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Laser and Multi-Energy Field Processing of High-Performance Materials
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Laser and Multi-Energy Field Processing of High-Performance Materials

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 10 June 2025 | Viewed by 8399

Special Issue Editors

Dr. Xiaoxiao Chen

E-Mail Website1 Website2
Guest Editor
Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo 315201, China
Interests: laser polishing; laser milling; laser processing; digital manufacturing; beam modulation; multi-energy field manufacturing; hybrid machining; five-axis machining; surface quality
Special Issues, Collections and Topics in MDPI journals
Dr. Yaou Zhang

E-Mail Website1 Website2
Guest Editor
School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
Interests: electric discharge machining; special processing technology; multi-energy field manufacturing; digital manufacturing; smart manufacturing; movement control of electromechanical systems and special robots
Special Issues, Collections and Topics in MDPI journals
Dr. Anhai Li

E-Mail Website1 Website2
Guest Editor
School of Mechanical Engineering, Shandong University, Jinan 250061, China
Interests: high-efficiency and precision machining; cutting tools; machined surface integrity; muti-scale and multi-physics modelling; cutting simulation
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The laser was a major invention of the 20th century, along with atomic energy, the computer and semiconductors. Laser processing technology is non-contact, which is suitable for the processing and manufacturing of various materials without cutting forces. During the machining process, the macro-/microprocessing of the mechanical motion and high-speed scanning of galvanometers can be realized. Compared with traditional processing, it has significant advantages in various aspects.

Today, with the development of materials science and technology, various new materials are emerging at a relentless pace. People's technical demand for material applications is constantly increasing, and advanced materials have been widely used in various fields. At the same time, composite processing technology is also gradually developing. The composite manufacturing of multiple energy fields can benefit from the advantages of various single energies. After the optimization of various energy field combinations, the high-performance processing of materials can be achieved.

This Special Issue will summarize recent advances in the fields of laser processing and multi-energy field composite manufacturing. Articles published in this Special Issue will cover a variety of topics including, but not limited to, laser processing, special processing technology, high-speed cutting, digital manufacturing, beam modulation, multi-energy field manufacturing, hybrid machining, five-axis machining, and surface quality. This Special Issue aims to showcase the latest achievements in the fields of laser processing and multi-energy field composite manufacturing; solicit the most important discoveries; highlight the challenges of processing mechanisms, theories, and technologies; and provide an outlook on future directions.

Dr. Xiaoxiao Chen
Dr. Yaou Zhang
Dr. Anhai Li
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • laser processing
  • special processing technology
  • high-speed cutting
  • digital manufacturing
  • beam modulation
  • multi-energy field manufacturing
  • hybrid machining
  • five-axis machining
  • high-performance materials
  • surface quality

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Related Special Issue

Published Papers (6 papers)

