Study of Laser/Matter Interaction for Industrial Microapplications

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Back to Core Research Programme AMorph – 4D Printing for Field Morphing Structures Automation of Composite and Hybrid Joining Process Coaxial Wire Additive Manufacturing Processes and In-Line Monitoring Tools Development of Coded Excitation Technique for Non-Metallic Pipes Inspection Development of Digital Twin technology as a demonstrator for real-time integrity assessment of crack growth in tensile specimens Development of Friction Stir Welding (FSW) for Hydrogen Fuel Storage Tanks Development of Leak-Before-Break Hydrogen Storage Composite Pressure Vessels With Polymeric Liner Establishing Assessment Methods for Determining Safe Service Limits of High-Temperature Materials in Extreme Environments Fracture toughness in aggressive environments: effect of crack monitoring techniques on test results In-process detection and non-destructive testing of electron beam weld imperfections Internal Bore Coatings for Applications in Corrosion and Hydrogen Environment Joining of Additively Manufactured Materials Long term behaviour of polymeric liner materials/coatings in hydrogen service Techniques for High Temperature Ultrasonic Inspection of Arc Welding Ultimate Leverage Fund

Project Code: 0905-10

Laser technology is considered very attractive in industry due to its high efficiency and high processing speed. It therefore has great potential in materials processing and manufacturing for micro-application purposes. However, the majority of the work is carried out empirically with little understanding of the fundamental principles involved. Understanding the relationship between laser beam characteristics and the physical conditions of the materials to be processed would enable a valuable numerical tool for process parameter definition for the conduction limited welding process to be developed, thus reducing the reliance upon empirical trials and personal experience in developing a process.

Objectives

Investigate the interaction between laser/matter and quality of the processed components as function of different laser processing conditions.

Evaluate the integrity of the produced samples and establish performance through appropriate testing procedures.

Develop a tool or procedure for assisting in equipment and process selection for micro laser processing applications.

Project Outline

The proposed project will focus on analysis of laser/matter behaviour under a range of laser processing conditions, including different energy densities and pulse widths in the case of pulsed lasers. Laser types will include fibre, Nd:YAG and diode lasers. The study will deal with some fundamental issues involved in laser-matter interaction and a range of pulsed and CW laser sources will be used to characterise welding, cutting, drilling, powder bed deposition (or sintering) and ablation processes. Work has been already carried out in the fields mentioned above, achieving successful and interesting outcomes. However a more thorough understanding of dominant process mechanisms at a molecular dynamics level is needed for better process control. Materials to be investigated will include high reflectance metals, composites and ceramics for micro-applications; they will be used in different forms, such as foil, wire, powder and flat plate.

Relevant Industry Sectors

Electronics, Sensors and Medical Devices and Aerospace.

Technical and Economic Benefits

The project will develop TWI’s core knowledge in the field of precision laser processing.

The project will support EngD study investigating laser/matter interaction mechanisms for industrial micro-applications.

Fundamental knowledge concerning laser/matter interaction using low power laser sources will be improved in order to meet the requirements of increased productivity, reduced costs and improved reliability for the benefit of TWI members.

TWI members will be able to make equipment selection decisions based on the fundamental requirements of the laser processing application.