuerza-desplazamiento del ensayo de indentación. El método propuesto permite discriminar los valores de indentación experimental que pudieran estar afectados por el redondeo de la punta del indentador. Además, esta técnica parece ser robusta y permite obtener valores fiables del modulo elástico. La segunda parte se centra en el proceso analítico para determinar la curva tensión-deformación a partir del ensayo de indentación, empleando un indentador esférico. Para poder asemejar la curva tension-deformación de indentación con la que se obtendría de un ensayo de tracción, Tabor determinó empíricamente un factor de constricción de la tensión () y un factor de constricción de la deformación (). Sin embargo, la elección del valor de y  necesitan una derivación analítica. Se describió analíticamente una nueva visión de la relación entre los factores de constricción de tensión y la deformación basado en la deducción de la ecuación de Tabor. Un modelo de elementos finitos y un diseño experimental se realizan para evaluar estos factores de constricción. A partir de los resultados obtenidos, las curvas tension-deformación extraidas de los ensayos de indentación esférica, afectadas por los correspondientes factores de constricción de tension y deformación, se ajustaron a la curva nominal tensión-deformación obtenida de ensayos de tracción convencionales. En la última parte, se estudian las propiedades del revestimiento de cermet Inconel 625-Cr3C2 que es depositado en el medio de una aleación de acero mediante un láser. Las propiedades mecánicas de la matriz de cermet son estudiadas mediante la técnica de indentación instrumentada, haciendo uso de las metodologías propuestas en el presente trabajo. In recent years, along with the development of MEMS technology, instrumented indentation, as one type of a non-destructive measurement technique, is widely used to characterize the elastic and plastic properties of metallic materials from the macro to the micro scale. However, due to the complex contact mechanisms under the indentation tip, it is necessary to propose a more convenient and simple method of instrumented indention to obtain comparable results from other conventional measurements. In this study, the aim is to improve the analytical procedure for extracting the elastic plastic properties of metallic materials by instrumented indentation. The first part focuses on the methodology for measuring the elastic properties of metallic materials. An alternative instrumented indentation methodology is presented. Based on the evolution of the contact stiffness and indentation load versus the depth of penetration, the possibility of obtaining the actual elastic modulus of an elastic-plastic bulk material through instrumented sharp indentation tests has been explored. The proposed methodology allows correcting the effect of the rounding of the indenter tip on the experimental indentation data. Additionally, this technique does not seem too sensitive to the pile-up phenomenon and allows obtaining convincing values of the elastic modulus. In the second part, an analytical procedure is proposed to determine the representative stress-strain curve from the spherical indentation. Tabor has determined the stress constraint factor (stress CF), and strain constraint factor (strain CF), empirically but the choice of a value for and is debatable and lacks analytical derivation. A new insight into the relationship between stress and strain constraint factors is analytically described based on the formulation of Tabor’s equation. Finite element model and experimental tests have been carried out to evaluate these constraint factors. From the results, representative stress-strain curves using the proposed strain constraint factor fit better with the nominal stress-strain curve than those using Tabor’s constraint factors. In the last part, the mechanical properties of an Inconel 625-Cr3C2 cermet coating which is deposited onto a medium alloy steel by laser cladding has been studied. The elastic and plastic mechanical properties of the cermet matrix are studied using depth-sensing indentation (DSI) on the micro scale.

Directional bend sensor based on an asymmetric modification of the fiber cladding by femtosecond laser

A femtosecond laser was used to modify a part of the cladding of a standard LPG bend sensor. The device produced wavelength shifts depending upon the direction of bend, thus making a shape sensor.

Bending characteristics of fiber long-period gratings with cladding index modified by femtosecond laser

A femtosecond laser has been used to asymmetrically modify the cladding of fiber containing long-period gratings. Following modification, devices in single-mode fiber are shown to be capable of sensing the magnitude and direction of bending in one plane by producing blue and red wavelength shifts depending upon the orientation of the bend. The resulting curvature sensitivities were -1.62 and +3.82 nm&middotm. Devices have also been produced using an elliptical core fiber to study the effects of the cladding modification on the two polarization eigenstates. A cladding modification applied on the fast axis of the fiber is shown to affect the light in the fast axis much more significantly than the light in the orthogonal state; this behavior may ultimately lead to a sensor capable of detecting the direction of bending in two dimensions for applications in shape sensing.