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Research

18 pages, 27272 KiB  
Article
Fluid Flow and Stress Field During Laser Cladding-Based Surface Repair of Aluminum Alloy: Multi-Track Simulation
by Quan Wu, Haiping Chu, Zhongkui Liu, Lihang Yang, Xiaosong Zhou, Yinfeng He and Yi Nie
Materials 2025, 18(7), 1603; https://doi.org/10.3390/ma18071603 - 2 Apr 2025
Viewed by 274
Abstract
Laser cladding (LC) is a promising technique for repairing aluminum alloy components, yet challenges like cracks and uneven surfaces persist due to unstable melt flow and thermal stress. This study employs both fluid flow and stress field models to investigate multi-track LC repair [...] Read more.
Laser cladding (LC) is a promising technique for repairing aluminum alloy components, yet challenges like cracks and uneven surfaces persist due to unstable melt flow and thermal stress. This study employs both fluid flow and stress field models to investigate multi-track LC repair mechanisms. Using a finite volume method (FVM), the dynamic evolution of the molten pool was quantified, revealing a maximum flow velocity of 0.2 m/s, a depth of 0.7 mm, and a width of 4 mm under optimized parameters (1600 W laser power, 600 mm/min scan speed). The model also identified that surface flaws between 300 and 900 μm were fully melted and repaired by a current or adjacent track. Finite element analysis (FEA) showed that multi-layer cladding induced a cumulative thermal stress exceeding 1300 MPa at interlayer interfaces, necessitating ≥ 3 s cooling intervals to mitigate cracking risks. These findings provide critical insights into process optimization, demonstrating that adjusting laser power and scan speed can control molten pool stability and reduce residual stress, thus improving repair quality for aluminum alloys. Full article
(This article belongs to the Special Issue Laser and Multi-Energy Field Processing of High-Performance Materials)
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13 pages, 6208 KiB  
Article
Evaluation of Laser Powder Bed Fusion-Fabricated 316L/CuCrZr Bimetal Joint
by Wengang Zhai, Guanchun Li and Wei Zhou
Materials 2025, 18(7), 1434; https://doi.org/10.3390/ma18071434 - 24 Mar 2025
Viewed by 303
Abstract
While a tensile test revealing joint fracture at the base material may indicate good joint quality under certain circumstances, this conclusion might overlook the importance of examining the joint interface because exceptions can occur when one side is significantly softer. This study investigates [...] Read more.
While a tensile test revealing joint fracture at the base material may indicate good joint quality under certain circumstances, this conclusion might overlook the importance of examining the joint interface because exceptions can occur when one side is significantly softer. This study investigates the fabrication of a 316L/CuCrZr bimetal structure using the laser powder bed fusion (LPBF) process. Cracks were observed at the joint interface. The microhardness measured approximately 200 HV at the cracked interface and 100 HV on the CuCrZr side. Tensile testing showed that fractures occurred on the CuCrZr side, despite the presence of cracks at the bonding interface of the 316L/CuCrZr bimetal joint. Spheroids of 316L and Cu were found at the interface due to the Fe-Cu immiscibility system. This immiscibility was the main reason for the formation of cracks. This highlights the need for a thorough microstructural examination of the bonding to ensure a comprehensive quality assessment. The LPBF-fabricated 316L/CuCrZr bimetal joint exhibits a yield strength of 203.0 MPa, a UTS of 287.5 MPa, and an elongation of 15.3%. Full article
(This article belongs to the Special Issue Laser and Multi-Energy Field Processing of High-Performance Materials)
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18 pages, 22204 KiB  
Article
Oxide Removal Mechanism and Process Optimization During Integrated Pulsed-Continuous Laser Cleaning of Q235B Carbon Steel
by Wei Zhang, Chunming Wang, Qiong Wu, Fei Yan, Guoli Zhu and Junqiang Wang
Materials 2025, 18(6), 1247; https://doi.org/10.3390/ma18061247 - 12 Mar 2025
Viewed by 525
Abstract
Laser cleaning has received extensive attention due to its high efficiency, non-pollution and easy automation. However, how to improve the cleaning quality has become the focus of current research. In this paper, we used a pulsed laser for cleaning experiments on Q235B carbon [...] Read more.
Laser cleaning has received extensive attention due to its high efficiency, non-pollution and easy automation. However, how to improve the cleaning quality has become the focus of current research. In this paper, we used a pulsed laser for cleaning experiments on Q235B carbon steel to investigate the effects of different process parameters on the surface cleaning quality. On this basis, a new cleaning method was innovatively proposed to improve the oxide removal efficiency, microstructure, and mechanical properties of cleaned samples. The results showed that pulsed laser cleaning of Q235B carbon steel was the most effective at a laser linewidth of 50 mm, pulsed frequency of 500 kHz, and cleaning speed of 15 mm/s. A great deal of craters formed on the surface of cleaned samples due to the thermal shock of the pulsed laser. Compared with other laser cleaning methods, integrated laser cleaning had an obvious effect in raising the oxide removal efficiency and reducing the surface roughness. The ridge structures on the sample surface also could be successfully eliminated, subsequently achieving smooth structures. Fine-crystalline structures were formed near the surface of tested samples, which significantly decreased the crystal orientation and increased the number of small angle grain boundaries and the GND density. The improvement in hardness was mainly on account of grain refinement in the integrated laser cleaning samples. In addition, a physical model was proposed to illustrate the oxide removal mechanism on integrated pulsed-continuous laser cleaning samples. This research can offer new theoretical and technical support for solving the long-standing problems of efficiency and quality in laser cleaning, thus significantly broadening the application of laser technology in manufacturing fields. Full article
(This article belongs to the Special Issue Laser and Multi-Energy Field Processing of High-Performance Materials)
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19 pages, 3089 KiB  
