Search Results (101)

Tube boilers are extensively employed in oil and gas refineries, as well as in petroleum, energy, and power generation industries, where they serve critical functions in local steam-generation units and combined-cycle gas turbine (CCGT) plants. However, these boilers are prone to defects arising from waterside corrosion (e.g., thinning of U-bend tubes), fireside corrosion, and material degradation caused by stress or creeping. Among these issues, wall thinning of tube bends is particularly severe, as it results in localized metal loss, reduced structural integrity, and an elevated risk of tube rupture or failure under high-temperature and high-pressure operating conditions. Such failures can significantly compromise boiler safety and efficiency, potentially leading to forced outages, costly unplanned repairs, or catastrophic damage if not detected in time. The current condition-monitoring policy for U-bends relies on scheduled preventive maintenance and unscheduled corrective interventions. In practice, this involves randomly checking approximately 10–20% of the tubes through spot scanning, partial scanning, or full scanning, with repairs typically carried out only after an undetected failure occurs. Such maintenance strategies generally require plant shutdowns, making the process time-consuming, labor-intensive, and ultimately not cost-effective. This paper reviews existing solutions, technologies, and research addressing the problem, and introduces femtosecond laser micromachined fiber optic sensors as a transformative approach for real-time monitoring of wall thickness reduction in U-bend boiler tubes, thereby opening pathways for further research. Full article

Femtosecond laser micromachining is a cornerstone of high-precision manufacturing, yet its multi-scale dynamics require a self-consistent bridging from atomic transitions to macroscopic morphology. This study establishes a multi-scale framework where Density Functional Theory (DFT) calculates temperature-dependent electronic thermal properties to inform both Two-Temperature Model-Molecular Dynamics (TTM-MD) and Finite Element Method (TTM-FEM) simulations. By comparing atomistic and macroscopic results, we systematically investigate the thermal-mechanical responses of copper ablation. The macroscopic TTM-FEM model, employing a removal criterion based on the enthalpy of vaporization, achieves high predictive accuracy for ablation depths in the low-to-medium power range up to 300 mW. However, a significant divergence at higher powers (>400 mW) highlights the physical transition from surface evaporation to phase explosion. Concurrently, the TTM-MD simulations provide microscopic insights into the transient temperature and stress evolution, establishing a physically synchronized link between atomic-scale dynamics and macroscopic results. This work defines the applicability boundaries of evaporation-based macroscopic models and provides a validated predictive tool for optimizing laser processing parameters in precision engineering. Full article

A robust and cost-effective fiber-optic ultrasound sensor based on a slope-symmetric Fabry–Perot interferometer (FPI) is presented, employing dual-channel quadrature-biased heterodyne interrogation with an acousto-optic modulator (AOM). By introducing a 200 MHz frequency shift that yields an effective π/2 phase offset between the direct (unshifted) and frequency-shifted optical paths, the system ensures complementary sensitivity: when one channel operates at zero slope on the FPI transfer function (minimum sensitivity), the other resides at maximum slope, providing inherent immunity to laser wavelength drift and environmental perturbations. Experimental validation demonstrates reliable ultrasound detection across varying operating points. At quadrature extremes, one channel achieves peak amplitudes of ±2 V while the other is quiescent, whereas intermediate points enable simultaneous detection with amplitudes of ±1.5 V (AOM channel) and ±0.05–0.1 V (direct channel), accompanied by corresponding DC levels ranging from ~0.4 V to 1.6 V. The AOM channel utilizes simple envelope detection after 9.5–11.5 MHz bandpass filtering, maintaining low cost, though coherent mixing is suggested for enhanced weak-signal performance. The angle-symmetric FPI design, combined with gold-disk reflector adaptations and potential femtosecond laser micromachining, further reduces fabrication costs without sacrificing finesse or sensitivity. This quadrature-biased approach offers superior stability compared to single-channel systems, making it highly suitable for practical applications in photoacoustic imaging, nondestructive testing, and structural health monitoring. Full article

A reflective in-fiber liquid microsphere whispering gallery mode (WGM) resonator based on a Y-waveguide coupler is proposed and experimentally demonstrated. The sphere resonator is introduced inside a single-mode fiber (SMF) by using femtosecond laser micromachining and fusion splicing. A Y-waveguide coupler is fabricated with femtosecond laser direct writing, which is used to simultaneously excite and collect the WGM field through evanescent field coupling. High-index liquids are filled into the sphere through a laser-drilled channel to form a liquid microsphere where the WGM resonation takes place. The WGM resonator is sensitive to the refractive index (RI) of the filled liquids, and a RI sensitivity of 439 nm/RIU is achieved in an index range from 1.672 to 1.692. The liquid microsphere resonator is also sensitive to temperature, with a sensitivity of −307.1 pm/°C obtained. The microsphere resonator is small in size and robust, which has broad application prospects in the field of food and the chemical industry. Full article