Low loss depressed cladding waveguide inscribed in YAG:Nd single crystal by femtosecond laser pulses

A depressed cladding waveguide with record low loss of 0.12 dB/cm is inscribed in YAG:Nd(0.3at.%) crystal by femtosecond laser pulses with an elliptical beam waist. The waveguide is formed by a set of parallel tracks which constitute the depressed cladding. It is a key element for compact and efficient CW waveguide laser operating at 1064 nm and pumped by a multimode laser diode. Special attention is paid to mechanical stress resulting from the inscription process. Numerical calculation of mode distribution and propagation loss with the elasto-optical effect taken into account leads to the conclusion that the depressed cladding is a dominating factor in waveguide mode formation, while the mechanical stress only slightly distorts waveguide modes.

Bending characteristics of fiber long-period gratings with cladding index modified by femtosecond laser

A femtosecond laser has been used to asymmetrically modify the cladding of fiber containing long-period gratings. Following modification, devices in single-mode fiber are shown to be capable of sensing the magnitude and direction of bending in one plane by producing blue and red wavelength shifts depending upon the orientation of the bend. The resulting curvature sensitivities were -1.62 and +3.82 nm·m. Devices have also been produced using an elliptical core fiber to study the effects of the cladding modification on the two polarization eigenstates. A cladding modification applied on the fast axis of the fiber is shown to affect the light in the fast axis much more significantly than the light in the orthogonal state; this behavior may ultimately lead to a sensor capable of detecting the direction of bending in two dimensions for applications in shape sensing. © 2006 IEEE.

Directional bend sensor based on an asymmetric modification of the fiber cladding by femtosecond laser

A femtosecond laser was used to modify a part of the cladding of a standard LPG bend sensor. The device produced wavelength shifts depending upon the direction of bend, thus making a shape sensor. © 2005 Optical Society of America.

Multi-stage ytterbium fiber-amplifier seeded by a gain-switched laser diode

We demonstrated all-fiber amplification of 11 ps pulses from a gain-switched laser diode at 1064 nm. The diode was driven at a repetition rate of 40 MHz and delivered 13 µW of fiber-coupled average output power. For the low output pulse energy of 325 fJ we have designed a multi-stage core pumped pre-amplifier in order to keep the contribution of undesired amplified spontaneous emission as low as possible. By using a novel time-domain approach for determining the power spectral density ratio (PSD) of signal to noise, we identified the optimal working point for our pre-amplifier. After the pre-amplifier we reduced the 40 MHz repetition rate to 1 MHz using a fiber coupled pulse-picker. The final amplification was done with a cladding pumped Yb-doped large mode area fiber and a subsequent Yb-doped rod-type fiber. With our setup we reached a total gain of 73 dB, resulting in pulse energies of >5.6 µJ and peak powers of >0.5 MW. The average PSD-ratio of signal to noise we determined to be 18/1 at the output of the final amplification stage.

Highly thermally responsive hybrid in-fiber slab waveguide grating structure with a plastic core and a silica cladding

A 1.2(height)×125(depth)×500(length) micro-slot was engraved along a fiber Bragg grating by chemically assisted femtosecond laser processing. By filling epoxy and UV-curing, waveguide with plastic-core and silica-cladding was created, presenting high thermal responding coefficient of 211pm/°C.

Highly refractive index sensitive femtosecond laser inscribed long period gratings

The distinct behaviour of femtosecond laser inscribed long period gratings, with a non-uniform index perturbation within the optical fibre core, has been studied experimentally. The non-uniform laser-induced perturbation results in light coupling from the core mode to a greater number of cladding modes than is the case with their UV laser inscribed counterparts, and this is made evident from the surrounding refractive index (SRI) grating response. Femtosecond inscribed long period gratings are shown to simultaneously couple to multiple sets of cladding modes. A 400μm LPG is shown to result in attenuation peaks that have both blue and red wavelength shifts over a 1250nm to 1700nm wavelength range. This gives rise to SRI sensitivities far greater than anything achievable by monitoring a single attenuation peak. The maximum sensitivity produced by monitoring a single attenuation peak was 1106nm/RIU, whereas monitoring opposing wavelength shifts resulted in a significantly improved sensitivity of 1680nm/RIU. © 2011 Copyright Society of Photo-Optical Instrumentation Engineers (SPIE).