Article
Experimental and Numerical Investigation on the Aerosol Micro-Jet 3D Printing of Flexible Electronic Devices
by Yuanming Zhang, Tao Zhu, Junke Jiao, Shiyu Song, Zhenqian Wang and Ziwen Wang
Materials 2023, 16(22), 7099; https://doi.org/10.3390/ma16227099 - 9 Nov 2023
Cited by 3 | Viewed by 1762
Abstract
In this study, the optimal forming parameters for printing flexible circuits using aerosol jet printing technology are explored through numerical simulation and experiments. The printhead during the deposition process is numerically simulated. By employing the controlled variable method, the process parameters such as [...] Read more.
In this study, the optimal forming parameters for printing flexible circuits using aerosol jet printing technology are explored through numerical simulation and experiments. The printhead during the deposition process is numerically simulated. By employing the controlled variable method, the process parameters such as gas flow rate, working distance, nozzle diameter, and printing speed are selected to investigate their effects on the morphology of the printed lines. Accordingly, single-factor experiments are designed to validate the printing of flexible circuits on both planar and curved substrates. Laser micro-sintering is utilized to improve the conductivity of the printed lines and ultimately fabricate flexible strain sensors. Under the sheath gas flow rate of 400 sccm, carrier gas flow rate of 100 sccm, working distance of 3 mm, nozzle diameter of 500 μm, and printing speed of 10 mm/s, the optimal morphology of the printed lines is achieved with low linewidth characteristics. The variations in the focal ratio, working distance, nozzle diameter, and printing speed significantly affect the minimum feature line width and morphology of the printed lines. Full article
(This article belongs to the Special Issue Laser and Multi-Energy Field Processing of High-Performance Materials)
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16 pages, 7962 KiB  
Article
Effects of Scanning Speed on the Polished Surface Quality of Mold Steel by Dual-Beam Coupling Nanosecond Laser
by Huihui Zhang, Xiaoxiao Chen, Wenwu Zhang and Dianbo Ruan
Materials 2023, 16(4), 1477; https://doi.org/10.3390/ma16041477 - 9 Feb 2023
Cited by 3 | Viewed by 2127
Abstract
In this paper, a novel dual-beam coupled nanosecond laser was used to polish S136D mold steel. The effects of scanning speed, total fluence, spot overlap ratio, and SPSN on surface quality were analyzed. The polished surface roughness Ra without ultrasonic cleaning is [...] Read more.
In this paper, a novel dual-beam coupled nanosecond laser was used to polish S136D mold steel. The effects of scanning speed, total fluence, spot overlap ratio, and SPSN on surface quality were analyzed. The polished surface roughness Ra without ultrasonic cleaning is too large due to slag, splash, and dust produced by laser polishing. When scanning speed is 1250 mm/min, surface roughness Ra with ultrasonic cleaning is reduced from the original surface 1.92 μm to 0.72 μm, and the surface roughness Ra is reduced by 62.50%. When the Ftot is 35.38 J/cm2, the minimum value of surface roughness Ra is 0.72 μm. If the total fluence is higher or lower, it is not conducive to reducing the surface roughness, the total fluence is higher, and there is a polished surface with SOM phenomenon. The polished surface with spot overlap ratio of 98.55% has a smooth morphology, and a minimum value of surface roughness Ra of 0.41 μm. When the specimen is inclined at a certain angle, the high-magnification camera captures color on the polished surface. It is found that the microscopic texture of molten material flow trace and polishing scanning track is obvious. Polished surface is mainly distributed with Fe, Cr, C, and O elements. The surface material processing speed per unit time is low, and the polishing surface quality is improved less. The maximum surface roughness Ra is 1.98 μm. The minimum Ra of polished surface with smoother morphology is 0.41 μm, and surface profile height is basically the same. The research results show that the new dual-beam coupled nanosecond laser polishing technology can improve surface quality of materials. This research work provides process guidance for laser polishing effect analysis and mechanism innovation. Full article
(This article belongs to the Special Issue Laser and Multi-Energy Field Processing of High-Performance Materials)
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10 pages, 3588 KiB  
Article
Microstructure and Properties of WC/Ni-Based Laser-Clad Coatings with Different WC Content Values
by Xuehui Shen, Hao Peng, Yunna Xue, Baolin Wang, Guosheng Su, Jian Zhu and Anhai Li
Materials 2022, 15(18), 6309; https://doi.org/10.3390/ma15186309 - 11 Sep 2022
Cited by 19 | Viewed by 2708
Abstract
The purpose of this work is to investigate the effect of the WC content on the surface characteristics and nanoindentation behaviors of WC/Ni-based composite laser-clad coatings. Four NiCrSiBC coatings with WC wt% of 30%, 40%, 50%, and 60%, respectively, were clad on carbon [...] Read more.
The purpose of this work is to investigate the effect of the WC content on the surface characteristics and nanoindentation behaviors of WC/Ni-based composite laser-clad coatings. Four NiCrSiBC coatings with WC wt% of 30%, 40%, 50%, and 60%, respectively, were clad on carbon steel substrates using a laser. The morphologies and phase compositions of four clad coatings were comparatively observed. In addition, the hardness and elastic modulus values of the four coatings were measured and quantitatively calculated. As a result, with the increase in WC, the coating grains were more refined. Meanwhile, cracks and WC particle breakage occurred in the 50–60% WC coatings, whereas this was not found in the 30–40% WC coatings. When the WC content increased from 40% up to 50%, the coating hardness and elastic modulus significantly increased. However, a further increase in WC from 50% to 60% did not result in considerable improvement in coating quality but considerably worsened the coating’s cracking behavior instead. Therefore, for WC/Ni-based composite coatings, a threshold exists for the WC content, and this value was 50% within the experimental scope of this study. Full article
(This article belongs to the Special Issue Laser and Multi-Energy Field Processing of High-Performance Materials)
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