Surface functionalisation of polymers is essential for enhancing properties such as wettability and mechanical resistance. This study presents a scalable, coating-free approach to fabricate hydrophobic and superhydrophobic Polydimethylsiloxane (PDMS) surfaces. Aluminium (AA2024) moulds were microstructured using a TruMicro femtosecond laser system to generate grid patterns with controlled hatch distances and depths, as well as laser-induced periodic surface structures (LIPSSs). These features were accurately replicated onto PDMS, as confirmed by scanning electron miscoscopy (SEM) and profilometry. Contact angle measurements showed a marked increase in hydrophobicity, reaching superhydrophobicity for optimised parameters, with surface stability maintained over four months without degradation. Full article

Structure-Modulated Long-Period Fiber Gratings (SM-LPFGs) represent an advancement in fiber optic sensor technology, moving beyond traditional photosensitivity-based fabrication to achieve enhanced performance through the direct physical modification of the geometry of the fiber. This review provides a comprehensive analysis of the primary fabrication techniques enabling this approach, including CO₂ laser inscription, femtosecond laser micromachining, electric-arc discharge, chemical etching, and fusion tapering. The central focus of this work is the elucidation of the definitive structure–performance relationship, systematically detailing how engineered geometries such as helical profiles, micro-tapers, and asymmetric grooves unlock novel sensing capabilities. We demonstrate how these specific structures are strategically designed to induce circular birefringence for torsion measurement, enhance evanescent field interaction for ultra-sensitive refractive index detection, and create localized stress concentrations for high-resolution strain and vector bending sensing. Furthermore, the review surveys the practical implementation of these sensors in critical application domains, including structural health monitoring, biomedical diagnostics, and environmental sensing. Finally, we conclude by summarizing key achievements and identifying promising future research directions, such as the development of hybrid fabrication processes, the integration of machine learning for advanced signal demodulation, and the path towards industrial-scale production. Full article

In this paper, we propose and experimentally demonstrate a dual-parameter fiber optic sensor, which combines a Fabry–Perot interferometer (FPI) and a Mach–Zehnder interferometer (MZI) for simultaneous pressure and temperature sensing. The Fabry–Perot (FP) cavity is formed by sandwiching a capillary fiber between a single-mode fiber and a dual-core fiber (DCF). A fluid channel is very close to the central core of the DCF. By precisely drilling micro-air chambers in the annular cladding of a capillary fiber (CF) using a femtosecond laser, external air pressure can directly affect the capillary fiber and induce changes in the refractive index of the air in the CF. The F-P cavity achieves a pressure sensitivity of 3.67 nm/MPa with a temperature cross-sensitivity of 2.82 pm/°C. The MZI is constructed using a dual-core fiber filled with silicone oil in the fluidic channel, which enhances temperature sensitivity through the thermo-optic effect. The MZI sensor exhibits a nonlinear temperature response with an average sensitivity of 103.43 pm/°C. The corresponding pressure cross-sensitivity is about –0.11 nm/MPa. Due to very low cross-sensitivity, simultaneous measurement of temperature and gas pressure is feasible. In addition, we implement a variant by replacing silicone oil with a UV-curable adhesive, which delivers a comparable FP-based pressure sensitivity of ~3.93 nm/MPa while yielding an MZI-based temperature sensitivity of 71.7 pm/°C and potentially improved long-term stability. Full article

Ferroelectric oxides, such as Pb(Zr,Ti)O₃ (PZT), have been shown to maintain stable ferroelectricity even in ultrathin film configurations. However, achieving controllable modulation of microstructure and physical responses in these ultrathin films remains challenging, limiting their potential applications in modern nanoelectronics and optoelectronics. Here, we propose a single-pulse femtosecond (fs) laser micromachining technique for high-precision engineering of microstructure and ferroelectric/piezoelectric responses in ultrathin PZT films. The results show that various microstructures can be selectively fabricated through precise control of fs laser fluence. Specifically, nano-concave arrays are formed via low-fluence laser irradiation, which is mainly attributed to the fs laser peening effect. In contrast, nano-volcano (nano-cave) structures are generated when the laser fluence is close to or reaches the ablation threshold. Additionally, applying an fs laser pulse with fluence exceeding a critical threshold enables the formation of nano-cave structures with controlled depth and width in PZT/Pt/SiO₂ multilayers. Piezoresponse force microscopy measurements demonstrate that the laser peening process significantly enhances the piezoelectric response while exerting minimal influence on the coercive field of PZT thin films. This improvement is attributed to the enhanced electromechanical energy transfer and concentrated compressive stresses distribution in PZT thin films resulting from the laser peening effect. Our study not only offers an effective strategy for microstructure and property engineering in ferroelectric materials at the nanoscale but also provides new insights into the underlying mechanism of ultrafast laser processing in ferroelectric thin films. Full article

Organ-on-a-chip (OoC) technology aims to replicate the functions of human organs and tissues. This study evaluates femtosecond laser micromachining (FLM) for producing PDMS membranes with controlled porosity as an alternative approach to conventional microfabrication for OoCs. Membranes of varying thicknesses were microdrilled, and the influence of laser parameters on microhole geometry was assessed, showing that pulse energy strongly affected hole diameter, whereas exposure time had a lesser impact. The heat-affected zone (HAZ) and taper angle, key indicators of microhole geometric quality, were also analyzed and found to be strongly dependent on membrane thickness. Prediction models were developed to guide parameter selection for future laser-based ablation processes. A numerical model that predicts plasma shielding effects provided further insight into the physics of PDMS laser ablation, revealing that higher pulse energies led to a marked increase in crater diameter. The fabricated membranes were integrated into an OoC device, onto which human mesenchymal stem cells were seeded. The results demonstrated strong cell adhesion, the rapid formation of a homogeneous monolayer, and no evidence of cytotoxicity. These findings confirm that FLM is a versatile and flexible technique for microdrilling PDMS membranes, enabling their effective integration into OoC. Full article

A single-crystal magnesium oxide (MgO) dual-Fabry–Perot (FP)-cavity sensor based on MEMS technology and laser micromachining is proposed for simultaneous measurement of temperature and pressure. The pressure sensitive cavity is processed by wet chemical etching and direct bonding, which can improve machining efficiency, ensure the quality of the reflection surface and achieve thermal stress matching. Femtosecond laser and micromachining technologies are used to fabricate a rough surface and a through hole to reduce the reflect surface and fix the optical fiber. The bottom surface of the pressure cavity and the upper surface of the MgO wafer form a temperature cavity. A cross-correlation signal demodulation algorithm combined with a temperature decoupling method is proposed to achieve dual-cavity demodulation and eliminate the cross-sensitivity between temperature and pressure, improving the accuracy of pressure measurement. Experimental results show that the proposed sensor can stably operate at an ambient environment of 22–800 °C and 0–0.5 MPa with a pressure sensitivity of approximately 0.20 µm/MPa (room temperature), a repeatability error of 2.06% and a hysteresis error of 1.90%. After temperature compensation, thermal crosstalk is effectively eliminated and the pressure measurement accuracy is 2.01%F.S. Full article

Femtosecond laser micromachining was utilized to build up a micro-through-hole array into a sacrificial film, which was coated onto a copper specimen. This micro-through hole was shaped in the paraboloidal profile, with its micro-dimple on the interface between the copper substrate and the film. This profile was simply in correspondence with the laser energy profile. The array was used as a nucleation and growth site for nickel cluster deposition during wet plating. The micro-pillared unit cells nucleated at the micro-dimple and grew on the inside of the micro-through hole. After removing the sacrificial film, cleansing, and polishing, the nickel micro-pillar array was obtained, standing on the copper substrate. These unit cells and their alignments were measured through scanning electron microscopy and laser microscopy. Thermographic microscopy with FT-IR was utilized to measure the IR emittance as a function of wavelength. The focused areas were varied by controlling the aperture to analyze the effects of arrayed microtextures on the IR emittance. Full article

Glass-based microfluidic devices are essential for applications such as diagnostics and drug discovery, which utilize their optical clarity and chemical stability. This review systematically analyzes pulsed laser micromachining as a transformative technique for fabricating glass-based microfluidic devices, addressing the limitations of conventional methods. By examining three pulse regimes—long (≥nanosecond), short (picosecond), and ultrashort (femtosecond)—this study evaluates how laser parameters (fluence, scanning speed, pulse duration, repetition rate, wavelength) and glass properties influence ablation efficiency and quality. A higher fluence improves the material ablation efficiency across all the regimes but poses risks of thermal damage or plasma shielding in ultrashort pulses. Optimizing the scanning speed balances the depth and the surface quality, with slower speeds enhancing the channel depth but requiring heat accumulation mitigation. Shorter pulses (femtosecond regime) achieve greater precision (feature resolution) and minimal heat-affected zones through nonlinear absorption, while long pulses enable rapid deep-channel fabrication but with increased thermal stress. Elevating the repetition rate improves the material ablation rates but reduces the surface quality. The influence of wavelength on efficiency and quality varies across the three pulse regimes. Material selection is critical to outcomes and potential applications: fused silica demonstrates a superior surface quality due to low thermal expansion, while soda–lime glass provides cost-effective prototyping. The review emphasizes the advantages of laser micromachining and the benefits of a wide range of applications. Future directions should focus on optimizing the process parameters to improve the efficiency and quality of the produced devices at a lower cost to expand their uses in biomedical, environmental, and quantum applications. Full article

Precision micromilling is currently widely used for the fabrication of injection mold inserts for the mass production of microfluidic devices. However, for complex devices with micrometer-scale and high density of structures, micromilling results in high production times and costs for production runs of hundreds or thousands of units. Femtosecond laser (fs-laser) technology has emerged as a promising solution for high-precision micromachining. This study analyzes the potential of fs-laser micromachining for the fabrication of injection mold inserts for the large-scale production of thermoplastic microfluidic devices. For the evaluation of technology, a reference design was defined. The parameters of the fs-laser process were optimized to achieve high resolution of the structures and optimal surface quality, aiming to minimize production times and costs while ensuring the quality of the final part. The microstructures were replicated in two different grades of COC (Cyclic Olefin Copolymer) by injection molding. The dimensional tolerance of the structures and the surface finish achieved both in the insert and the polymer parts were characterized by scanning electron microscopy (SEM) and confocal microscopy. The surface quality of the final parts and its suitability for microfluidic fabrication were also assessed performing chemical bonding tests. The fs-laser machining process has shown great potential for the mass production of microfluidic devices. The developed process has enabled for a reduction of up to 90% in the fabrication times of the insert compared to micromilling. The parts exhibited very smooth surfaces, with roughness values (Sa) of 64.6 nm for the metallic insert and 71.8 nm and 72.9 nm for the COC E-140 and 8007S-04 replicas, respectively. The dimensional tolerance and the surface quality need to be improved to be competitive with the finishes achieved with precision micromilling. Nonetheless, there is still room for improvement considering the significant reduction in the production times through new laser processing strategies. Full article

4H-SiC (silicon carbide), known as the third-generation semiconductor, has been widely used in high-power electronic devices. However, surface defects on wafers can seriously affect the key parameters and stability of silicon carbide devices. In this work, we pioneered a dual-laser comparative framework to systematically investigate the effects of continuous wave (CW) and femtosecond (FS) pulse laser micromachining on 4H-SiC epitaxial layers. CW laser restructuring optimized lattice integrity at sub-melting thresholds, while ultrafast FS pulse laser achieved submicron roughness control (from 8 μm to <0.5 μm) without obvious thermal collateral damage. To reveal the dynamic mechanism during the laser modification, multi-physics finite element models were adopted that decouple thermal and non-thermal mechanisms. This work expands the feasibility of laser micromachining for next-generation SiC device manufacturing. Full article

As inspired by nature, wettability of bio-based material surfaces can be controlled by combining appropriate surface chemistries and topographies mimicking the structure of plant leaves or animals. The need for bio-based nanocellulose coatings with enhanced hydrophobic properties becomes technically relevant for extending their applications in the technological domain with better protection and lifetime of the coatings. In this work, the water repellence of spray-coated nanocellulose coatings with hydrophobically modified cellulose microfiber (mCMF coatings), or hydrophobically modified cellulose nanofiber (mCNF coatings) was enhanced after femtosecond laser patterning. In particular, the influences of different island-like pattern geometries and pattern sizes were systematically studied. The island-like patterns were experimentally created with single posts that have variable sizes of the valleys (B = 30 to 15 µm) and top surface area (T = 120 to 15 µm), resulting in good resolution of the patterns down to the size of the laser beam diameter (15 µm). Depending on the intrinsic homogeneity and porosity of sprayed mCMF and mCNF coatings, the quality and resolution of the island-like patterns is better for the mCNF coatings with thinner and more homogeneous sizes of the cellulose nanofibrils. The increase in apparent water contact angle on patterned nanocellulose coatings can be estimated from the theoretical Cassie–Baxter state of wetting and shows maximum values up to θ_s = 128° (mCMF coatings), or θ_s = 140° (mCNF coatings), for the smallest pattern sizes in parallel with minimum contact angle hysteresis of Δθ = 14° (mCMF coatings), or Δθ < 9° (mCNF coatings). The study demonstrated that femtosecond laser patterning technology provides high flexibility and adaptivity to create surface patterns in appropriate dimensions with enhanced hydrophobicity of nanocellulose coatings. Full article